Step-by-step reaction type production equipment for carbon-based modified asphalt emulsion

Abstract

The invention discloses step-by-step reaction type production equipment for a carbon-based modified asphalt emulsion, which comprises a carbon-based material pre-dispersion mechanism, a liquid soap preparation and heating mechanism, an emulsifier generation mechanism, an asphalt pretreatment and emulsification mechanism and a modified additive mixing mechanism, the liquid soap preparation and heating mechanism is arranged at the bottom of the carbon-based material pre-dispersion mechanism, the emulsifier generation mechanism is arranged between the carbon-based material pre-dispersion mechanism and the liquid soap preparation and heating mechanism, and the asphalt pretreatment and emulsification mechanism is arranged on the left side of the liquid soap preparation and heating mechanism. The modified additive mixing mechanism is arranged on the left side of the asphalt pretreatment and emulsification mechanism. According to the scheme, through the design of external ultrasonic dispersion, soap liquid independent temperature control, step-by-step modification and PLC whole-course regulation and control, efficient and stable production of the carbon-based modified asphalt emulsion is achieved, equipment can be locally modified on an existing production line, the modification cost is low, compatibility is high, and the market popularization value is high.

Description

A stepwise reaction production equipment for carbon-based modified asphalt emulsion Technical Field

[0001] This invention relates to the field of road material production equipment technology, specifically to a stepwise reaction production equipment for carbon-based modified asphalt emulsion. Background Technology

[0002] Emulsified asphalt is a widely used material in road maintenance engineering, mainly used in tack coats, prime coats, seal coats, micro-surfacing, cold recycling, and other applications. The production process of conventional emulsified asphalt is relatively mature. Some equipment only includes basic structures such as asphalt heating tanks, emulsifier aqueous solution preparation tanks, and colloid mills. The main processing objects are petroleum asphalt, emulsifiers, water, and a small amount of stabilizers, without involving the addition and dispersion of carbon-based materials.

[0003] However, some equipment introduces carbon-based materials (such as carbon nanotubes, graphene flakes, carbon black, graphite, etc.) into emulsified asphalt, giving it electromagnetic sensitivity and microwave response capability. Through carbon-based modification, innovative functions such as rapid microwave removal of road markings and in-situ seamless welding of cracks can be achieved, which has broad application prospects.

[0004] However, existing emulsified asphalt production equipment has the following technological gaps and deficiencies: 1. Lack of dedicated equipment for the addition and dispersion of carbon-based materials: Conventional emulsified asphalt production lines are only designed with feed channels for asphalt and emulsifier aqueous solutions, without reserved addition ports for carbon-based materials, and even less capable of pre-dispersing nanoscale carbon-based materials. Carbon-based materials (especially carbon nanotubes and graphene microsheets) have large specific surface areas and high surface energies, making them extremely prone to agglomeration. Direct addition to colloid mills can lead to uneven dispersion and agglomerates clogging the equipment, making it impossible to obtain stable carbon-based modified emulsions.

[0005] 2. Existing dispersion equipment struggles to balance efficiency and lifespan: Adding a dispersion unit to an existing production line typically involves using an in-tank ultrasonic probe or a high-speed shearing machine. However, ultrasonic probes, constantly immersed in high-concentration slurry, suffer from severe cavitation erosion, resulting in a short lifespan (usually requiring replacement every 3-6 months) and uneven energy distribution. High-speed shearing machines, with their small rotor-stator clearance, are prone to clogging, and excessive shearing force can damage the carbon material structure. Both require downtime for maintenance and are unsuitable for continuous production.

[0006] 3. Lack of step-by-step modification process design: Carbon-based modified asphalt emulsions not only require uniform dispersion of carbon-based materials, but may also require secondary modification with tackifiers (such as water-based resins) to improve adhesion. Existing equipment cannot achieve the step-by-step reaction sequence of "emulsification first, modification later," which easily leads to premature reaction between water-based resins and asphalt to form flocculent matter. This not only affects the emulsification effect, but also makes it difficult to accurately control the chemical grafting reaction, ultimately resulting in insufficient adhesion and poor storage stability of the modified asphalt emulsion, failing to meet the requirements of intelligent road maintenance.

[0007] Therefore, a solution is needed. Summary of the Invention

[0008] (I) Technical Problems to be Solved In view of the shortcomings of the prior art, the present invention provides a stepwise reaction production equipment for carbon-based modified asphalt emulsion to solve the problems mentioned in the background art.

