Low temperature process for preparing asphalt mix compositions

Abstract

The present invention relates to a method for producing an asphalt mix composition, comprising the steps of: (1) preparing an asphalt composition and heating the composition to a temperature in the range of 150 to 175°C; (2) preparing granular material and heating the material to a temperature in the range of 130 to 170°C; (3) preparing one or more thermosetting reactive compounds; (4) adding the one or more thermosetting reactive compounds prepared in (3) to the asphalt composition obtained in (1) and homogenizing the mixture for a time in the range of 2 to 180 seconds; and (5) adding the mixture obtained in (4) to the granular material obtained in (2) and homogenizing the slurry for a time in the range of 5 to 180 seconds, wherein the temperature of the resulting asphalt mix composition is in the range of 130 to 155°C. Furthermore, the present invention relates to an asphalt mix composition obtained or obtainable by the method, uses thereof, and a method for asphalt pavement construction at low laying temperatures.

Description

[Technical Field]

[0001] The present invention relates to a low temperature process for preparing an asphalt mix composition, an asphalt mix composition obtained or obtainable by said process, its uses, and a process for asphalt paving at low laying temperatures. [Background technology]

[0002] introduction Generally, asphalt is a colloidal material containing various molecular species classified as asphaltenes and maltenes. Asphalt has viscoelastic and thermoplastic properties, which cause it to change properties at various temperatures, from extremely cold to extremely hot. Asphalt tends to soften in hot weather and crack in extreme cold. At low temperatures, asphalt becomes brittle and prone to cracking, but at high temperatures it softens and loses its physical properties.

[0003] The addition of thermosetting reactive components as binders, or more generally as modifiers, can make the physical properties of the asphalt more consistent at different temperatures and / or improve the physical properties over the range of temperatures to which the asphalt is exposed.

[0004] Such asphalts modified by added binders or modifiers have been known in the art for many years. However, there remains a need in the asphalt industry for improved asphalts. This is in part due to several drawbacks of currently known polymer-modified asphalts. These drawbacks include, for example, permanent deformation (rutting), flexural fatigue, susceptibility to moisture, and reduced resilience when used at low temperatures.

[0005] WO 01 / 30911 A1 discloses an asphalt composition containing about 1 to 8 wt. % polymeric MDI, based on the total weight of the composition, where the polymeric MDI has a functionality of at least 2.5. This document also relates to a method for preparing the asphalt composition using a reaction time of less than 2 hours. The formation of the product MDI-asphalt is measured by the increase in viscosity of the product or, more preferably, by dynamic mechanical analysis (DMA).

[0006] WO 01 / 30912 A1 discloses an aqueous asphalt emulsion which contains, in addition to asphalt and water, an emulsifiable polyisocyanate. This document also relates to an aggregate composition containing said emulsion, and to a method for preparing said composition.

[0007] WO 01 / 30913 A1 discloses an asphalt composition comprising about 1 to 5% by weight of a polymeric MDI-based prepolymer, based on the total weight of the composition, wherein the polymeric MDI has a functionality of at least 2.5. This document also relates to a method for preparing said asphalt composition.

[0008] https: / / eapa.org / wp-content / uploads / 2018 / 07 / EAPA-paper-Warm-MixAsphalt-version-2014-1.pdf, “The use of Warm Mix Asphalt,” EAPA Position Paper, January 1, 2014, pp. 1-23, discloses warm mix asphalt (WMA) technology for producing asphalt with properties or performance equivalent to conventional HMA at temperatures slightly above 100°C.

[0009] https: / / www.faa.gov / documentlibrary / media / advisory_circular / 150-5370-14A / 150_5370_14a_app 1 _part_I I_a.pdf: "Hot Mix Asphalt Paving Handbook, AC 150 / 5370-14A, Appendix 1, Part II-a," January 1, 2001, pages 1-11, discloses hot mix asphalt plant operation in several types of asphalt plant environments: batch plants, cocurrent drum mix plants, and countercurrent drum mix plants.

[0010] http: / / web.archive.org / web / 20071223141536 / http: / / www.in.gov / indot / files / chapter_03(5).pdf: "HOT MIX ASPHALT PLANT OPERATIONS, Chapter 3," December 23, 2007, pages 1-78, discloses hot mix asphalt plant operations in batch and drum plant environments, HMA properties, aggregate mixing, plant inspection and scale checks, plant calibration, and the impact of plant type on plant troubleshooting.

[0011] http: / / www.astecinc.com / images / file / literature / Nomad_with_Baghouse.pdf: "NOMAD™ Hot Mix Asphalt Plant", January 1, 2008, pages 1-5 discloses a Nomad™ hot mix asphalt plant with a cold feed bin, scalping screen, drying drum, liquid asphalt tank, twin shaft coater, baghouse, surge bin and control room.

[0012] https: / / store.asphaltpavement.org / pdfs / ec-101.pdf: "Best Management Practices To Minimize Emissions During HMA Construction; EC-101 4 / 00," April 1, 2000, pp. 1-12, discloses best management practices to minimize emissions during HMA construction. In this context, it discloses that hot mix asphalt (HMA) manufacturers need to recognize that using appropriate storage, mixing, and compaction temperatures for HMA is key to minimizing emissions. Furthermore, it discloses that the primary goal is to minimize temperatures while meeting the specified density.

[0013] Malcolm D Graham et al. “Reduced Mixing Time for Asphalt Concrete Mixes”, Paper presented at the 47 th Annual Meeting, January 1, 1968, pp. 1-17, discloses a reduction in mixing time in asphalt concrete mixers, mentioned in the context that plant-by-plant testing is necessary for the time to be considered reduced, since individual plant design and conditions affect the time requirements for proper distribution of aggregate particles and asphalt coating.

[0014] BECKER Y et al., "Polymer Modified Asphalt," VISION TECNOLOGICA, INTEVEP, LOS TEQUES, VE, vol. 9, no. 1, January 1, 2001, pp. 39-50, discloses that polymer modification of asphalt is considered the best option for improving asphalt properties. It further discloses that polymers significantly increase the useful temperature range of the binder. It further discloses that potential limitations associated with modified bitumen include (i) increased cost, (ii) potential compatibility and stability issues, (iii) potential storage issues with bitumen, (iv) mixing temperature, and (v) the length of time the material must be held at elevated temperatures before installation.

[0015] Bjarne Bo Jensen et al. “15 YEARS EXPERIENCE ADDING POLYMER POWDER DIRECLY INTO THE ASPHALT MIXER”, 5 th Eurasphalt & Eurobitume Congress, 13-15 th June 2012, Istanbul, June 15, 2012, pp. 1-8, discloses an attempt to increase the polymer loading of special polymer powders to obtain better asphalt properties (better rutting resistance and better fatigue resistance). Laboratory results show improved binder properties, and field tests on various types of roads have shown improved performance of asphalt pavements (less crack propagation and better rutting resistance). Furthermore, it is disclosed that when the polymer is added directly to the asphalt mixer, it is possible to modify even small amounts of asphalt with different bitumen hardness, and no special bitumen storage facilities are required.

[0016] In a study by HESAMI EBRAHIM et al., "Study of the amine-based liquid anti-stripping agents by simulating hot mix asphalt plant production process," CONSTRUCTION AND BUILDING MATERIALS, vol. 157, 2017, pp. 1011-1017, they simulated HMA manufacturing conditions and then investigated the effect of two amine-based liquid anti-stripping agents on the performance of the HMA using tensile strength ratio (TSR) and semicircular specimen bend (SCB) tests. They also disclosed that the results of this study showed that the effectiveness of these additives was significantly reduced after prolonged heating for HMA manufacturing.

[0017] Luo Sang et al., "Performance evaluation of epoxy-modified open-graded porous asphalt concrete," CONSTRUCTION AND BUILDING MATERIALS, Elsevier, Netherlands, vol. 76, December 12, 2014, pp. 97-102, discloses a novel open-graded porous asphalt mixture that uses epoxy asphalt as a binder to improve the mixture's durability. This study selected a type of epoxy asphalt successfully applied to dense-graded asphalt concrete for bridge deck paving. The study also describes the procedure for compacting the mixture into slab specimens, as well as a series of laboratory tests conducted to evaluate the performance of the novel mixture, including cantabrio loss, permeability, sound absorption, splitting tensile strength, friction, shear stiffness, shear strength, and wheel rutting tests. The results also show that the epoxy-modified open-graded porous asphalt mixture exhibited superior overall performance compared to conventional open-graded porous asphalt mixtures.

[0018] Fang Changqing et al., "Preparation and Properties of Isocyanate and Nanoparticle Composite Modified Asphalt," CONSTRUCTION AND BUILDING MATERIALS, Elsevier, Netherlands, Vol. 119, May 13, 2016, pp. 113-118, discloses that isocyanate-modified asphalt samples were obtained by adding a quantitative amount of isocyanate to base asphalt. Isocyanate- and nanoparticle-modified asphalt samples were prepared by adding quantitative amounts of isocyanate and three inorganic nanoparticles (silicon dioxide, titanium dioxide, and zinc oxide) to the base asphalt. The isocyanate-modified asphalt and the isocyanate- and nanoparticle-modified asphalt were characterized by physical tests, SEM, fluorescence microscopy, TG, and FTIR tests, demonstrating that the high- and low-temperature performance of the isocyanate- and nanoparticle-modified asphalt was effectively improved. Furthermore, it is disclosed that from a microscopic point of view, the modification of the base asphalt is very important, and as a result, the temperature sensitivity of the composite modified asphalt is reduced. Furthermore, it is disclosed that the thermal stability is also improved at the same time when compared with the base asphalt and the isocyanate modified asphalt.

[0019] EP 3 006 525 A1 discloses an asphalt-urethane composition containing at least component (A) obtained by adding an MDI prepolymer produced by reacting a polyolefin polyol having two or more hydroxyl groups, a short-chain polyhydric alcohol, an MDI monomer, an MDI monomer, and a solvent a, and component (B) containing asphalt, a catalyst, and a solvent b.

[0020] WO 2017 / 125421 A1 discloses a method for producing an asphalt composition for road paving, which includes a step of mixing asphalt, polyester resin, and aggregate at 130°C or higher and 200°C or lower for 30 seconds or longer, wherein the polyester resin is a polyester having a constituent component derived from an alcohol component containing 65 mol% or more of an alkylene oxide adduct of bisphenol A and a constituent component derived from a carboxylic acid component containing 50 mol% or more of at least one selected from the group consisting of terephthalic acid and isophthalic acid, and has a softening point of 95°C or higher and 130°C or lower and a hydroxyl group value of 20 mgKOH / g or higher and 50 mgKOH / g or lower, and the polyester resin is mixed in a ratio of 5 to 50 parts by mass per 100 parts by mass of asphalt.

[0021] EP 0 537 638 B1 discloses a polymer-modified bitumen composition containing 0.5 to 10 parts by weight of a functionalized polyoctenamer per 100 parts by weight of bitumen, and optionally a crosslinker, characterized in that the polyoctenamer is predominantly a trans-polyoctenamer and contains carboxyl groups and groups derived therefrom, such as maleic acid.

[0022] Meanwhile, WO 2018 / 228840 A1 discloses an improved asphalt composition that exhibits improved physical properties in that they are more consistent across temperatures, the asphalt composition being obtainable by a process comprising mixing asphalt with a thermosetting reactive compound and stirring the mixture for at least 2.5 hours.