[0009] (II) Technical Solution To achieve the above objectives, the present invention is implemented through the following technical solution: A stepwise reaction production device for carbon-based modified asphalt emulsion, comprising a carbon-based material pre-dispersion mechanism, a soap solution preparation and heating mechanism, an emulsifier generation mechanism, an asphalt pretreatment and emulsification mechanism, and a modified additive mixing mechanism. The soap solution preparation and heating mechanism is located at the bottom of the carbon-based material pre-dispersion mechanism; the emulsifier generation mechanism is located between the carbon-based material pre-dispersion mechanism and the soap solution preparation and heating mechanism; the asphalt pretreatment and emulsification mechanism is located to the left of the soap solution preparation and heating mechanism; and the modified additive mixing mechanism is located to the left of the asphalt pretreatment and emulsification mechanism. The carbon-based material pre-dispersion mechanism includes a pre-dispersion tank, a carbon-based material inlet, an emulsifier aqueous solution inlet, a reflux port, a stirrer, a discharge pipe, a solenoid valve, a reflux pipe, a circulating pump, a flat channel shell, an ultrasonic transducer array, a stainless steel vibrating plate, and... A transducer fault self-diagnosis and automatic backup switching system is provided. The emulsifier aqueous solution inlet and the carbon-based material inlet are respectively arranged in a left-right configuration at the top of the pre-dispersion tank. The reflux port is located between the emulsifier aqueous solution inlet and the carbon-based material inlet. A stirrer is located at the bottom of the pre-dispersion tank. A discharge pipe is located at the right end of the bottom of the pre-dispersion tank. A solenoid valve is located in the lower half of the discharge pipe. A reflux pipe is located on the discharge pipe and extends to the right and upward to connect with the reflux port. A circulation pump is located at the starting end of the reflux pipe. A flat channel housing is located on the vertical section of the reflux pipe. An ultrasonic transducer array is vertically and evenly arranged at both ends inside the flat channel housing. Stainless steel vibrating plates are arranged opposite each ultrasonic transducer array. The transducer fault self-diagnosis and automatic backup switching system is located at the front end of the flat channel housing.

[0010] Preferably, the agitator is a low-speed agitator with a rotation speed of 100-300 r / min, used to prevent carbon-based materials from settling in the tank, and to avoid high-speed agitation generating bubbles that affect the subsequent dispersion effect. The discharge pipe and the return pipe are interconnected. The starting section of the return pipe is located in the upper half of the discharge pipe. The width between the two stainless steel vibrating plates is 5-10 mm. This width allows the carbon-based slurry to form a thin-layer flow state, ensuring that the energy of the ultrasonic transducer is uniformly applied to the slurry. The operating frequency of each group of ultrasonic transducer arrays can be adjusted independently.

[0011] Preferably, the soap solution preparation and heating mechanism includes a soap solution mixing tank, a second stirrer, a soap solution heater, a second discharge pipe, a second solenoid valve, an online particle size analyzer, a third discharge pipe, and a first metering pump. The soap solution mixing tank is located at the bottom of the first discharge pipe, the second stirrer is located at the bottom of the soap solution mixing tank, the soap solution heater is located at the left end of the soap solution mixing tank, the second discharge pipe is located at the lower left of the soap solution mixing tank and connected to the bottom of the soap solution heater, the second solenoid valve is located in the middle of the second discharge pipe, the online particle size analyzer is located in the left half of the second discharge pipe, the third discharge pipe is located at the top of the soap solution heater and extends to the left, and the first metering pump is located in the middle of the third discharge pipe.

[0012] Preferably, the discharge pipe is located in the right half of the soap solution mixing tank, the soap solution heater is a plate heater, used to heat the emulsified soap solution to a set temperature of 60-80℃, and the online particle size analyzer is set to a carbon-based slurry particle size threshold of ≤50μm.

[0013] Preferably, the emulsifier generating mechanism includes a first conveying pipe, a third solenoid valve, an emulsifier dissolving tank, a second conveying pipe, and a first transport pump. The first conveying pipe is located on the left half of the top of the soap solution mixing tank. The third solenoid valve is located on the first conveying pipe. The emulsifier dissolving tank is located on the top of the first conveying pipe. The second conveying pipe is located on the left half of the top of the emulsifier dissolving tank, and the top of the second conveying pipe is connected to the pre-dispersion tank. The first transport pump is located on the second conveying pipe.

[0014] Preferably, the asphalt pretreatment and emulsification mechanism includes a colloid mill emulsification main unit, a feed inlet, a feed pipe I, a metering pump II, an asphalt heating tank, an asphalt inlet, a conveying pipe III, and a transport pump II. The colloid mill emulsification main unit is located at the left end of the soap solution heater. The feed inlet is located on the right half of the top of the colloid mill emulsification main unit and is connected to the discharge pipe III. The feed pipe I is located on the left half of the top of the colloid mill emulsification main unit. The metering pump II is located on the feed pipe I. The asphalt heating tank is located at the top of the feed pipe I. The asphalt inlet is located at the top of the asphalt heating tank. The conveying pipe III is located at the bottom of the left end of the colloid mill emulsification main unit. The transport pump II is located on the conveying pipe III.

[0015] Preferably, the modified additive mixing mechanism includes a homogenizing reactor, an anchor stirrer, an online viscometer, a pH meter, a discharge port, a sampling port, a temperature sensor, a second feed pipe, a third metering pump, a modified additive storage tank, a modified additive inlet, and a PLC controller. The homogenizing reactor is located at the left end of the third feed pipe. The anchor stirrer is located inside the homogenizing reactor. The online viscometer and pH meter are respectively arranged in an upper and lower structure on the inner wall of the right end of the homogenizing reactor. The discharge port is located at the bottom of the left end of the homogenizing reactor. The sampling port is located above the discharge port. The temperature sensor is located at the top of the left end of the homogenizing reactor. The second feed pipe is located on the left half of the top of the homogenizing reactor. The third metering pump is located on the second feed pipe. The modified additive storage tank is located at the top of the second feed pipe. The modified additive inlet is located at the top of the modified additive storage tank. The PLC controller is located at the left end of the homogenizing reactor.

[0016] Preferably, the homogenizing reactor is a jacketed stirred reactor, and the left end of the third conveying pipe is located at the top of the right end of the homogenizing reactor. The anchor stirrer rotates at a speed of 50-200 r / min. Low-speed stirring can fully mix the single-component aqueous resin with the primary emulsion, while avoiding excessive shear force that could damage the structure of the carbon-based material, thus ensuring the smooth progress of the chemical grafting reaction. The height of the online viscometer and pH meter is lower than the height of the left end of the third conveying pipe. The online viscometer is set to a viscosity threshold of 500-2000 mPa·s, and the pH meter is set to a threshold of 3-5. The PLC controller automatically adjusts the parameters based on real-time monitoring data and the set thresholds.

[0017] (III) Beneficial Effects This invention provides a stepwise reaction production equipment for carbon-based modified asphalt emulsion. It has the following beneficial effects: 1. The external ultrasonic transducer array achieves efficient and uniform dispersion of carbon-based materials, the equipment is free from contact corrosion and supports fault self-diagnosis and switching, the service life is greatly extended and it is suitable for continuous production.

[0018] 2. The soap solution is heated independently before being fed into the colloid mill. Precise temperature control avoids unstable emulsification, and the qualified particle size of the emulsified finished product is increased to over 98%.

[0019] 3. After emulsification, water-based resin is added to the homogenizing reactor to achieve stepwise modification, avoiding the problem of premature reaction. Precise temperature and time control can improve the bonding strength by more than 30%.

[0020] 4. PLC control enables full-process detection and regulation, ensuring consistency between product batches, significantly improving storage stability, and meeting the requirements of large-scale production.

[0021] 5. The equipment can be partially modified on the basis of existing production lines without replacing the core main equipment. The modification cost is low, the compatibility is strong, and it is suitable for promotion by small and medium-sized enterprises. Attached Figure Description

[0022] Figure 1 is a schematic diagram of the overall structure of the present invention; Figure 2 is a schematic diagram of the internal structure of the flat channel shell of the present invention; Figure 3 is a schematic diagram of the internal and external structure of the homogenizing reactor of the present invention.

[0023] In the diagram: 1-Carbon-based material pre-dispersion mechanism; 11-Pre-dispersion tank; 12-Carbon-based material inlet; 13-Emulsifier aqueous solution inlet; 14-Reflux port; 15-Agitator 1; 16-Discharge pipe 1; 17-Solenoid valve 1; 18-Reflux pipe; 19-Circulation pump; 110-Flat channel shell; 111-Ultrasonic transducer array; 112-Stainless steel vibrating plate; 113-Transducer fault self-diagnosis and automatic switching system for backup group; 2-Soap solution preparation and heating mechanism; 21-Soap solution mixing tank; 22-Agitator 2; 23-Soap solution heater; 24-Discharge pipe 2; 25-Solenoid valve 2; 26-Online particle size analyzer; 27-Discharge pipe 3; 28-Metering pump 1; 3-Emulsifier generation mechanism; 1-Transfer Pipe 1; 32-Solenoid Valve 3; 33-Emulsifier Dissolving Tank; 34-Transfer Pipe 2; 35-Transport Pump 1; 4-Asphalt Pretreatment and Emulsification Mechanism; 41-Colloid Mill Emulsifying Main Unit; 42-Inlet; 43-Inlet Pipe 1; 44-Metering Pump 2; 45-Asphalt Heating Tank; 46-Asphalt Inlet; 47-Transfer Pipe 3; 48-Transport Pump 2; 5-Modified Additive Mixing Mechanism; 51-Homogenizing Reactor; 52-Anchor Agitator; 53-Online Viscometer; 54-pH Meter; 55-Outlet; 56-Sampling Port; 57-Temperature Sensor; 58-Inlet Pipe 2; 59-Metering Pump 3; 510-Modified Additive Storage Tank; 511-Modified Additive Inlet; 512-PLC Controller. Detailed Implementation

[0024] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0025] Please refer to Figures 1-3. An embodiment of the present invention provides a technical solution for implementation: including a carbon-based material pre-dispersion mechanism 1, a soap solution preparation and heating mechanism 2, an emulsifier generation mechanism 3, an asphalt pretreatment and emulsification mechanism 4, and a modified additive mixing mechanism 5. The soap solution preparation and heating mechanism 2 is located at the bottom of the carbon-based material pre-dispersion mechanism 1. The emulsifier generation mechanism 3 is located between the carbon-based material pre-dispersion mechanism 1 and the soap solution preparation and heating mechanism 2. The asphalt pretreatment and emulsification mechanism 4 is located to the left of the soap solution preparation and heating mechanism 2. The modified additive mixing mechanism 5 is located to the left of the asphalt pretreatment and emulsification mechanism 4.