[0023] In European Patent Application No. 19198042.4, a method for preparing an asphalt mix composition is disclosed that uses a specific series of short mixing steps in the temperature range of 110-200°C. [Prior art documents] [Patent documents]

[0024] [Patent Document 1] WO 01 / 30911 A1 [Patent Document 2] WO 01 / 30912 A1 [Patent Document 3] WO 01 / 30913 A1 [Patent Document 4] EP 3 006 525 A1 [Patent Document 5] WO 2017 / 125421 A1 [Patent Document 6] EP 0 537 638 B1 [Patent Document 7] WO 2018 / 228840 A1 [Patent Document 8] European Patent Application No. 19198042.4 [Non-patent literature]

[0025] [Non-Patent Document 1] https: / / eapa.org / wp-content / uploads / 2018 / 07 / EAPA-paper-Warm-MixAsphalt-version-2014-1.pdf “The use of Warm Mix Asphalt,” EAPA Position Paper, January 1, 2014, pp. 1–23 [Non-patent document 2] https: / / www.faa.gov / documentlibrary / media / advisory_circular / 150-5370-14A / 150_5370_14a_app 1 _part_I I_a. pdf: "Hot Mix Asphalt Paving Handbook, AC 150 / 5370-14A, Appendix 1, Part II-a", January 1, 2001, pp. 1-11 [Non-patent document 3] http: / / web.archive.org / web / 20071223141536 / http: / / www.in.gov / indot / files / chapter_03(5).pdf: "HOT MIX ASPHALT PLANT OPERATIONS, Chapter 3", December 23, 2007, pp. 1-78

Non-patent document 4

Non-patented document 5

Non-patent document 6

Non-patent document 7

Non-patent document 8

[0026] Although significant improvements have been achieved with respect to the physical properties of asphalt compositions, the aforementioned benefits require greater efforts in reducing energy consumption during preparation and asphalt pavement construction. In view of the above, there remains a need to provide improved methods for obtaining such materials in a highly effective manner, particularly with respect to energy efficiency, workability during asphalt pavement construction, and asphalt mix performance.

[0027] It was therefore an object of the present invention to provide an improved energy efficient method for preparing asphalt mix compositions that exhibit advantageous physical properties and high performance. [Means for solving the problem]

[0028] According to the present invention, the terms "asphalt," "bitumen," "asphalt binder," and "asphalt composition" are used equivalently. Generally, asphalt is a colloidal material containing various molecular species classified as asphaltenes and maltenes.

[0029] The asphalt / bitumen / asphalt binder / asphalt composition can be unmodified or modified. Unmodified asphalt / bitumen / asphalt binder / asphalt composition, also referred to as paving-grade bitumen / paving-grade asphalt, can have, for example, a penetration grade (=pen grade) of 50-70 or 70-100 (measured according to DIN EN 1426). Modified asphalt compositions can be, for example, polymer-modified bitumen (PmB). The respective polymer can be selected from the group consisting of thermoplastic elastomers, latexes, thermoplastic polymers, thermosetting polymers, and mixtures of two or more thereof. The thermoplastic elastomer can be, for example, styrene-butadiene elastomer (SBE), styrene-butadiene styrene (SBS), or styrene-butadiene rubber (SBR). An example of an SBS-modified bitumen is PmB 25 / 55-55 RC.

[0030] In accordance with the present invention, the terms "reclaimed asphalt pavement" (also abbreviated as RAP), "recycled asphalt," "reclaimed asphalt," "reclaimed asphalt pavement material," and "reclaimed asphalt mix" are used interchangeably to describe a material that may also be described as "reprocessed pavement containing asphalt and aggregate."

[0031] In accordance with the present invention, the term "granular material" is similarly used to describe a component that may also be described as one or more "aggregates." Further, in accordance with the present invention, the granular material or aggregate may include one or more of gravel, sand, filler, and fine aggregate. In this regard, additional specific and / or preferred embodiments are disclosed herein.

[0032] According to the present invention, the terms "asphalt mix composition" and "asphalt mix" are used to describe a mixture of aggregate / granular material, recycled asphalt, any type of additives (e.g., thermosetting reactive compounds, fibers, rejuvenating additives, reactive modifiers, etc.), and asphalt / bitumen / asphalt binder / asphalt composition (modified or unmodified).

[0033] In accordance with the present invention, the terms "reclaimed asphalt" or "reclaimed bitumen" or "reclaimed asphalt binder" are used to describe the asphalt / bitumen extracted from the asphalt mix composition. The respective recovery procedures are described in the experimental section.

[0034] According to the present invention, the term "homogenized" or "homogenization" is used to describe the mixing of various elements into a mixture that is uniform throughout, e.g., by mixing, to make the structure or composition uniform throughout.

[0035] Therefore, it has surprisingly been found that, contrary to the teachings of the prior art, modification of the respective asphalt with a thermosetting reactive compound can be achieved even at low temperatures during the preparation process, resulting in asphalt mix compositions having improved physical properties of the asphalt after intensive mixing with granular materials such as sand or gravel, in that the physical properties are more consistent at various temperatures (i.e., the asphalt contained in such asphalt mix compositions exhibits an increased useful temperature interval (UTI), a decreased irrecoverable creep compliance (Jnr), an increased elastic response, an increased softening point, and a decreased penetration, thus resulting in better performance of the corresponding asphalt mix compositions in terms of, for example, improved rutting resistance, fatigue resistance, low temperature resistance, and road durability over a wider temperature range). It has therefore been found, quite surprisingly, that asphalt mix compositions with advantageous properties can be obtained using specific consecutive, relatively short mixing steps in combination with low-temperature processing, resulting not only in significant time and energy savings during the preparation process, but also in further advantages over benchmark asphalt mixes known in the prior art, such as SBS-modified bitumen, namely: (i) reduced asphalt mixing temperatures, resulting in reduced CO2 emissions since the aggregate, recycled asphalt, and asphalt binder are heated to lower temperatures; (ii) reduced bitumen emissions (aerosols and fumes) at the construction site during asphalt laying; and (iii) modified asphalt mixes exhibiting high workability at low laying temperatures with shorter cooling periods after paving.

[0036] Without being bound by this theory, the inventors believe that the superior workability even with a high recycled asphalt content is a result of the fact that, even at comparable low processing temperatures, the thermosetting reactive compound reacts and crosslinks with the aged bitumen derived from the recycled asphalt and the unaged, unmodified pavement-grade bitumen. Due to oxidative degradation, the aged bitumen possesses a higher density of functional groups (generated by oxidation). Due to the nature of the reactive modifier, the functional groups available on both the aged and unaged bitumen serve as anchor groups for reactive crosslinking, and thus chemically linking the aged and unaged bitumen.

[0037] Accordingly, the present invention provides a method for preparing an asphalt mix composition, comprising the steps of: (1) preparing an asphalt composition and heating the composition to a temperature in the range of 150 to 175°C; (2) providing a granular material and heating the material to a temperature in the range of 130 to 170°C; (3) providing one or more thermosetting reactive compounds; (4) adding one or more thermosetting reactive compounds prepared in (3) to the asphalt composition obtained in (1) and homogenizing the mixture for a time ranging from 2 to 180 seconds; (5) adding the mixture obtained in (4) to the granular material obtained in (2) and homogenizing the slurry for a time period ranging from 5 to 180 seconds, wherein the temperature of the resulting asphalt mix composition is in the range of 130 to 155°C.

[0038] The temperature of the homogenized slurry obtained in (5), i.e., the resulting asphalt mixture composition, is preferably in the range of 132 to 155°C, more preferably 135 to 152°C, more preferably 135 to 150°C, more preferably 135 to 148°C, more preferably 135 to 147°C, more preferably 135 to 145°C.

[0039] The total time from the addition of the thermosetting reactive compound (4) to the subsequent obtaining of the homogenized slurry (5) is preferably in the range of 10 seconds to 7 days, more preferably 10 seconds to 3 days, more preferably 15 seconds to 1 day, more preferably 15 seconds to 12 hours, more preferably 20 seconds to 6 hours, more preferably 20 seconds to 1 hour, more preferably 25 seconds to 30 minutes, more preferably 25 seconds to 15 minutes, more preferably 30 seconds to 6 minutes, more preferably 30 seconds to 3 minutes, more preferably 35 seconds to 2 minutes, more preferably 35 seconds to 90 seconds, more preferably 40 seconds to 85 seconds, more preferably 45 seconds to 70 seconds, and more preferably 50 seconds to 60 seconds.

[0040] After (4) and before (5), the mixture obtained in (4) is preferably stored at a temperature in the range of 60 to 175°C, more preferably 70 to 170°C, more preferably 80 to 168°C, more preferably 90 to 165°C, more preferably 110 to 165°C, more preferably 130 to 163°C, more preferably 150 to 160°C.

[0041] After (4) and before (5), the mixture obtained in (4) is preferably stored for a time in the range of 0 seconds to 7 days, more preferably 5 seconds to 3 days, more preferably 10 seconds to 1 day, more preferably 15 seconds to 12 hours, more preferably 20 seconds to 6 hours, more preferably 25 seconds to 1 hour, more preferably 30 seconds to 30 minutes, more preferably 35 seconds to 15 minutes, more preferably 40 seconds to 6 minutes, more preferably 45 seconds to 3 minutes, more preferably 50 seconds to 2 minutes, more preferably 55 seconds to 90 seconds, and more preferably 60 seconds to 70 seconds.

[0042] After (4) and before (5), it is preferable to mix the mixture obtained in (4) at a mixing speed of 100 rpm or less, more preferably 50 rpm or less, more preferably 25 rpm or less, more preferably 20 rpm or less, more preferably 15 rpm or less, more preferably 10 rpm or less, more preferably 5 rpm or less, more preferably 3 rpm or less.

[0043] Preferably, the mixture obtained in (4) is not mixed after (4) and before (5), and more preferably, the mixture obtained in (4) is not homogenized after (4) and before (5).

[0044] Alternatively, the mixture obtained in (4) is preferably treated directly in (5).

[0045] In (1), the asphalt composition is preferably heated to a temperature in the range of 150 to 172°C, more preferably 155 to 172°C, more preferably 155 to 170°C, more preferably 158 to 170°C, more preferably 160 to 170°C.

[0046] In (2), the granular material is preferably heated to a temperature in the range of 135 to 170°C, more preferably 140 to 170°C, more preferably 145 to 170°C, more preferably 150 to 170°C, more preferably 155 to 168°C.

[0047] The homogenization in (5) is preferably carried out at a temperature in the range of 135 to 155°C, more preferably 138 to 155°C, more preferably 140 to 155°C, more preferably 140 to 152°C, more preferably 145 to 150°C.

[0048] Generally, the asphalt composition used in the present invention can be any known asphalt, and generally includes any bitumen compound. The asphalt composition can be any material known as bitumen or asphalt. In particular, in the context of the present invention, the term "asphalt" or "asphalt composition" as used herein preferably refers to the definition set forth in ASTM D8-02 (asphalt is defined as a dark brown to black cementitious material whose primary component is bitumen, whether found in nature or obtained from petroleum processing).