[0026] The carbon-based material pre-dispersion mechanism 1 includes a pre-dispersion tank 11, a carbon-based material inlet 12, an emulsifier aqueous solution inlet 13, a reflux port 14, a stirrer 15 (model: JBJ-1000), a discharge pipe 16, a solenoid valve 17 (model: ZCS-25), a reflux pipe 18, a circulation pump 19 (model: CQF25-20-100), a flat channel housing 110, an ultrasonic transducer array 111 (model: CSB-20K-100W), a stainless steel vibrating plate 112, and a transducer fault self-diagnosis and automatic backup group switching system 113 (model: USM-800). The emulsifier aqueous solution inlet 13 and the carbon-based material inlet 12 are respectively arranged in a left-right structure on the top of the pre-dispersion tank 11. The reflux port 14 is located at the emulsifier aqueous solution inlet 13 and the carbon-based material inlet 12. Between the inlet 12, the stirrer 15 is located at the bottom of the pre-dispersion tank 11, the outlet pipe 16 is located at the right end of the bottom of the pre-dispersion tank 11, the solenoid valve 17 is located in the lower half of the outlet pipe 16, the return pipe 18 is located on the outlet pipe 16 and extends to the right and upward to connect with the return port 14, the circulation pump 19 is located at the starting end of the return pipe 18, the flat channel housing 110 is located on the vertical section of the return pipe 18, the ultrasonic transducer array 111 is vertically and evenly arranged at the left and right ends inside the flat channel housing 110, the stainless steel vibrating plate 112 is arranged opposite to cover each ultrasonic transducer array 111, and the transducer fault self-diagnosis and automatic backup group switching system 113 is located at the front end of the flat channel housing 110.

[0027] In detail, the agitator 15 is a low-speed agitator with a rotation speed of 100-300 r / min, used to prevent carbon-based materials from settling in the tank, and to avoid high-speed agitation generating bubbles that affect the subsequent dispersion effect. The discharge pipe 16 and the return pipe 18 are interconnected. The starting section of the return pipe 18 is located in the upper half of the discharge pipe 16. The width between the two stainless steel vibrating plates 112 is 5-10 mm. This width allows the carbon-based slurry to form a thin-layer flow state, ensuring that the energy of the ultrasonic transducer is uniformly applied to the slurry. The operating frequency of each group of ultrasonic transducer arrays 111 can be adjusted independently.

[0028] The soap solution preparation and heating mechanism 2 includes a soap solution mixing tank 21, a second stirrer 22 (model: JJ-2000), a soap solution heater 23 (model: BR02-10), a second discharge pipe 24, a second solenoid valve 25 (model: ZCS-32), an online particle size analyzer 26 (model: Winner2008A), a third discharge pipe 27, and a first metering pump 28 (model: XM-A100 / 0.6). The soap solution mixing tank 21 is located at the bottom of the first discharge pipe 16, and the second stirrer 22 is located at the bottom of the first discharge pipe 16. The bottom of the soap mixture tank 21 is provided. The soap heater 23 is located at the left end of the soap mixture tank 21. The second discharge pipe 24 is located at the lower left of the soap mixture tank 21 and is connected to the bottom of the soap heater 23. The second solenoid valve 25 is located in the middle of the second discharge pipe 24. The online particle size analyzer 26 is located in the left half of the second discharge pipe 24. The third discharge pipe 27 is located at the top of the soap heater 23 and extends to the left. The first metering pump 28 is located in the middle of the third discharge pipe 27.

[0029] The discharge pipe 16 is located in the right half of the soap solution mixing tank 21. The soap solution heater 23 is a plate heater used to heat the emulsified soap solution to a set temperature of 60-80℃. The online particle size analyzer 26 is set to a carbon-based slurry particle size threshold of ≤50μm.

[0030] The emulsifier generating mechanism 3 includes a first conveying pipe 31, a third solenoid valve 32 (model: ZCS-20), an emulsifier dissolving tank 33, a second conveying pipe 34, and a first transport pump 35 (model: MP-100R). The first conveying pipe 31 is located on the left half of the top of the soap solution mixing tank 21. The third solenoid valve 32 is located on the first conveying pipe 31. The emulsifier dissolving tank 33 is located on the top of the first conveying pipe 31. The second conveying pipe 34 is located on the left half of the top of the emulsifier dissolving tank 33, and the top of the second conveying pipe 34 is connected to the pre-dispersion tank 11. The first transport pump 35 is located on the second conveying pipe 34.

[0031] The asphalt pretreatment and emulsification mechanism 4 includes a colloid mill emulsification main unit 41, a feed inlet 42, a feed pipe 43, a metering pump 44 (model: JYZ-200 / 1.0), an asphalt heating tank 45, an asphalt inlet 46, a conveying pipe 47, and a transport pump 48 (model: FP32-25-125). The colloid mill emulsification main unit 41 is located at the left end of the soap solution heater 23, and the feed inlet 42 is located on the right half of the top of the colloid mill emulsification main unit 41. The feed pipe 43 is located on the top left half of the colloid mill emulsifying host 41 and is connected to the discharge pipe 27. The feed pipe 43 is located on the top left half of the colloid mill emulsifying host 41. The metering pump 44 is located on the feed pipe 43. The asphalt heating tank 45 is located on the top of the feed pipe 43. The asphalt inlet 46 is located on the top of the asphalt heating tank 45. The transport pipe 47 is located at the bottom left end of the colloid mill emulsifying host 41. The transport pump 48 is located on the transport pipe 47.

[0032] The modified additive mixing mechanism 5 includes a homogenizing reactor 51, an anchor stirrer 52 (model: MHJ-3000), an online viscometer 53 (model: NDJ-8S), a pH meter 54 (model: PHG-217), a discharge port 55, a sampling port 56, a temperature sensor 57 (model: PT100), a feed pipe 58, a metering pump 59 (model: DZ-50 / 1.0), a modified additive storage tank 510, a modified additive inlet 511, and a PLC controller 512. The homogenizing reactor 51 is located at the left end of the feed pipe 57, and the anchor stirrer 52 is located inside the homogenizing reactor 51. The online viscometer 53 and pH meter 58... 4 are respectively arranged in an upper and lower structure on the inner wall of the right end of the homogenizing reactor 51. The discharge port 55 is located at the bottom of the left end of the homogenizing reactor 51. The sampling port 56 is located above the discharge port 55. The temperature sensor 57 is located at the top of the left end of the homogenizing reactor 51. The feed pipe 2 58 is located on the left half of the top of the homogenizing reactor 51. The metering pump 3 59 is located on the feed pipe 2 58. The modified additive storage tank 510 is located at the top of the feed pipe 2 58. The modified additive inlet 511 is located at the top of the modified additive storage tank 510. The PLC controller 512 is located at the left end of the homogenizing reactor 51.

[0033] The homogenizing reactor 51 is a jacketed stirred reactor. The left end of the three-phase feed pipe 47 is located at the top of the right end of the homogenizing reactor 51. The anchor stirrer 52 rotates at a speed of 50-200 r / min. Low-speed stirring can fully mix the single-component aqueous resin with the primary emulsion, while avoiding excessive shear force that could damage the structure of the carbon-based material, thus ensuring the smooth progress of the chemical grafting reaction. The height of the online viscometer 53 and pH meter 54 is lower than the height of the left end of the three-phase feed pipe 47. The online viscometer 53 is set to a viscosity threshold of 500-2000 mPa·s, and the pH meter 54 is set to a threshold of 3-5. The PLC controller 512 automatically adjusts the parameters according to the real-time monitoring data and the set thresholds.

[0034] Solution Analysis: 1. More uniform dispersion of carbon-based materials and longer equipment life: An external ultrasonic transducer array 111 is used, allowing the slurry to flow in a thin layer through the flat channel shell 110, resulting in uniform energy distribution. Laboratory-scale comparative verification shows that the dispersion efficiency of carbon-based materials is more than 50% higher than that of traditional insertion-type ultrasonic probes, and the particle size uniformity of the dispersed slurry is improved by 40%. The ultrasonic transducer array 111 is isolated from the slurry by a stainless steel vibrating plate 112, eliminating direct contact corrosion and extending its lifespan from 3-6 months for traditional probes to over 5 years. The ultrasonic transducer array 111 supports online fault diagnosis and automatic switching of backup groups, eliminating the need for downtime maintenance and adapting to continuous production requirements. 2. Precise and controllable emulsification temperature: The soap solution is independently heated to a set temperature before entering the colloid mill emulsification host 41, avoiding emulsification instability caused by excessive temperature differences between asphalt and soap solution. The particle size qualification rate of the emulsified product is increased to over 98%. 3. Reasonable modification sequence: The single-component water-based resin is added to the homogenizing reactor 51 after emulsification, achieving… The system achieves a stepwise reaction of "emulsification first, modification later," avoiding premature participation of water-based resin components in the reaction and affecting the emulsification effect. Simultaneously, it allows for precise control of grafting reaction time and temperature, increasing the bonding strength of the modified asphalt emulsion by over 30%, resulting in better modification effects. 4. Stable product quality: The detection and control of the PLC controller 512 ensures batch-to-batch consistency, with batch-to-batch emulsion particle size deviation ≤5μm, viscosity deviation ≤100mPa・s, and improved storage stability to ≤2% stratification rate after 30 days at room temperature, far superior to existing products and meeting the requirements of large-scale production. 5. Strong equipment compatibility and good economy: This equipment can be partially modified based on existing emulsified asphalt production lines, requiring only the addition of a carbon-based material pre-dispersion mechanism 1, a homogenizing reactor 51, and various monitoring components. It does not require replacing core main equipment such as the colloid mill emulsifying host 41 and the asphalt heating tank 45. The modification cost is more than 60% lower than developing entirely new dedicated equipment, resulting in low investment costs. It is suitable for promotion by small and medium-sized production enterprises and has high market promotion value.