[0049] The asphalt composition prepared in (1) has a penetration selected from the group consisting of 20-30, 30-45, 35-50, 40-60, 50-70, 70-100, 100-150, 160-220, and 250-330, or a performance grade selected from the group consisting of 52-16, 52-22, 52-28, 52-34, 52-40, 58-16, 58-22, 58-28, 58-34, 58-40, 64-16, 64-22, and more preferably, the asphalt composition prepared in (1) has a penetration selected from the group consisting of 30 to 45, 35 to 50, 40 to 60, 50 to 70, 70 to 100, 100 to 150, and 160 to 220, or a performance grade and more preferably, the asphalt composition prepared in (1) has a penetration of 40 to 60, 50 to 70, 70 to 100, and 100 to 150. The asphalt composition prepared in (1) is preferably selected from the group consisting of 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 40, 41, 42, 43, 44, 45, 46, 47, 48, 50, 51, 52, 53, 54, 55, 56, 57, 58, 60, 61, 62, 63, 64, 65, 70, 71, 72, 73, 74, 75, 76, 77, 78, 80, 81, 82, 83, 84, 85, 86, 87, 88, 89, 90, 91, 92, 93, 94, 95, 96, 97, 98, 99, 100, 101, 112, 113, 114, 115, 116, 117, 118, 120, 122, 124, 126, 128, 129, 130, 131, 132, 133, 134, 135, 136, 137, 138, 139, 140, 141, 142, 143, 144,

[0050] If the asphalt composition prepared in (1) contains modified bitumen, the bitumen may contain any of the following additives: chemical modifiers (e.g., organometallic compounds, sulfur, phosphoric acid (PA), polyphosphoric acid (PPA), sulfonic acid, sulfuric acid, carboxylic acid anhydrides, acid esters, dibenzoyl peroxide, silanes, organic and inorganic urea sulfides), recycled materials (e.g., crumb rubber, plastics), fibers (e.g., lignin, cellulose, glass fiber, magnesium aluminosilicate, polyester, polypropylene), adhesion promoters (e.g., organic amines, amides), natural asphalt (e.g., Trinidad Lake Asphalt (T It is preferred that the rubber composition be modified with one or more compounds selected from the group consisting of: acrylic acid esters (LA), Gilsonite, rock asphalt), antioxidants (e.g., phenols, organic zinc compounds, organic lead compounds), fillers (e.g., carbon black, slaked lime, lime, fly ash), viscosity modifiers (e.g., flax oil, wax), reactive polymers (e.g., random terpolymers of ethylene, acrylic acid esters and glycidyl methacrylate, maleic anhydride grafted styrene-butadiene-styrene copolymers), and mixtures of two or more thereof.

[0051] The one or more thermosetting reactive compounds in (3) preferably comprise one or more compounds selected from the group consisting of polyisocyanates, epoxy resins, melamine formaldehyde resins, and mixtures of two or more thereof, preferably from the group consisting of aliphatic polyisocyanates, araliphatic polyisocyanates, aromatic polyisocyanates, and mixtures of two or more thereof, more preferably from the group consisting of aromatic diisocyanates, oligomeric aromatic polyisocyanates, and mixtures of two or more thereof; more preferably, the one or more thermosetting reactive compounds comprise a mixture of one or more aromatic diisocyanates and one or more oligomeric aromatic polyisocyanates; more preferably, the one or more thermosetting reactive compounds consist of a mixture of one or more aromatic diisocyanates and one or more oligomeric aromatic polyisocyanates.

[0052] According to the present invention, the polyisocyanate is preferably aliphatic, cycloaliphatic, or araliphatic, and more preferably an aromatic polyisocyanate known in the art. Such polyfunctional isocyanates are known and can be prepared by methods known per se. Polyfunctional isocyanates can also be used, particularly as mixtures, so that the polyisocyanate in this case contains various polyfunctional isocyanates. According to the present invention, the polyisocyanate is a polyfunctional isocyanate having two (hereinafter referred to as diisocyanate) or three or more isocyanate groups per molecule. Furthermore, according to the present invention, the term "oligomeric polyisocyanate," more specifically "oligomeric aromatic polyisocyanate," refers to a polyfunctional isocyanate having three or four or more isocyanate groups per molecule.

[0053] In particular, according to the present invention, polyisocyanates are alkylene diisocyanates in which the alkyl group has 4 to 12 carbon atoms, such as 1,12-dodecane diisocyanate, 2-ethyltetramethylene diisocyanate-1,4, 2-methylpentamethylene diisocyanate-1,5, tetramethylene diisocyanate-1,4, preferably hexamethylene diisocyanate-1,6; alicyclic diisocyanates such as cyclohexane-1,3- and 1,4-diisocyanate, and any mixtures of these isomers, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethylcyclohexane (IPDI), 2,4- and 2,6-hexahydrotoluene diisocyanate, and the corresponding isomer mixtures. , 4,4'-, 2,2'- and 2,4'-dicyclohexylmethane diisocyanate and the corresponding isomeric mixtures, preferably aromatic polyisocyanates such as 2,4- and 2,6-toluene diisocyanate and the corresponding isomeric mixtures, 4,4'-, 2,4'- and 2,2'-diphenylmethane diisocyanate and the corresponding isomeric mixtures, mixtures of 4,4'- and 2,4'-diphenylmethane diisocyanate, polyphenylpolymethylene polyisocyanates, mixtures of 4,4'-, 2,4'- and 2,2'-diphenylmethane diisocyanate with polyphenylpolyethylene polyisocyanate, and mixtures of MDI and toluene diisocyanate.

[0054] Particularly suitable are 2,2'-, 2,4'- and / or 4,4'-diphenylmethane diisocyanate, 1,5-naphthylene diisocyanate (NDI), 2,4- and / or 2,6-toluene diisocyanate (TDI), 3,3'-dimethyldiphenyl diisocyanate, 1,2-diphenylethane diisocyanate and / or p-phenylene diisocyanate (PPDI), tri-, tetra-, penta-, hexa-, hepta- and / or octamethyl diisocyanate, 2-methylpentamethylene-1,5-diisocyanate, 2-ethylbutylene-1,4 -diisocyanates, pentamethylene-1,5-diisocyanate, butylene-1,4-diisocyanate, 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane (isophorone diisocyanate, IPDI), 1,4- and / or 1,3-bis(isocyanatomethyl)cyclohexane (HXDI), 1,4-cyclohexane diisocyanate, 1-methyl-2,4- and / or -2,6-cyclohexane diisocyanate, and 4,4'-, 2,4'- and / or 2,2'-dicyclohexylmethane diisocyanate.

[0055] Modified polyisocyanates, i.e., products obtained by chemical reaction of organic polyisocyanates and containing at least two reactive isocyanate groups per molecule, are also preferably used. Particular mention should be made of polyisocyanates containing ester, urea, biuret, allophanate, carbodiimide, isocyanurate, uretdione, carbamate and / or urethane groups, often together with unreacted polyisocyanates.

[0056] According to the invention, the polyisocyanate particularly preferably comprises 2,2'-MDI, 2,4'-MDI, 4,4'-MDI, or a mixture of at least two of these isocyanates (also known as monomeric diphenylmethane or MMDI), or oligomeric MDI consisting of higher-core MDI homologues having at least three aromatic nuclei and a functionality of at least 3, or a mixture of two or more of the above-mentioned diphenylmethane diisocyanates, or crude MDI obtained in the preparation of MDI, or preferably a mixture of at least one higher-core MDI homologue with at least one low-molecular-weight MDI derivative, 2,2'-MDI, 2,4'-MDI or 4,4'-MDI (such mixtures are also known as polymeric MDI). The average functionality of the polymeric MDI-containing polyisocyanates can vary from about 2.2 to about 4, particularly 2.4 to 3.8, and especially 2.6 to 3.0.

[0057] Polyfunctional isocyanates, or mixtures of several MDI-based polyfunctional isocyanates, are known and commercially available, for example, from BASF. According to the present invention, the one or more thermosetting reactive compounds preferably contain at least 70% by weight, particularly preferably at least 90% by weight, and in particular 100% by weight, of one or more isocyanates selected from the group consisting of 2,2'-MDI, 2,4'-MDI, 4,4'-MDI, and larger MDI homologues, based on the total weight of the one or more thermosetting reactive compounds. The content of larger homologues having more than three rings is preferably at least 20% by weight, particularly preferably more than 30% by weight and less than 80% by weight, based on the total weight of the one or more thermosetting reactive compounds.

[0058] The viscosity of the thermosetting reactive compound(s) used in the method of the present invention can vary over a wide range. Preferably, the thermosetting reactive compound(s) have a viscosity at 25°C of 100 to 3,000 mPa·s, particularly preferably 100 to 1,000 mPa·s, particularly preferably 100 to 600 mPa·s, in particular 200 to 600 mPa·s, and in particular 400 to 600 mPa·s. The viscosity of the thermosetting reactive compound(s) can vary over a wide range.

[0059] When the one or more thermosetting reactive compounds include an aliphatic polyisocyanate, the aliphatic polyisocyanate may be an alkylene diisocyanate in which the alkylene group has 4 to 12 carbon atoms, and mixtures of two or more thereof, such as 1,12-dodecane diisocyanate, 2-ethyltetramethylene diisocyanate-1,4, 2-methylpentamethylene diisocyanate-1,5, tetramethylene diisocyanate-1,4, hexamethylene diisocyanate-1,6, trimethyl diisocyanate, tetramethyl diisocyanate, pentamethyl diisocyanate, hexamethyl diisocyanate, heptamethyl diisocyanate, octamethyl diisocyanate, 2-methylpentamethylene-1,5-diisocyanate, 2-ethylbutylene-1,4-diisocyanate, pentamethylene-1, Preferably, the aliphatic polyisocyanate comprises one or more compounds selected from the group consisting of hexamethylene diisocyanate-1,6, hexamethylene diisocyanate-1,5-diisocyanate, and butylene-1,4-diisocyanate, preferably trimethyl diisocyanate, tetramethyl diisocyanate, pentamethyl diisocyanate, hexamethyl diisocyanate, heptamethyl diisocyanate, octamethyl diisocyanate, 2-methylpentamethylene-1,5-diisocyanate, 2-ethylbutylene-1,4-diisocyanate, pentamethylene-1,5-diisocyanate, butylene-1,4-diisocyanate, and mixtures of two or more thereof; more preferably, the aliphatic polyisocyanate comprises hexamethylene diisocyanate-1,6, hexamethylene diisocyanate-1,6.

[0060] When the one or more thermosetting reactive compounds comprise a cycloaliphatic polyisocyanate, the aliphatic polyisocyanate may be 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane (isophorone diisocyanate, IPDI), 1,4-bis(isocyanatomethyl)cyclohexane and / or 1,3-bis(isocyanatomethyl)cyclohexane (HXDI), 1,4-cyclohexane diisocyanate, 1-methyl-2,4- and / or or -2,6-cyclohexane diisocyanate, 4,4'-dicyclohexylmethane diisocyanate, 2,2'-dicyclohexylmethane diisocyanate, 2,4'-dicyclohexylmethane diisocyanate, cyclohexane-1,3-diisocyanate, cyclohexane-1,4-diisocyanate, 2,4-hexahydrotoluene diisocyanate, 2,6-hexahydrotoluene diisocyanate, 4,4'-dicyclohexylmethane diisocyanate From the group consisting of isocyanates, 2,2'-dicyclohexylmethane diisocyanate, 2,4'-dicyclohexylmethane diisocyanate, and mixtures of two or more thereof, preferably 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane (isophorone diisocyanate, IPDI), 1,4-bis(isocyanatomethyl)cyclohexane and / or 1,3-bis(isocyanatomethyl)cyclohexane Preferably, the alicyclic compound comprises one or more alicyclic compounds selected from the group consisting of cyclohexane (HXDI), 1,4-cyclohexane diisocyanate, 1-methyl-2,4- and / or -2,6-cyclohexane diisocyanate, and 4,4'-dicyclohexylmethane diisocyanate, 2,2'-dicyclohexylmethane diisocyanate, 2,4'-dicyclohexylmethane diisocyanate, and mixtures of two or more thereof.

[0061] When the one or more thermosetting reactive compounds comprise an aromatic polyisocyanate, the aromatic polyisocyanate, and preferably the aromatic diisocyanate, is selected from the group consisting of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 2,2'-diphenylmethane diisocyanate, 1,5-naphthylene diisocyanate (NDI), 3,3'-dimethyldiphenyl diisocyanate, 1,2-diphenylethane diisocyanate, 1,5-naphthylene diisocyanate (NDI), 1,5-naphthylene diisocyanate, ... cyanate, p-phenylene diisocyanate (PPDI), and mixtures of two or more thereof, preferably 2,4-toluene diisocyanate (2,4-TDI), 2,6-toluene diisocyanate (2,6-TDI), 4,4'-diphenylmethane diisocyanate (4,4'-MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI), 2,2'-diphenylmethane diisocyanate (2,2'-MDI), crude MDI obtained in MDI preparation, and and mixtures of two or more thereof, more preferably 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 2,2'-diphenylmethane diisocyanate, and mixtures of two or more thereof (mixtures of the isomers 4,4'-, 2,4'-, and 2,2'-diphenylmethane diisocyanate are also referred to as monomeric diphenylmethane or MMDI). Preferably, the aromatic polyisocyanate, and preferably the aromatic diisocyanate, comprises a mixture of 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, and 2,2'-diphenylmethane diisocyanate, and more preferably the aromatic polyisocyanate, and preferably the aromatic diisocyanate, consists of a mixture of 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, and 2,2'-diphenylmethane diisocyanate.

[0062] When the one or more thermosetting reactive compounds comprise a polyisocyanate, it is preferred that the polyisocyanate comprises a modified polyisocyanate, preferably a modified organic polyisocyanate, more preferably a modified organic polyisocyanate, containing one or more ester, urea, biuret, allophanate, carbodiimide, isocyanurate, uretdione, carbamate and / or urethane groups.

[0063] When the one or more thermosetting reactive compounds include an oligomeric aromatic polyisocyanate, the oligomeric aromatic polyisocyanate preferably includes one or more compounds selected from the group consisting of polyphenylpolymethylene polyisocyanates, polyphenylpolyethylene polyisocyanates, and mixtures of two or more thereof, preferably one or more polymethylene polyphenyl isocyanates, polyethylene polyphenyl isocyanates, and mixtures of two or more thereof; more preferably, the aromatic polyisocyanate includes one or more polymethylene polyphenyl isocyanates; more preferably, the aromatic polyisocyanate consists of one or more polymethylene polyphenyl isocyanates.

[0064] When the one or more thermosetting reactive compounds comprise an oligomeric aromatic polyisocyanate, the oligomeric aromatic polyisocyanate preferably comprises one or more oligomers of larger core homologs of one or more of 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, and 2,2'-diphenylmethane diisocyanate, wherein the larger core homologs have at least three aromatic nuclei and a functionality of at least three.

[0065] When the one or more thermosetting reactive compounds include one or more compounds selected from the group consisting of polyisocyanate, epoxy resin, melamine formaldehyde resin, and a mixture of two or more of them, the one or more thermosetting reactive compounds are polymeric MDI, and the total amount of 4,4'-MDI in the polymeric MDI is preferably in the range of 26 to 98 mass%, preferably in the range of 30 to 95 mass%, more preferably in the range of 35 to 92 mass%, relative to 100 mass% of the one or more thermosetting reactive compounds.

[0066] When the one or more thermosetting reactive compounds include one or more compounds selected from the group consisting of polyisocyanate, epoxy resin, melamine formaldehyde resin, and a mixture of two or more thereof, the one or more thermosetting reactive compounds are polymeric MDI, and the two-ring content of the polymeric MDI is preferably in the range of 20 to 62%, more preferably in the range of 26 to 48% by mass, and most preferably in the range of 26 to 48% by mass, relative to 100% by mass of the polymeric MDI. When the one or more thermosetting reactive compounds include one or more compounds selected from the group consisting of polyisocyanates, epoxy resins, melamine formaldehyde resins, and mixtures of two or more of them, the average number of isocyanate groups in the one or more thermosetting reactive compounds, and preferably in the entire polyisocyanate contained in the compounds, is preferably 2.1 to 3.5, preferably 2.3 to 3.2, more preferably 2.4 to 3, more preferably 2.5 to 2.9, and more preferably 2.6 to 2.8.

[0067] The iron content of the one or more thermosetting reactive compounds is preferably in the range of 1 to 100 wppm, preferably 1 to 80 wppm, more preferably 1 to 60 wppm, more preferably 1 to 40 wppm, more preferably 1 to 20 wppm, more preferably 1 to 10 wppm, more preferably 1 to 5 wppm.

[0068] It is preferred that the one or more thermosetting reactive compounds exhibit a viscosity in the range of 100 to 3,000 mPa·s, preferably 100 to 1,000 mPa·s, more preferably 100 to 600 mPa·s, more preferably 200 to 600 mPa·s, more preferably 400 to 600 mPa·s, the viscosity being measured at 25°C.

[0069] When the one or more thermosetting reactive compounds comprise one or more epoxy resins, the epoxy resin is one or more compounds selected from the group consisting of aromatic epoxy resins, alicyclic epoxy resins, and mixtures of two or more thereof, more preferably bisphenol A bisglycidyl ether (DGEBA), bisphenol F bisglycidyl ether, ring-hydrogenated bisphenol A bisglycidyl ether, ring-hydrogenated bisphenol F bisglycidyl ether, bisphenol S bisglycidyl ether (DGEBS), tetraglycidylmethylenedianiline (TGMDA), epoxy novolac (epicrocarbonate), bisphenol A bisglycidyl ether (DGEBS), bisphenol F bisglycidyl ether (DGEBS), bisphenol S bisglycidyl ether (DGEBS), bisphenol F bisglycidyl ether (DGEBS), bisphenol S bisglycidyl ether (DGEBS), bisphenol F bisglycidyl ether (BGMDA), bisphenol F bisglycidyl ether (BGMDA), bisphenol S ... Preferably, the epoxy resin comprises one or more compounds selected from the group consisting of bisphenol A bisglycidyl ether and / or bisphenol F bisglycidyl ether, and more preferably, the epoxy resin consists solely of bisphenol A bisglycidyl ether and / or bisphenol F bisglycidyl ether.

[0070] When the one or more thermosetting reactive compounds comprise one or more melamine formaldehyde resins, the melamine formaldehyde resin preferably comprises an aqueous melamine resin mixture having a resin content in the range of 50 to 70% by mass, based on 100% by mass of the aqueous melamine resin mixture, and in which the melamine and formaldehyde are present in the resin in a molar ratio of 1:3 to 1:1, preferably 1:1.3 to 1:2.0, and more preferably 1:1.5 to 1:1.7.

[0071] Furthermore, when the one or more thermosetting reactive compounds include one or more melamine formaldehyde resins, the melamine formaldehyde resin preferably contains 1 to 10% by mass of a polyhydric alcohol, more preferably 3 to 6% by mass of a polyhydric alcohol, and more preferably C2 to C6 12 It is preferred that the composition contains 3 to 6 mass% of a diol, more preferably 3 to 6 mass% of one or more compounds selected from the group consisting of diethylene glycol, propylene glycol, butylene glycol, pentanediol, hexanediol, and mixtures of two or more thereof, and more preferably 3 to 6 mass% of diethylene glycol.

[0072] Furthermore, when the one or more thermosetting reactive compounds contain one or more melamine formaldehyde resins, the melamine formaldehyde resins preferably contain 0 to 8 mass% of caprolactam and 0.5 to 10 mass% of 2-(2-phenoxyethoxy)-ethanol and / or polyethylene glycol having an average molecular weight of 200 to 1,500, relative to 100 mass% of the melamine formaldehyde resin.

[0073] In (4), the mixture is preferably homogenized for a time in the range of 3 to 120 seconds, more preferably 4 to 90 seconds, more preferably 6 to 60 seconds, more preferably 8 to 40 seconds, more preferably 10 to 30 seconds, more preferably 12 to 25 seconds, more preferably 15 to 20 seconds.

[0074] In (5), the slurry is preferably homogenized for a time in the range of 10 to 120 seconds, more preferably 15 to 100 seconds, more preferably 20 to 80 seconds, more preferably 30 to 60 seconds, more preferably 40 to 50 seconds.

[0075] The mass ratio of the total amount of one or more thermosetting reactive compounds to the asphalt composition is preferably in the range of 0.1:99.9 to 25:75, more preferably 0.3:99.7 to 15:85, more preferably 0.5:99.5 to 10:90, more preferably 0.8:99.2 to 7:93, more preferably 1:99 to 5:95, more preferably 1.3:98.7 to 4:96, more preferably 1.5:98.5 to 3.5:96.5, more preferably 1.8:98.2 to 3.2:96.8, more preferably 2:98 to 3:97, more preferably 2.2:97.8 to 2.8:97.2, and more preferably 2.4:97.6 to 2.6:97.4.

[0076] The mass ratio of the mixture obtained in (4) to the granular material obtained in (2) is preferably in the range of 0.5:99.5 to 25:75, more preferably 1:99 to 20:80, more preferably 1.5:98.5 to 15:85, more preferably 2:98 to 10:90, more preferably 2.5:97.5 to 7:93, more preferably 3:97 to 5:95, more preferably 3.5:96.5 to 4.5:95.5.

[0077] The granular material prepared in (2) preferably comprises one or more granular materials selected from the group consisting of gravel, recycled asphalt paving material, sand, one or more filler materials, and mixtures of two or more thereof, more preferably from the group consisting of limestone, basanite, diabase, recycled asphalt paving material, and mixtures of two or more thereof, more preferably from the group consisting of limestone, basanite, diabase, recycled asphalt paving material, and mixtures of two or more thereof.

[0078] The asphalt composition prepared in (1) preferably includes one or more additives, more preferably one or more fibrous materials and / or one or more rejuvenating additives. It is particularly preferred that the asphalt composition prepared in (1) includes cellulose fibers. According to the present invention, the fibrous materials, rejuvenating additives, and cellulose fibers are considered additives.

[0079] If the asphalt composition prepared in (1) contains one or more additives, the asphalt composition prepared in (1) preferably contains 10% by mass or less of the one or more additives, based on 100% by mass of the asphalt composition, preferably 5% by mass or less, more preferably 3% by mass or less, more preferably 2% by mass or less, more preferably 1% by mass or less, more preferably 0.5% by mass or less, and more preferably 0.1% by mass or less of the one or more additives, based on 100% by mass of the asphalt composition.

[0080] The granular material prepared in (2) preferably contains 5 to 100% by mass of recycled asphalt pavement material relative to 100% by mass of the granular material, and more preferably contains 10 to 90% by mass, more preferably 15 to 80% by mass, more preferably 20 to 70% by mass, more preferably 25 to 60% by mass, more preferably 30 to 50% by mass, and more preferably 35 to 45% by mass of recycled asphalt pavement material relative to 100% by mass of the granular material.

[0081] No particular limitation is applied to the particle size of the granular material prepared in (2). Preferably, the granular material prepared in (2) exhibits a particle size in the range of 0.1 to 70 mm, more preferably 0.3 to 50 mm, more preferably 0.5 to 40 mm, more preferably 1 to 30 mm, more preferably 3 to 25 mm, more preferably 5 to 20 mm, more preferably 7 to 15 mm, more preferably 8 to 11 mm.

[0082] The addition in (4) is preferably carried out by dosing at least a portion of the one or more thermosetting reactive compounds into at least a portion of the asphalt composition, particularly preferably by using a metering pump.

[0083] The addition in (4) is preferably carried out in a receiver tank, more preferably a weighted receiver tank.

[0084] When the addition in (4) is carried out in a receiver tank or a weighed receiver tank, it is preferred to add the asphalt composition obtained in (1) to the receiver tank or the weighed receiver tank before the addition of the one or more thermosetting reactive compounds.

[0085] Preferably, the homogenization in (4) is carried out using one or more dynamic mixers, more preferably using one or more circulation pumps and / or high shear mixers and / or one or more stirrers and / or one or more screws, more preferably using one or more stirrers.

[0086] The homogenization in (4) is preferably carried out using one or more static mixers, more preferably using one or more nozzles and / or a Sulzer mixer and / or a Kenics mixer.

[0087] Preferably, the homogenization in (4) is carried out at least in part in a mixing unit, more preferably in a weighted stirred vessel.

[0088] The homogenization in (4) is preferably carried out by mixing. When the homogenization in (4) is carried out by mixing, the mixing speed is preferably in the range of 30 to 12,000 rpm, more preferably 50 to 8,000 rpm, more preferably 100 to 5,000 rpm, more preferably 300 to 4,000 rpm, more preferably 500 to 3,000 rpm, more preferably 800 to 2,500 rpm, more preferably 1,000 to 2,000 rpm, more preferably 1,200 to 1,800 rpm, and more preferably 1,400 to 1,600 rpm.