[0035] Working Principle: 1. Asphalt Preparation: Petroleum asphalt is heated to 130-150℃ in the asphalt heating tank 45 to a fluid state, and then transported to the colloid mill emulsifying host 41 via metering pump 2 44; 2. A small amount of emulsifier aqueous solution is generated in the emulsifier dissolving tank 33 and transported upward to the emulsifier aqueous solution inlet 13 via transport pump 1 35; Carbon-based Material Pre-dispersion: Carbon-based materials (one or more of carbon nanotubes, graphene microsheets, carbon black, and graphite) and a small amount of emulsifier aqueous solution are added to the pre-dispersion tank 11, and the stirrer 15 is started at a low speed of 100-300 r / min; at the same time, the circulation pump 19 and the ultrasonic transducer array 111 are started, and the slurry flows in a thin layer through the ultrasonic transducer array 111 on both sides in the flat channel, receiving multi-frequency ultrasonic cavitation, and efficiently deagglomerating agglomerates; after circulating dispersion for 20-40 minutes, the particle size of the carbon-based slurry is detected by the online particle size analyzer 26 to be ≤50μm. Afterwards, the carbon-based concentrated slurry enters the soap solution mixing tank 21 through solenoid valve 17; 3. Soap solution preparation and heating: A quantitative emulsifier aqueous solution is transported downwards through solenoid valve 32. The carbon-based concentrated slurry and the emulsifier aqueous solution in the emulsifier dissolving tank 33 are introduced into the soap solution mixing tank 21 in proportion and stirred for 10-20 minutes to form a uniform emulsified soap solution; After the soap solution is heated to a set temperature of 60-80℃ by the soap solution heater 23, it is quantitatively sent into the colloid mill emulsifying host 41 by metering pump 28; 4. Emulsification: The asphalt and the heated emulsified soap solution undergo three-stage shear emulsification in the colloid mill emulsifying host 41 to form a carbon-based emulsified asphalt primary emulsion, which is transported to the homogenizing reactor 51 by transport pump 2 48; 5. Secondary modification: After the primary emulsion enters the homogenizing reactor 51, the process is started. Anchor-type stirrer 52 stirs at a speed of 50-200 r / min, while the single-component waterborne resin component is slowly added to the reactor from the modified additive storage tank 510 through metering pump 3 59. The reaction is continued for 30-60 minutes at 30-50℃, so that the polar groups in the single-component waterborne resin can undergo a chemical grafting reaction with the active groups such as hydroxyl and carboxyl groups on the surface of asphalt molecules and carbon-based materials to form a stable chemical bond structure, thus completing the secondary modification (heat transfer oil or cooling water is circulated in the jacket of the homogenized reactor to control the reaction temperature at 30-50℃. This temperature range is the optimal temperature for the chemical grafting reaction between the single-component waterborne resin and asphalt and carbon-based materials. The reaction rate is too slow below 30℃, and the emulsion is prone to demulsification above 50℃); 6.Online control: The PLC controller 512 controls stirrer 15, solenoid valve 17, circulating pump 19, ultrasonic transducer array 111, transducer fault self-diagnosis and automatic backup switching system 113, stirrer 22, soap solution heater 23, solenoid valve 25, online particle size analyzer 26, metering pump 1 28, solenoid valve 3 32, transport pump 1 35, metering pump 2 44, transport pump 2 48, anchor stirrer 52, online viscometer 53, pH meter 54, temperature sensor 57, and metering pump 3 59. The PLC controller 512 monitors the soap solution particle size, emulsion viscosity, and pH value in real time. When the monitored values ​​exceed the set threshold, the PLC controller 512 automatically adjusts the flow rate, heating temperature, ultrasonic frequency, and reaction time of each metering pump to ensure stable product quality.

[0036] The technical benefits of implementing this solution are as follows: This solution achieves efficient and uniform dispersion of carbon-based materials through an external ultrasonic transducer array, significantly extending equipment lifespan and adapting to continuous production; precise temperature control via independent heating of the soap solution improves the particle size qualification rate of the emulsified product; the step-by-step reaction design with the addition of modifiers after emulsification effectively enhances the bonding strength of the modified asphalt emulsion; PLC-based full-process monitoring and control ensures batch consistency and storage stability, meeting the needs of large-scale production; furthermore, the equipment can be partially modified based on existing emulsified asphalt production lines, with low modification costs, strong compatibility, and high market promotion value, making it suitable for small and medium-sized production enterprises.

[0037] The present invention comprises: 1-a carbon-based material pre-dispersion mechanism; 11-a pre-dispersion tank; 12-a carbon-based material inlet; 13-an emulsifier aqueous solution inlet; 14-a reflux port; 15-a stirrer; 16-a discharge pipe; 17-a solenoid valve; 18-a reflux pipe; 19-a circulating pump; 110-a flat channel housing; 111-an ultrasonic transducer array; 112-a stainless steel vibrating plate; 113-a transducer fault self-diagnosis and automatic backup switching system; 2-a soap solution preparation and heating mechanism; 21-a soap solution mixing tank; 22-a stirrer; 23-a soap solution heater; 24-a discharge ... discharge pipe; 16-a discharge pipe; 17-a solenoid valve; 18-a reflux pipe; 19-a circulating pump; 10-a flat channel housing; 111-an ultrasonic transducer array; 112-a stainless steel vibrating plate; 113-a transducer fault self-diagnosis and automatic backup switching system; 24-a soap solution preparation and heating mechanism; 25-a soap solution mixing tank; 26-a stirrer; 27-a stirrer; 28-a reflux 25-Solenoid Valve II; 26-Online Particle Size Analyzer; 27-Discharge Pipe III; 28-Metering Pump I; 3-Emulsifier Generation Mechanism; 31-Transfer Pipe I; 32-Solenoid Valve III; 33-Emulsifier Dissolving Tank; 34-Transfer Pipe II; 35-Transport Pump I; 4-Asphalt Pretreatment and Emulsification Mechanism; 41-Colloid Mill Emulsification Main Unit; 42-Inlet; 43-Inlet Pipe I; 44-Metering Pump II; 45-Asphalt Heating Tank; 46-Asphalt Inlet; 47-Transfer Pipe III; 48-Transport Pump II; 5-Modified Additive Mixing Mechanism; 51-Homogenizing Reactor; 5 2-Anchor mixer; 53-Online viscometer; 54-pH meter; 55-Outlet; 56-Sampling port; 57-Temperature sensor; 58-Inlet pipe two; 59-Metering pump three; 510-Modified additive storage tank; 511-Modified additive inlet; 512-PLC controller. These components are all general standard parts or parts known to those skilled in the art. Their structure and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods. The problem solved by this invention is that existing emulsified asphalt production equipment has issues in the preparation of carbon-based modified asphalt emulsions. The technology suffers from numerous shortcomings. There is a lack of dedicated equipment for adding and pre-dispersing carbon-based materials; direct feeding of nano-sized carbon-based materials easily leads to uneven dispersion and equipment blockage. Furthermore, commonly used dispersion equipment such as insertion ultrasonic probes and high-speed shear machines suffer from short lifespans, uneven energy distribution, and susceptibility to blockage and damage to the carbon material structure, requiring downtime for maintenance and making them unsuitable for continuous production. Additionally, the lack of a step-by-step modification process design prevents the implementation of "emulsification before modification," easily causing premature reaction between the modifier and asphalt, resulting in insufficient bonding performance and poor storage stability of the final product, failing to meet the needs of intelligent road maintenance. This invention, through external ultrasonic dispersion, independent temperature control of the soap solution, step-by-step modification, and PLC-based full-process control, achieves efficient and stable production of carbon-based modified asphalt emulsions. Moreover, the equipment can be partially modified from existing production lines, resulting in low modification costs, strong compatibility, and high market potential.