[0089] The addition in (5) is preferably carried out by introducing at least a portion of the mixture obtained in (4) into at least a portion of the granular material obtained in (2). It is particularly preferred that the addition in (5) is carried out by introducing at least a portion of the mixture obtained in (4) into at least a portion of the granular material obtained in (2) using a metering pump.

[0090] The homogenization in (5) is preferably carried out using one or more dynamic mixers, more preferably using one or more agitators and / or one or more screws, more preferably using a twin-shaft compulsory mixer (twin-shaft pug mill).

[0091] The homogenization in (5) is preferably carried out in a mixing device, which is particularly preferably part of an asphalt mixing plant.

[0092] When the homogenization in (5) is carried out in a mixing device, it is preferred to add the granular material obtained in (2) to the mixing device before adding the mixture obtained in (4).

[0093] In (4), it is preferred that the addition and homogenization are carried out simultaneously.

[0094] In (5), it is preferred that the addition and homogenization are carried out simultaneously.

[0095] (4) and / or (5), more preferably (4) and (5), are preferably carried out in an oxygen-containing atmosphere, more preferably in an atmosphere containing 1 to 21% by volume, more preferably 5 to 21% by volume, more preferably 10 to 21% by volume of oxygen. It is particularly preferred that (4) and / or (5), more preferably (4) and (5), are carried out in air.

[0096] It is preferred that (4) and / or (5), more preferably (4) and (5), are carried out as a batch process or a continuous process. It is especially preferred that (4) and / or (5), more preferably (4) and (5), are carried out as a continuous process.

[0097] Furthermore, the present invention relates to an asphalt mix composition obtained or obtainable according to the method according to any one of the embodiments disclosed herein.

[0098] Furthermore, the present invention relates to the use of the asphalt mix composition according to any one of the embodiments disclosed herein for paving applications.

[0099] The present invention further provides a method for laying asphalt pavement at low laying temperatures, comprising: (1) loading the asphalt mixture composition obtained by the method according to any one of claims 1 to 13 into a vehicle designed for transporting asphalt mixtures from a silo of an asphalt mixing plant; (2) placing the asphalt mixture composition into a paving machine at a construction site; (3) This method includes a step of laying asphalt using a paving machine and then compacting it with a road roller, and the temperature during laying is in the range of 110°C to 155°C.

[0100] Generally, transportation of the asphalt mix composition from the asphalt mixing plant to the construction site, filling with a paver, and compaction with a road roller can be accomplished by any suitable method known in the art.

[0101] Generally, the laying temperature has a significant impact on the workability of each asphalt mixture composition and the amount of bitumen aerosol and fume emissions. Generally, asphalt mixture compositions prepared at temperatures above 160°C are used during the laying of asphalt pavement construction. According to the present invention, the term "low laying temperature" means that asphalt pavement construction is carried out at a laying temperature of 155°C or less using asphalt mixture compositions prepared at a temperature range of 130°C to 155°C.

[0102] The temperature during laying is preferably in the range of 115 to 155°C, more preferably 120 to 152°C, more preferably 125 to 150°C, more preferably 125 to 148°C, more preferably 130 to 148°C, more preferably 135 to 145°C.

[0103] The emission of bitumen aerosols and fumes during asphalt paving work is between 0.2 and 10 mg / m 3 , more preferably 0.2 to 9 mg / m 3 , more preferably 0.2 to 8.5 mg / m 3 , more preferably 0.2 to 8.3 mg / m 3 , more preferably 0.2 to 8 mg / m 3 , more preferably 0.2 to 7 mg / m 3 It is preferable that the range is:

[0104] The present invention is further described by the following series of embodiments and combinations of embodiments resulting from the indicated dependencies and backward references. In particular, it should be noted that wherever a range of embodiments is mentioned, for example, in the context of terms such as "the method according to any one of embodiments 1 to 4," all embodiments within this range are intended to be expressly disclosed to those skilled in the art. That is, this wording should be understood by those skilled in the art to be synonymous with "the method according to any one of embodiments 1, 2, 3, and 4." Furthermore, it should be clearly noted that the following series of embodiments represents a suitably structured portion of the description of general and preferred aspects of the present invention, rather than a claim set determining the scope of protection.

[0105] Embodiment 1. A method for preparing an asphalt mix composition, comprising: (1) preparing an asphalt composition and heating the composition to a temperature in the range of 150 to 175°C; (2) providing a granular material and heating the material to a temperature in the range of 130 to 170°C; (3) providing one or more thermosetting reactive compounds; (4) adding one or more thermosetting reactive compounds prepared in (3) to the asphalt composition obtained in (1) and homogenizing the mixture for a time ranging from 2 to 180 seconds; (5) adding the mixture obtained in (4) to the granular material obtained in (2) and homogenizing the slurry for a time period ranging from 5 to 180 seconds; The method, wherein the temperature of the resulting asphalt mix composition is in the range of 130 to 155°C, more preferably 132°C to 155°C, more preferably 135°C to 152°C, more preferably 135°C to 150°C, more preferably 135°C to 148°C, more preferably 135°C to 147°C, more preferably 135°C to 145°C.

[0106] Embodiment 2. The method of embodiment 1, wherein the total time from the addition of the thermosetting reactive compound in (4) to the subsequent obtaining of the homogenized slurry in (5) is in the range of 10 seconds to 7 days, preferably 10 seconds to 3 days, more preferably 15 seconds to 1 day, more preferably 15 seconds to 12 hours, more preferably 20 seconds to 6 hours, more preferably 20 seconds to 1 hour, more preferably 25 seconds to 30 minutes, more preferably 25 seconds to 15 minutes, more preferably 30 seconds to 6 minutes, more preferably 30 seconds to 3 minutes, more preferably 35 seconds to 2 minutes, more preferably 35 seconds to 90 seconds, more preferably 40 seconds to 85 seconds, more preferably 45 seconds to 70 seconds, more preferably 50 seconds to 60 seconds.

[0107] Embodiment 3. The method of embodiment 1 or 2, wherein after (4) and before (5), the mixture obtained in (4) is stored at a temperature in the range of 60 to 175°C, more preferably 70 to 170°C, more preferably 80 to 168°C, more preferably 90 to 165°C, more preferably 110 to 165°C, more preferably 130 to 163°C, more preferably 150 to 160°C.

[0108] Embodiment 4. The method of any one of embodiments 1 to 3, wherein after (4) and before (5), the mixture obtained in (4) is stored for a time in the range of 0 seconds to 7 days, preferably 5 seconds to 3 days, more preferably 10 seconds to 1 day, more preferably 15 seconds to 12 hours, more preferably 20 seconds to 6 hours, more preferably 25 seconds to 1 hour, more preferably 30 seconds to 30 minutes, more preferably 35 seconds to 15 minutes, more preferably 40 seconds to 6 minutes, more preferably 45 seconds to 3 minutes, more preferably 50 seconds to 2 minutes, more preferably 55 seconds to 90 seconds, and more preferably 60 seconds to 70 seconds.

[0109] Embodiment 5. The method of any one of embodiments 1 to 4, wherein after (4) and before (5), the mixture obtained in (4) is mixed at a mixing speed of 100 rpm or less, preferably 50 rpm or less, more preferably 25 rpm or less, more preferably 20 rpm or less, more preferably 15 rpm or less, more preferably 10 rpm or less, more preferably 5 rpm or less, more preferably 3 rpm or less.

[0110] Embodiment 6. The method of any one of embodiments 1 to 4, wherein the mixture obtained in (4) is not mixed after (4) and before (5), and preferably the mixture obtained in (4) is not homogenized after (4) and before (5).

[0111] Embodiment 7. The method of embodiment 1, wherein the mixture obtained in (4) is directly treated in (5).

[0112] In embodiment 8.(1), the method of any one of embodiments 1 to 7, wherein the asphalt composition is heated to a temperature in the range of 150 to 172°C, preferably 155 to 172°C, more preferably 155 to 170°C, more preferably 158 to 170°C, more preferably 160 to 170°C.

[0113] In embodiment 9.(2), the method of any one of embodiments 1 to 8, wherein the granular material is heated to a temperature in the range of 135 to 170°C, more preferably 140 to 170°C, more preferably 145 to 170°C, more preferably 150 to 170°C, more preferably 155 to 168°C.

[0114] Embodiment 10. The method of any one of embodiments 1 to 9, wherein the homogenization in (5) is carried out at a temperature in the range of 135 to 155°C, more preferably 138 to 155°C, more preferably 140 to 155°C, more preferably 140 to 152°C, more preferably 145 to 150°C.

[0115] Embodiment 11. The method of any one of embodiments 1 to 10, wherein the penetration of the asphalt composition prepared in (1) is selected from the group consisting of 20 to 30, 30 to 45, 35 to 50, 40 to 60, 50 to 70, 70 to 100, 100 to 150, 160 to 220, and 250 to 330, more preferably from the group consisting of 30 to 45, 35 to 50, 40 to 60, 50 to 70, 70 to 100, 100 to 150, and 160 to 220, more preferably from the group consisting of 40 to 60, 50 to 70, 70 to 100, and 100 to 150; more preferably, the penetration of the asphalt composition prepared in (1) is 50 to 70 or 70 to 100, and the penetration is determined according to DIN EN 1426.

[0116] Embodiment 12. The method of any one of embodiments 1 to 11, wherein the asphalt composition prepared in (1) comprises a modified bitumen.

[0117] Embodiment 13. The modified bitumen is a modified bitumen containing at least one of: chemical modifiers (e.g., organometallic compounds, sulfur, phosphoric acid (PA), polyphosphoric acid (PPA), sulfonic acid, sulfuric acid, carboxylic acid anhydrides, acid esters, dibenzoyl peroxide, silanes, organic and inorganic urea sulfides), recycled materials (e.g., crumb rubber, plastics), fibers (e.g., lignin, cellulose, glass fibers, magnesium aluminosilicate, polyester, polypropylene), adhesion promoters (e.g., organic amines, amides), natural asphalt (e.g., Trinidad Lake Asphalt (TLA), Gilsonite, Rocka), 13. The method of embodiment 12, wherein the composition has been modified with one or more compounds selected from the group consisting of sphalts, antioxidants (e.g., phenols, organozinc compounds, organolead compounds), fillers (e.g., carbon black, hydrated lime, lime, fly ash), viscosity modifiers (e.g., flax oil, wax), reactive polymers (e.g., random terpolymers of ethylene, acrylic ester and glycidyl methacrylate, maleic anhydride grafted styrene-butadiene-styrene copolymers), and mixtures of two or more thereof.

[0118] Embodiment 14. The method of any one of embodiments 1 to 13, wherein the one or more thermosetting reactive compounds comprise one or more compounds selected from the group consisting of polyisocyanates, epoxy resins, melamine formaldehyde resins, and mixtures of two or more thereof, preferably from the group consisting of fatty acid polyisocyanates, araliphatic polyisocyanates, aromatic polyisocyanates, and mixtures of two or more thereof, more preferably from the group consisting of aromatic diisocyanates, oligomeric aromatic polyisocyanates, and mixtures of two or more thereof; more preferably, the one or more thermosetting reactive compounds comprise a mixture of one or more aromatic diisocyanates and one or more oligomeric aromatic polyisocyanates; more preferably, the one or more thermosetting reactive compounds consist of a mixture of one or more aromatic diisocyanates and one or more oligomeric aromatic polyisocyanates.

[0119] Embodiment 15. The aliphatic polyisocyanate is selected from the group consisting of alkylene diisocyanates having 4 to 12 carbon atoms in the alkylene group, and mixtures of two or more thereof, 1,12-dodecane diisocyanate, 2-ethyltetramethylene diisocyanate-1,4, 2-methylpentamethylene diisocyanate-1,5, tetramethylene diisocyanate-1,4, hexamethylene diisocyanate-1,6, trimethyl diisocyanate, tetramethyl diisocyanate, pentamethyl diisocyanate, hexamethyl diisocyanate, heptamethyl diisocyanate, octamethyl diisocyanate, 2-methylpentamethylene-1,5-diisocyanate, 2-ethylbutylene-1,4-diisocyanate, pentamethylene-1,5-diisocyanate, butylene-1 15. The method of embodiment 14, wherein the aliphatic polyisocyanate comprises one or more compounds selected from the group consisting of hexamethylene diisocyanate-1,6,4-diisocyanates, preferably trimethyl diisocyanate, tetramethyl diisocyanate, pentamethyl diisocyanate, hexamethyl diisocyanate, heptamethyl diisocyanate, octamethyl diisocyanate, 2-methylpentamethylene-1,5-diisocyanate, 2-ethylbutylene-1,4-diisocyanate, pentamethylene-1,5-diisocyanate, butylene-1,4-diisocyanate, and mixtures of two or more thereof; more preferably, the aliphatic polyisocyanate comprises hexamethylene diisocyanate-1,6, more preferably, the aliphatic polyisocyanate consists of hexamethylene diisocyanate-1,6.

[0120] Embodiment 16. The aliphatic polyisocyanate is selected from the group consisting of 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane (isophorone diisocyanate, IPDI), 1,4-bis(isocyanatomethyl)cyclohexane and / or 1,3-bis(isocyanatomethyl)cyclohexane (HXDI), 1,4-cyclohexane diisocyanate, 1-methyl-2,4- and / or -2,6-cyclohexane diisocyanate, 4,4'-Dicyclohexylmethane diisocyanate, 2,2'-Dicyclohexylmethane diisocyanate, 2,4'-Dicyclohexylmethane diisocyanate, Cyclohexane-1,3-diisocyanate, Cyclohexane-1,4-diisocyanate, 2,4-Hexahydrotoluene diisocyanate, 2,6-Hexahydrotoluene diisocyanate, 4,4'-Dicyclohexylmethane diisocyanate, 2,2'-Dicyclohex 16. The method of embodiment 14 or 15, comprising one or more alicyclic compounds selected from the group consisting of silmethane diisocyanate, 2,4'-dicyclohexylmethane diisocyanate, and mixtures of two or more thereof, preferably from the group consisting of 1-isocyanato-3,3,5-trimethyl-5-isocyanatomethyl-cyclohexane (isophorone diisocyanate, IPDI), 1,4-bis(isocyanatomethyl)cyclohexane and / or 1,3-bis(isocyanatomethyl)cyclohexane (HXDI), 1,4-cyclohexane diisocyanate, 1-methyl-2,4- and / or -2,6-cyclohexane diisocyanate, and 4,4'-dicyclohexylmethane diisocyanate, 2,2'-dicyclohexylmethane diisocyanate, 2,4'-dicyclohexylmethane diisocyanate, and mixtures of two or more thereof.

[0121] Embodiment 17. The aromatic polyisocyanate, and preferably the aromatic diisocyanate, is selected from the group consisting of 2,4-toluene diisocyanate, 2,6-toluene diisocyanate, 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 2,2'-diphenylmethane diisocyanate, 1,5-naphthylene diisocyanate (NDI), 3,3'-dimethyldiphenyl diisocyanate, 1,2-diphenylethane diisocyanate, p-phenylene diisocyanate, From the group consisting of 2,4-toluene diisocyanate (2,4-TDI), 2,6-toluene diisocyanate (2,6-TDI), 4,4'-diphenylmethane diisocyanate (4,4'-MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI), 2,2'-diphenylmethane diisocyanate (2,2'-MDI), crude MDI obtained by MDI preparation, and mixtures of two or more thereof, preferably 2,4-toluene diisocyanate (2,4-TDI), 2,6-toluene diisocyanate (2,6-TDI), 4,4'-diphenylmethane diisocyanate (4,4'-MDI), 2,4'-diphenylmethane diisocyanate (2,4'-MDI), 2,2'-diphenylmethane diisocyanate (2,2'-MDI), crude MDI obtained by MDI preparation, MDI), and mixtures of two or more thereof, more preferably 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, 2,2'-diphenylmethane diisocyanate, and mixtures of two or more thereof (mixtures of the isomers 4,4'-, 2,4'-, and 2,2'-diphenylmethane diisocyanate are also referred to as monomeric diphenylmethane or MMDI), and more preferably aromatic polyisocyanate. 17. The method of any one of embodiments 14 to 16, wherein the polyisocyanate, and preferably the aromatic diisocyanate, comprises a mixture of 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, and 2,2'-diphenylmethane diisocyanate; more preferably, the aromatic polyisocyanate, and preferably the aromatic diisocyanate, consists of a mixture of 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, and 2,2'-diphenylmethane diisocyanate.

[0122] Embodiment 18. The method of any one of embodiments 14 to 17, wherein the polyisocyanate comprises a modified polyisocyanate, preferably a modified organic polyisocyanate, more preferably a modified organic polyisocyanate, containing one or more ester, urea, biuret, allophanate, carbodiimide, isocyanurate, uretdione, carbamate, and / or urethane groups.

[0123] Embodiment 19. The method of any one of embodiments 14 to 18, wherein the oligomeric aromatic polyisocyanate comprises one or more compounds selected from the group consisting of polyphenylpolymethylene polyisocyanates, polyphenylpolyethylene polyisocyanates, and mixtures of two or more thereof, preferably one or more polymethylene polyphenylisocyanates, polyethylene polyphenylisocyanates, and mixtures of two or more thereof; more preferably, the aromatic polyisocyanate comprises one or more polymethylene polyphenylisocyanates; more preferably, the aromatic polyisocyanate consists of one or more polymethylene polyphenylisocyanates.

[0124] Embodiment 20. The method of any one of embodiments 14 to 19, wherein the oligomeric aromatic polyisocyanate comprises one or more oligomers of larger core homologs of one or more of 4,4'-diphenylmethane diisocyanate, 2,4'-diphenylmethane diisocyanate, and 2,2'-diphenylmethane diisocyanate, wherein the larger core homologs have at least three aromatic nuclei and a functionality of at least three.

[0125] Embodiment 21. The method of any one of embodiments 14 to 20, wherein the one or more thermosetting reactive compounds are polymeric MDI, and the total amount of 4,4'-MDI in the polymeric MDI is in the range of 26 to 98% by weight, preferably in the range of 30 to 95% by weight, and more preferably in the range of 35 to 92% by weight, based on 100% by weight of the one or more thermosetting reactive compounds.

[0126] Embodiment 22. The method of any one of embodiments 14 to 21, wherein the one or more thermosetting reactive compounds are polymeric MDI, and the two-ring content of the polymeric MDI is in the range of 20 to 62% by weight, more preferably in the range of 26 to 48% by weight, and most preferably in the range of 26 to 48% by weight, based on 100% by weight of the polymeric MDI.

[0127] Embodiment 23. The method of any one of embodiments 14 to 22, wherein the average functionality of isocyanate groups in the one or more thermosetting reactive compounds, and preferably the entire polyisocyanate contained in the compounds, is 2.1 to 3.5, preferably 2.3 to 3.2, more preferably 2.4 to 3, more preferably 2.5 to 2.9, and more preferably 2.6 to 2.8.

[0128] Embodiment 24. The method of any one of embodiments 1 to 23, wherein the iron content of the one or more thermosetting reactive compounds ranges from 1 to 100 wppm, preferably from 1 to 80 wppm, more preferably from 1 to 60 wppm, more preferably from 1 to 40 wppm, more preferably from 1 to 20 wppm, more preferably from 1 to 10 wppm, more preferably from 1 to 5 wppm.

[0129] Embodiment 25. The method of any one of embodiments 1 to 24, wherein the one or more thermosetting reactive compounds exhibit a viscosity in the range of 100 to 3,000 mPa·s, preferably 100 to 1,000 mPa·s, more preferably 100 to 600 mPa·s, more preferably 200 to 600 mPa·s, more preferably 400 to 600 mPa·s, wherein the viscosity is measured at 25°C.

[0130] Embodiment 26. The epoxy resin is one or more compounds selected from the group consisting of aromatic epoxy resins, cycloaliphatic epoxy resins, and mixtures of two or more thereof, preferably bisphenol A bisglycidyl ether (DGEBA), bisphenol F bisglycidyl ether, ring-hydrogenated bisphenol A bisglycidyl ether, ring-hydrogenated bisphenol F bisglycidyl ether, bisphenol S bisglycidyl ether (DGEBS), tetraglycidylmethylenedianiline (TGMDA), epoxy novolac (from epichlorohydrin and phenolic resins (novolacs)). 26. The method of any one of embodiments 14 to 25, wherein the epoxy resin comprises one or more compounds selected from the group consisting of bisphenol A bisglycidyl ether and / or bisphenol F bisglycidyl ether, and more preferably the epoxy resin consists of bisphenol A bisglycidyl ether and / or bisphenol F bisglycidyl ether.

[0131] Embodiment 27. The method of any one of embodiments 14 to 26, wherein the melamine formaldehyde resin comprises an aqueous melamine resin mixture having a resin content in the range of 50 to 70% by weight, based on 100% by weight of the aqueous melamine resin mixture, and wherein the melamine and formaldehyde are present in the resin in a molar ratio of 1:3 to 1:1, preferably 1:1.3 to 1:2.0, and more preferably 1:1.5 to 1:1.7.

[0132] Embodiment 28. The melamine formaldehyde resin contains 1 to 10% by weight of a polyhydric alcohol, preferably 3 to 6% by weight of a polyhydric alcohol, more preferably C2 to C6 1228. The method of any one of embodiments 14 to 27, comprising 3 to 6% by weight of a diol, more preferably 3 to 6% by weight of one or more compounds selected from the group consisting of diethylene glycol, propylene glycol, butylene glycol, pentanediol, hexanediol, and mixtures of two or more thereof, and more preferably 3 to 6% by weight of diethylene glycol.

[0133] Embodiment 29. The method of any one of embodiments 14 to 28, wherein the melamine formaldehyde resin contains 0 to 8% by weight of caprolactam and 0.5 to 10% by weight of 2-(2-phenoxyethoxy)-ethanol and / or polyethylene glycol having an average molecular weight of 200 to 1,500, each relative to 100% by weight of the melamine formaldehyde resin.

[0134] Embodiment 30. The method of any one of embodiments 1 to 29, wherein in (4), the mixture is homogenized for a time in the range of 3 to 120 seconds, preferably 4 to 90 seconds, more preferably 6 to 60 seconds, more preferably 8 to 40 seconds, more preferably 10 to 30 seconds, more preferably 12 to 25 seconds, more preferably 15 to 20 seconds.

[0135] Embodiment 31. The method of any one of embodiments 1 to 30, wherein in (5), the slurry is homogenized for a time in the range of 10 to 120 seconds, preferably 15 to 100 seconds, more preferably 20 to 80 seconds, more preferably 30 to 60 seconds, more preferably 40 to 50 seconds.

[0136] Embodiment 32. The method of any one of embodiments 1 to 31, wherein the mass ratio of the total amount of the one or more thermosetting reactive compounds to the asphalt composition is in the range of 0.1:99.9 to 25:75, preferably 0.3:99.7 to 15:85, more preferably 0.5:99.5 to 10:90, more preferably 0.8:99.2 to 7:93, more preferably 1:99 to 5:95, more preferably 1.3:98.7 to 4:96, more preferably 1.5:98.5 to 3.5:96.5, more preferably 1.8:98.2 to 3.2:96.8, more preferably 2:98 to 3:97, more preferably 2.2:97.8 to 2.8:97.2, more preferably 2.4:97.6 to 2.6:97.4.