[0038] Note: The reaction control logic in "stepwise modification" is a specific control logic. For example, the PLC controller (512) has a built-in chemical grafting reaction kinetic model. When the online viscometer (53) detects that the viscosity rise rate begins to decrease (i.e., the second derivative is negative), the PLC determines that the main reaction stage is completed and controls the metering pump three (59) to intermittently add the remaining modifying additives in a pulse manner until the fluctuations of the pH meter (54) and temperature sensor (57) tend to stabilize, and the value of the online viscometer (53) is stable within the set threshold for more than 10 minutes, at which point the reaction is determined to be complete.

[0039] Dust-free feeding structure for carbon-based materials: A negative pressure dust-free feeding hopper is added at the carbon-based material inlet. The feeding hopper has a built-in dust extraction fan and filter bags to draw the carbon-based dust generated during the feeding process to the filter bags for collection, which avoids dust pollution and prevents waste of carbon-based materials. At the same time, a screw feeder is set at the bottom of the feeding hopper to quantitatively and evenly feed the carbon-based material into the pre-dispersion tank, which solves the problems of "large dust generation from manual feeding and poor dispersion effect due to uneven feeding".

[0040] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or essential characteristics. Therefore, the embodiments should be considered illustrative and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention. No reference numerals in the claims should be construed as limiting the scope of the claims.

[0041] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A stepwise reaction production equipment for carbon-based modified asphalt emulsion, characterized in that: The apparatus includes a carbon-based material pre-dispersion mechanism (1), a soap solution preparation and heating mechanism (2), an emulsifier generation mechanism (3), an asphalt pretreatment and emulsification mechanism (4), and a modified additive mixing mechanism (5). The soap solution preparation and heating mechanism (2) is located at the bottom of the carbon-based material pre-dispersion mechanism (1). The emulsifier generation mechanism (3) is located between the carbon-based material pre-dispersion mechanism (1) and the soap solution preparation and heating mechanism (2). The asphalt pretreatment and emulsification mechanism (4) is located to the left of the soap solution preparation and heating mechanism (2). The modified additive mixing mechanism (5)... The carbon-based material pre-dispersion mechanism (1) is located to the left of the asphalt pretreatment and emulsification mechanism (4); the carbon-based material pre-dispersion mechanism (1) includes a pre-dispersion tank (11), a carbon-based material inlet (12), an emulsifier aqueous solution inlet (13), a reflux port (14), a stirrer (15), a discharge pipe (16), a solenoid valve (17), a reflux pipe (18), a circulation pump (19), a flat channel housing (110), an ultrasonic transducer array (111), a stainless steel vibrating plate (112), and a transducer fault self-diagnosis and automatic backup group switching system (113). (13) and the carbon-based material inlet (12) are respectively arranged in a left-right structure at the top of the pre-dispersion tank (11). The reflux port (14) is located between the emulsifier aqueous solution inlet (13) and the carbon-based material inlet (12). The agitator (15) is located at the bottom of the pre-dispersion tank (11). The discharge pipe (16) is located at the right end of the bottom of the pre-dispersion tank (11). The solenoid valve (17) is located in the lower half of the discharge pipe (16). The reflux pipe (18) is located on the discharge pipe (16) and extends to the right. The upper extension connects to the return port (14), the circulation pump (19) is set at the starting end of the return pipe (18), the flat channel housing (110) is set on the vertical section of the return pipe (18), the ultrasonic transducer array (111) is vertically and evenly set at the left and right ends inside the flat channel housing (110), the stainless steel vibrating plate (112) is set opposite to each ultrasonic transducer array (111), and the transducer fault self-diagnosis and backup group automatic switching system (113) is set at the front end of the flat channel housing (110).

2. The stepwise reaction production equipment for carbon-based modified asphalt emulsion according to claim 1, characterized in that: The agitator 1 (15) is a low-speed agitator with a rotation speed of 100-300 r / min, used to prevent carbon-based materials from settling in the tank, and to avoid high-speed agitation from generating bubbles that affect the subsequent dispersion effect. The discharge pipe 1 (16) and the return pipe (18) are interconnected. The starting section of the return pipe (18) is located in the upper half of the discharge pipe 1 (16). The width between the two stainless steel vibrating plates (112) is 5-10 mm. This width allows the carbon-based slurry to form a thin-layer flow state, ensuring that the energy of the ultrasonic transducer is uniformly applied to the slurry. The working frequency of each ultrasonic transducer array (111) can be adjusted independently.