[0137] Embodiment 33. The method of any one of embodiments 1 to 32, wherein the mass ratio of the mixture obtained in (4) to the granular material obtained in (2) is in the range of 0.5:99.5 to 25:75, preferably 1:99 to 20:80, more preferably 1.5:98.5 to 15:85, more preferably 2:98 to 10:90, more preferably 2.5:97.5 to 7:93, more preferably 3:97 to 5:95, more preferably 3.5:96.5 to 4.5:95.5.

[0138] Embodiment 34. The method of any one of embodiments 1 to 33, wherein the granular material provided in (2) comprises one or more granular materials selected from the group consisting of gravel, recycled asphalt pavement, sand, one or more filler materials, and mixtures of two or more thereof, preferably from the group consisting of limestone, basanite, diabase, recycled asphalt pavement, and mixtures of two or more thereof, more preferably from the group consisting of limestone, basanite, diabase, recycled asphalt pavement, and mixtures of two or more thereof.

[0139] Embodiment 35. The method of any one of embodiments 1 to 34, wherein the asphalt composition prepared in (1) comprises one or more additives, preferably one or more fibrous materials and / or one or more rejuvenating additives, and more preferably, the asphalt composition prepared in (1) comprises cellulose fibers.

[0140] Embodiment 36. The method of embodiment 35, wherein the asphalt composition prepared in (1) comprises 10% by weight or less of one or more additives, based on 100% by weight of the asphalt composition, preferably 5% by weight or less, more preferably 3% by weight or less, more preferably 2% by weight or less, more preferably 1% by weight or less, more preferably 0.5% by weight or less, and more preferably 0.1% by weight or less of one or more additives, based on 100% by weight of the asphalt composition.

[0141] Embodiment 37. The method of any one of embodiments 1 to 36, wherein the granular material prepared in (2) comprises 5 to 100% by weight of recycled asphalt pavement relative to 100% by weight of the granular material, and more preferably, the granular material comprises 10 to 90% by weight, more preferably 15 to 80% by weight, more preferably 20 to 70% by weight, more preferably 25 to 60% by weight, more preferably 30 to 50% by weight, more preferably 35 to 45% by weight of recycled asphalt pavement relative to 100% by weight of the granular material.

[0142] Embodiment 38. The method of any one of embodiments 1 to 37, wherein the granular material provided in (2) exhibits a particle size in the range of 0.1 to 70 mm, preferably 0.3 to 50 mm, more preferably 0.5 to 40 mm, more preferably 1 to 30 mm, more preferably 3 to 25 mm, more preferably 5 to 20 mm, more preferably 7 to 15 mm, more preferably 8 to 11 mm.

[0143] Embodiment 39. The method of any one of embodiments 1 to 38, wherein the adding in (4) is carried out by dosing at least a portion of the one or more thermosetting reactive compounds into at least a portion of the asphalt composition, and the dosing is preferably carried out using a metering pump.

[0144] Embodiment 40. The method of any one of embodiments 1 to 39, wherein the addition in (4) is carried out in a receiver tank, preferably a weighted receiver tank.

[0145] Embodiment 41. The method of embodiment 40, wherein the asphalt composition obtained in (1) is added to the receiver tank before the addition of the one or more thermosetting reactive compounds.

[0146] Embodiment 42. The method according to any one of embodiments 1 to 41, wherein the homogenization in (4) is carried out using one or more dynamic mixers, preferably using one or more circulation pumps, and / or high shear mixers, and / or one or more stirrers, and / or one or more screws, preferably using one or more stirrers.

[0147] Embodiment 43. The method according to any one of embodiments 1 to 42, wherein the homogenization in (4) is carried out using one or more static mixers, preferably using one or more nozzles, and / or a Sulzer mixer, and / or a Kenics mixer.

[0148] Embodiment 44. The method according to any one of embodiments 1 to 43, wherein the homogenization in (4) is carried out at least in part in a mixing unit, preferably in a weighted agitation tank.

[0149] Embodiment 45. The method of any one of embodiments 1 to 44, wherein the homogenization in (4) is carried out by mixing, and preferably the mixing speed is in the range of 30 to 12,000 rpm, preferably 50 to 8,000 rpm, more preferably 100 to 5,000 rpm, more preferably 300 to 4,000 rpm, more preferably 500 to 3,000 rpm, more preferably 800 to 2,500 rpm, more preferably 1,000 to 2,000 rpm, more preferably 1,200 to 1,800 rpm, more preferably 1,400 to 1,600 rpm.

[0150] Embodiment 46. The method of any one of embodiments 1 to 45, wherein the adding in (5) is carried out by adding at least a portion of the mixture obtained in (4) to at least a portion of the granular material obtained in (2), and the adding is preferably carried out using a metering pump.

[0151] Embodiment 47. The method according to any one of embodiments 1 to 46, wherein the homogenization in (5) is carried out using one or more dynamic mixers, preferably using one or more agitators and / or one or more screws, more preferably using a twin-shaft compulsory mixer (twin-shaft pug mill).

[0152] Embodiment 48. The method of any one of embodiments 1 to 47, wherein the homogenization in (5) is carried out in a mixing device, preferably the mixing device is part of an asphalt mixing plant.

[0153] Embodiment 49. The method of embodiment 48, wherein the granular material obtained in (2) is added to the mixing device before the addition of the mixture obtained in (4).

[0154] Embodiment 50. The method of any one of embodiments 1 to 49, wherein in (4), the adding and homogenizing are carried out simultaneously.

[0155] Embodiment 51. The method of any one of embodiments 1 to 50, wherein in (5), the adding and homogenizing are carried out simultaneously.

[0156] Embodiment 52. The method of any one of embodiments 1 to 51, wherein (4) and / or (5), preferably (4) and (5), are carried out under an oxygen-containing atmosphere, preferably under an atmosphere containing oxygen in an amount of 1 to 21% by volume, more preferably 5 to 21% by volume, more preferably 10 to 21% by volume, more preferably (4) and / or (5), preferably (4) and (5), are carried out in air.

[0157] Embodiment 53. The method of any one of embodiments 1 to 52, wherein (4) and / or (5), preferably (4) and (5), are carried out as a batch process or a continuous process, preferably as a continuous process.

[0158] Embodiment 54. An asphalt mix composition obtained by the method according to any one of embodiments 1 to 53.

[0159] Embodiment 55. Use of the asphalt mix composition of embodiment 54 in paving applications.

[0160] Embodiment 56. A method for asphalt pavement construction at low laying temperatures, comprising: (1) loading the asphalt mix composition obtained by the method according to any one of embodiments 1 to 53 into a vehicle designed for transporting asphalt mixes from a silo of an asphalt mixing plant; (2) placing the asphalt mix composition into a paving machine at a construction site; (3) A method for laying asphalt using a paving machine and subsequently compacting it with a road roller, wherein the temperature during laying is in the range of 110°C to 155°C, preferably 115 to 155°C, more preferably 120 to 152°C, more preferably 125 to 150°C, more preferably 125 to 148°C, more preferably 130 to 148°C, more preferably 135 to 145°C, and the amount of bitumen aerosol and fumes emitted during asphalt paving work is 0.2 to 10 mg / m 3 , more preferably 0.2 to 9 mg / m 3 , more preferably 0.2 to 8.5 mg / m 3 , more preferably 0.2 to 8.3 mg / m 3 , more preferably 0.2 to 8 mg / m 3 , more preferably 0.2 to 7 mg / m 3 The method is in the range of

[0161] The present invention is further illustrated by the following examples and reference examples. [Example]

[0162] Experimental section Characterization Method <Softening point DIN EN 1427> Two horizontal disks of bitumen, placed in a brass ring mold with a seat, are heated at a controlled rate in a liquid bath while each supports a steel ball. The softening point is reported as the average temperature at which the two disks soften sufficiently to allow each bitumen-encased ball to fall a distance of 25 ± 0.4 mm.

[0163] <Dynamic Shear Rheometer (DSR) DIN EN 14770-ASTM D7175> The dynamic shear rheometer test system consists of parallel plates, a means of controlling specimen temperature, a loading device, and a control and data acquisition system.

[0164] <Temperature sweep DIN EN 14770> This test is intended to measure the complex shear modulus and phase angle of asphalt binders. The test consists of compressing a specimen of 8 or 25 mm diameter between parallel metal plates at a specified frequency and temperature. One parallel plate is oscillated relative to the other parallel plate at a deflection angle amplitude of 1.59 Hz in this case. The required amplitude must be selected so that the test falls within the region of linear behavior. The test is repeated at 30, 40, 50, 60, 70, 80, and 90°C.

[0165] <Multiple Stress Creep Recovery Test (MSCRT) DIN EN 16659-ASTM D7405> This test method is used to measure the presence of an elastic response of asphalt binders under shear creep and recovery at two stress levels (0.1 and 3.2 kPa) and a specified temperature (60°C). The test uses a DSR to apply a 25 mm load at a constant stress for 1 second, followed by a 9 second recovery. Ten creep and recovery cycles are performed at a creep stress of 0.100 kPa, followed by 10 cycles at a creep stress of 3.200 kPa.

[0166] <Bitumen Emission Measurement (Aerosol and Mist) Method 6305-1> Aerosols and fumes during asphalt construction were determined according to IFA (Institut fur Arbeitsschutz der Deutschen Gesetzlichen Unfallversicherung) method 6305-1. The decision limit was 0.2 mg / m 3 is.

[0167] <Recovery of asphalt binder from asphalt mixture composition (recovered asphalt)> Using an asphalt analyzer, approximately 3 kg of asphalt mixture composition is mixed with trichloroethylene. The aggregate is separated from the asphalt binder in a process that takes approximately 60 minutes. After this procedure, approximately 600 ml of trichloroethylene and bitumen solution is obtained. The solution is then distilled by partially submerging the rotary evaporator's rotary distillation flask in a heated oil bath while subjecting it to partial vacuum and airflow. This process involves two stages. The first stage takes 60 minutes and is carried out at 90°C, 40 kPa pressure, and 75 rpm. The second stage is carried out at 160°C, 2 kPa pressure, and 75 rpm. Depending on the type of asphalt binder and the asphalt binder content in the asphalt mixture, 100–150 g of asphalt binder is recovered and then subjected to testing as needed.

[0168] Example 1: Preparation of asphalt mix composition in an asphalt mixing plant at low mixing temperature (asphalt: modified with As20) The batch asphalt mixing plant was equipped with a customized metering injection system (heatable injection lines, metering pumps) that allowed the injection of thermosetting reactive compounds into the asphalt metering vessel (stirring vessel) at the asphalt mixing plant. Furthermore, the asphalt metering vessel was equipped with an agitator that would activate when i) the thermosetting reactive compounds were metered and ii) a minimum fill level of 20 kg of asphalt was reached. The additive metering amount and speed, as well as mixing, were controlled via the asphalt mixing plant's process control system.

[0169] Approximately 1000 tonnes of asphalt mixture composition was produced in which the asphalt was modified with polymeric diphenylmethane diisocyanate (hereinafter referred to as "As20"), which has an average isocyanate functionality of 2.7. The batch size was 4 tonnes. The granulometry curve of the asphalt mixture was AC 22 BS. The particle size distribution obtained for the produced asphalt mixture is shown in Table 1. The asphalt mixture contained 50% by weight of recycled asphalt (aggregate + asphalt) and 50% by weight of virgin material. The total asphalt content in the asphalt and aggregate mixture was 4.7% by weight, or 188 kg of asphalt per 4 tonne batch. Of the 188 kg of asphalt, 108 kg came from recycled asphalt, and the remaining 80 kg came from the addition of unmodified (paving-grade) asphalt pen 70 / 100 (penetration of 7-10 mm according to DIN EN 1426). The amount of thermosetting reactive compound As20 used was 3.76 kg, i.e., 2.0% by mass based on the total amount of asphalt used (i.e., asphalt from recycled asphalt + added unmodified (paving-grade) asphalt pen 70 / 100).

[0170] The raw granular material and recycled asphalt were preheated separately and then mixed together for 6 seconds (premix). The heating power and mixing time were adjusted to achieve a final asphalt mixture temperature of 140-155°C. 80 kg of unmodified (paving-grade) asphalt pen70 / 100 was preheated to a temperature of 165-175°C and weighed into a mixing vessel (= asphalt weigher). Next, 3.76 kg of As20 was added to the asphalt while stirring (1500 rpm), and the resulting mixture was further mixed. Here, the metering rate was set to 0.1 L / s to 2.0 L / s, and the further mixing time was set to 10 seconds (see Table 3). The resulting modified asphalt was added to a mixing unit (two-shaft compulsory mixer) together with the premixed material (a mixture of raw aggregate and recycled asphalt with a temperature of ≦170°C), and the resulting mixture was further mixed. The total time for further mixing was now 20 seconds (see Table 3). The temperature of the final asphalt mix composition obtained at this stage of the process was determined to be 145-150°C (see Table 3). The asphalt mix composition was then discharged into a silo where it could be loaded onto trucks or stored for several hours. The mixture is then used for road paving.

[0171] (Example 2) Asphalt laying at 135 to 145 ° C (asphalt: modified with As20) The asphalt mixture composition prepared in Example 1 was used for road paving (binder layer, AC 22 BS). The paving was carried out using a Vogele Super 1800-3i paving machine. The temperature of the asphalt mixture composition during laying ranged from 135°C to 145°C (see Table 6). The bitumen emissions (aerosol and fumes) during laying were 1.03 mg / m 3 , 1.30 mg / m 3 , and 6.67 mg / m 3(See Table 6.) Additionally, samples of the asphalt mix composition were taken directly from the paving machine. The asphalt binder was then extracted from the samples according to the above procedures and subjected to various characterization methods. The results are shown in Table 4.

[0172] Comparative Example 1: Preparation of Asphalt Mix Composition in an Asphalt Mixing Plant at Typical Mixing Temperatures (Asphalt: Modified with SBS, i.e., PmB 25 / 55-55 RC) The batch asphalt mixing plant was equipped with a customized metering system (heatable injection line, metering pump) that allowed the thermosetting reactive compound to be metered into the asphalt metering vessel (stirring vessel) of the asphalt mixing plant. Furthermore, the asphalt metering vessel was equipped with an agitator that i) metered the thermosetting reactive compound and ii) activated when a minimum filling level of 20 kg of asphalt was reached. The metering amount and speed of the additive, as well as the mixing, were controlled by the process control system of the asphalt mixing plant. For Comparative Example 1, the thermosetting reactive compound was not metered in.

[0173] Approximately 805 tonnes of asphalt mix composition containing 2.1% by weight of SBS-modified bitumen (PmB 25 / 55-55 RC) was produced. The batch size was 4 tonnes. The granulometry curve of the asphalt mixture was AC 22 BS. The particle size distribution obtained for the produced asphalt mixture is shown in Table 2. The asphalt mixture contained 50% by weight of recycled asphalt (aggregate + asphalt) and 50% by weight of virgin material. The total asphalt content in the asphalt and aggregate mixture was 4.8% by weight, or 192 kg of asphalt per 4 tonne batch. Of the 192 kg of asphalt, 108 kg came from the recycled asphalt, and the remaining 84 kg came from the addition of PmB 25 / 55-55 RC (an SBS-modified bitumen with a softening point of 62.6°C).

[0174] The virgin granular material and recycled asphalt were preheated separately and then mixed together for 6 seconds (premix). The heating power and mixing time were adjusted to achieve a final asphalt mix composition temperature of 160-175°C. 84 kg of PmB 25 / 55-55 RC was preheated to a temperature of 165-175°C and weighed into an asphalt scale. The asphalt along with the premixed materials (a mixture of virgin aggregate and recycled asphalt with a temperature of ≦200°C) was added to a mixing unit (twin-shaft compulsory mixer), and the resulting mixture was further mixed. The total further mixing time was 18 seconds. The temperature of the final asphalt mix composition obtained at this stage of the process was determined to be 165-175°C (see Table 3). The asphalt mix composition was then discharged to a silo, where it could be loaded onto trucks or stored for several hours. The mixture was then used for road paving.

[0175] (Comparative Example 2) Asphalt laying at 160-170°C (Asphalt: Modified with SBS, PmB 25 / 55-55 RC) The asphalt mixture composition prepared in Comparative Example 1 was used for road paving (binder layer, AC 22 BS). Paving was carried out using a Vogele Super 1800-3i paving machine. The temperature of the asphalt mixture composition during laying was in the range of 160°C to 170°C (see Table 6). The bitumen emission (aerosol and fumes) during laying was 2.81 mg / m 3 , 3.07 mg / m 3 , and 10.38 mg / m 3 (See Table 6.) Additionally, samples of the asphalt mix composition were taken directly from the paving machine. The asphalt binder was then extracted from the samples according to the above procedures and subjected to various characterization methods. The results are shown in Table 4.

[0176] (Comparative Example 3) Preparation of Asphalt Mix Composition in an Asphalt Mixing Plant at Typical Mixing Temperatures (Asphalt: Unmodified, Paving Grade Asphalt) The batch asphalt mixing plant was equipped with a customized injection system (heatable injection line, injection pump) that allowed the injection of the thermosetting reactive compound into the asphalt metering vessel (stirring vessel) in the asphalt mixing plant. Furthermore, the asphalt metering vessel was equipped with an agitator that i) metered the thermosetting reactive compound and ii) activated when a minimum filling level of 20 kg of asphalt was reached. The metered amount and speed of the additive, as well as the mixing, were controlled by the process control system of the asphalt mixing plant. For Comparative Example 3, the thermosetting reactive compound was not metered in.

[0177] A 7-ton asphalt mix composition containing 2.1% by weight of unmodified (paving-grade) asphalt (pen grade 70 / 100, i.e., 7-10 mm penetration according to DIN EN 1426) was produced. The batch size was 3.5 tons. The granulometry curve of the asphalt mix was AC 22 BS. The asphalt mix contained 50% by weight of recycled asphalt (aggregate + asphalt) and 50% by weight of virgin material. The total asphalt content in the asphalt and aggregate mixture was 4.8% by weight, i.e., 168 kg of asphalt per 3.5 ton batch. Of the 168 kg of asphalt, 94.5 kg came from the recycled asphalt, and the remaining 73.5 kg came from the addition of unmodified (paving-grade) asphalt pen 70 / 100.

[0178] The virgin granular material and recycled asphalt were preheated separately and then mixed together for 6 seconds. The heating power and mixing time were adjusted to achieve a final asphalt mix composition temperature of 160-175°C. 73.5 kg of unmodified (paving grade) asphalt pen 70 / 100 was preheated to a temperature of 165-175°C and weighed into an asphalt scale. The asphalt along with the premixed materials (a mixture of virgin aggregate and recycled asphalt with a temperature of ≦200°C) was added to a mixing unit (two-shaft compulsory mixer), and the resulting mixture was further mixed. The total further mixing time was 20 seconds. The temperature of the final asphalt mix composition obtained at this stage of the process was determined to be 161°C (see Table 3). The asphalt mix composition was then discharged into a silo, from which the composition was withdrawn immediately after a sample of the asphalt mix was taken. The asphalt binder from each sample was extracted according to the procedures described in Chapter 3. The recovered asphalt was then subjected to various characterization methods. The results are shown in Table 4.

[0179] [Table 1]

[0180] [Table 2]

[0181] [Table 3]

[0182] [Table 4]

[0183] [Table 5]

[0184] [Table 6]

[0185] It was surprisingly discovered that asphalt mix compositions prepared according to the present invention, even with a recycled asphalt content of 50% by mass, still handled well during paving, where the temperature of the asphalt mix in the paving process ranged from 110 to 155°C. Comparing the properties of the recovered asphalt binders in Table 4, the asphalt binder modified with As20 performed well, exhibiting a greater softening point and recovery at 3.2 kPa, a greater phase angle, and a lower irrecoverable creep compliance (J) compared to the unmodified version. nr ) decreases. Moreover, the performance properties of the SBS and As20 modified binders are at similar levels.

[0186] As can be seen from Table 5, As20 modification of asphalt binders generally increases the viscosity of unmodified binders, but to a much lesser extent than SBS modification. This explains the superior workability of asphalt mix compositions containing As20-modified binders at temperatures between 130°C and 155°C compared to asphalt mixes containing SBS-modified binders at those temperatures. SBS-modified asphalt mixes are known not to be properly processable at such low temperatures. This is also illustrated by the example in Table 5, where the viscosity of the polymer-modified bitumen is nearly twice as high at 135°C as that of the As20-modified bitumen.

Claims

1. A method for producing an asphalt mixture composition, (1) providing an asphalt composition and heating the composition to a temperature in the range of 150 to 175°C; (2) providing a granular material and heating the material to a temperature in the range of 130 to 170°C; (3) providing one or more thermosetting reactive compounds including a polyisocyanate; (4) adding one or more thermosetting reactive compounds prepared in (3) to the asphalt composition obtained in (1) and homogenizing the mixture for a time ranging from 2 to 180 seconds; (5) adding the mixture obtained in (4) to the particulate material obtained in (2) and homogenizing the slurry for a time ranging from 5 to 180 seconds; The temperature of the resulting asphalt mixture composition is in the range of 130 to 155°C, and the mass ratio of the total amount of the one or more thermosetting reactive compounds to the asphalt composition is in the range of 0.1:99.9 to 25:

75.

2. 10. The method of claim 1, wherein after (4) and before (5), the mixture obtained in (4) is stored at a temperature in the range of 130 to 160°C.

3. 3. The method according to claim 1 or 2, wherein after (4) and before (5), the mixture obtained in (4) is mixed at a mixing speed of 100 rpm or less.

4. 2. The method of claim 1, wherein the mixture obtained in (4) is directly treated in (5).

5. 5. The method according to any one of claims 1 to 4, wherein the mass ratio of the mixture obtained in (4) to the granular material obtained in (2) is in the range of 0.5:99.5 to 25:

75.

6. 6. The method of any one of claims 1 to 5, wherein the granular material provided in (2) comprises one or more granular materials selected from the group consisting of gravel, recycled asphalt paving material, sand, one or more filler materials, and mixtures of two or more thereof.

7. 7. The method of any one of claims 1 to 6, wherein the asphalt composition prepared in (1) comprises one or more additives.

8. The method of any one of claims 1 to 7, wherein the granular material provided in (2) comprises 5 to 100% by weight of recycled asphalt pavement material.

9. 9. The method according to any one of claims 1 to 8, wherein the granular material provided in (2) exhibits a particle size in the range of 0.1 to 70 mm.

10. 10. The method of claim 1, wherein (4) and / or (5) are carried out under an oxygen-containing atmosphere.

11. 11. The method of any one of claims 1 to 10, wherein (4) and / or (5) are carried out as a batch process or a continuous process.

12. An asphalt mix composition obtained or obtainable according to the method of any one of claims 1 to 11.

13. 13. Use of the asphalt mix composition of claim 12 in paving applications.

14. A method for asphalt paving at low laying temperatures, comprising: (1) loading the asphalt mix composition obtained by the method according to any one of claims 1 to 11 into a vehicle designed for transporting asphalt mixes from a silo of an asphalt mixing plant; (2) placing the asphalt mixture composition into a paving machine at a construction site; (3) The method includes a step of laying asphalt using a paving machine and then compacting it using a road roller. The method wherein the temperature during installation is in the range of 110°C to 155°C.

15. The total amount of bitumen aerosols and fumes during asphalt paving work is 10 mg / m ３ The method of claim 14, wherein the

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