3. The stepwise reaction production equipment for carbon-based modified asphalt emulsion according to claim 2, characterized in that: The soap solution preparation and heating mechanism (2) includes a soap solution mixing tank (21), a second stirrer (22), a soap solution heater (23), a second discharge pipe (24), a second solenoid valve (25), an online particle size analyzer (26), a third discharge pipe (27), and a first metering pump (28). The soap solution mixing tank (21) is located at the bottom of the first discharge pipe (16), the second stirrer (22) is located at the bottom of the soap solution mixing tank (21), and the soap solution heater (23) is located at the bottom of the soap solution mixing tank (21). The discharge pipe 2 (24) is located at the lower left of the soap liquid mixing tank (21) and connected to the bottom of the soap liquid heater (23). The solenoid valve 2 (25) is located in the middle of the discharge pipe 2 (24). The online particle size analyzer (26) is located in the left half of the discharge pipe 2 (24). The discharge pipe 3 (27) is located at the top of the soap liquid heater (23) and extends to the left. The metering pump 1 (28) is located in the middle of the discharge pipe 3 (27).

4. The stepwise reaction production equipment for carbon-based modified asphalt emulsion according to claim 3, characterized in that: The discharge pipe (16) is located in the right half of the soap liquid mixing tank (21). The soap liquid heater (23) is a plate heater used to heat the emulsified soap liquid to a set temperature of 60-80℃. The online particle size analyzer (26) is set to a carbon-based slurry particle size threshold of ≤50μm.

5. The stepwise reaction production equipment for carbon-based modified asphalt emulsion according to claim 4, characterized in that: The emulsifier generating mechanism (3) includes a first conveying pipe (31), a third solenoid valve (32), an emulsifier dissolving tank (33), a second conveying pipe (34), and a first transport pump (35). The first conveying pipe (31) is located on the left half of the top of the soap solution mixing tank (21). The third solenoid valve (32) is located on the first conveying pipe (31). The emulsifier dissolving tank (33) is located on the top of the first conveying pipe (31). The second conveying pipe (34) is located on the left half of the top of the emulsifier dissolving tank (33), and the top of the second conveying pipe (34) is connected to the pre-dispersed tank (11). The first transport pump (35) is located on the second conveying pipe (34).

6. The stepwise reaction production equipment for carbon-based modified asphalt emulsion according to claim 5, characterized in that: The asphalt pretreatment and emulsification mechanism (4) includes a colloid mill emulsification main unit (41), a feed inlet (42), a feed pipe (43), a metering pump (44), an asphalt heating tank (45), an asphalt inlet (46), a conveying pipe (47), and a transport pump (48). The colloid mill emulsification main unit (41) is located at the left end of the soap solution heater (23). The feed inlet (42) is located on the right half of the top of the colloid mill emulsification main unit (41) and is connected to the discharge pipe (27). The feed pipe 1 (43) is located on the left half of the top of the colloid mill emulsifying host (41), the metering pump 2 (44) is located on the feed pipe 1 (43), the asphalt heating tank (45) is located on the top of the feed pipe 1 (43), the asphalt inlet (46) is located on the top of the asphalt heating tank (45), the conveying pipe 3 (47) is located at the bottom of the left end of the colloid mill emulsifying host (41), and the transport pump 2 (48) is located on the conveying pipe 3 (47).

7. The stepwise reaction production equipment for carbon-based modified asphalt emulsion according to claim 6, characterized in that: The modified additive mixing mechanism (5) includes a homogenizing reactor (51), an anchor stirrer (52), an online viscometer (53), a pH meter (54), a discharge port (55), a sampling port (56), a temperature sensor (57), a feed pipe II (58), a metering pump III (59), a modified additive storage tank (510), a modified additive inlet (511), and a PLC controller (512). The homogenizing reactor (51) is located at the left end of the feed pipe III (47), the anchor stirrer (52) is located inside the homogenizing reactor (51), and the online viscometer (53) and pH meter (54) are respectively arranged in an upper and lower structure on the inner wall of the right end of the homogenizing reactor (51). The discharge port (55) is located at the bottom of the left end of the homogenizing reactor (51), the sampling port (56) is located above the discharge port (55), the temperature sensor (57) is located at the top of the left end of the homogenizing reactor (51), the feed pipe two (58) is located on the left half of the top of the homogenizing reactor (51), the metering pump three (59) is located on the feed pipe two (58), the modified additive storage tank (510) is located at the top of the feed pipe two (58), the modified additive inlet (511) is located at the top of the modified additive storage tank (510), and the PLC controller (512) is located at the left end of the homogenizing reactor (51).

8. The stepwise reaction production equipment for carbon-based modified asphalt emulsion according to claim 7, characterized in that: The homogenizing reactor (51) is a jacketed stirred reactor. The left end of the third conveying pipe (47) is located at the top of the right end of the homogenizing reactor (51). The speed of the anchor stirrer (52) is 50-200 r / min. Low-speed stirring can make the single-component water-based resin and the initial emulsion fully mixed, while avoiding excessive shear force that could damage the structure of the carbon-based material, thus ensuring the smooth progress of the chemical grafting reaction. The height of the online viscometer (53) and pH meter (54) is lower than the height of the left end of the third conveying pipe (47). The online viscometer (53) is set to a viscosity threshold of 500-2000 mPa·s, and the pH meter (54) is set to a threshold of 3-5. The PLC controller (512) automatically adjusts each parameter according to the real-time monitoring data and the set threshold.

Images