Asphalt Emulsion Stabilization Using Purified Coal Particles
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Solution Overview
Problem
There is a need for alternative and economical sources of high-quality feedstocks for asphalt compositions that can improve durability and performance across various climatic conditions, while also addressing waste management issues from coal mining by-products.
Innovation Solution
Utilizing purified coal products with low ash and water content as additives in asphalt production, specifically combining these products with asphalt feedstock to create a blended mixture, which can enhance stiffness, upper temperature performance, and stabilize asphalt emulsions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If purified coal products are used as additives in asphalt production, then durability and upper temperature performance are improved, but the complexity of material selection and processing increases
Solution Approach 1:
The patent applies parameter changes by specifying precise compositional parameters for purified coal products (ash content <10 wt%, water content <5 wt%, particle size distribution with at least 90% by volume no greater than 25 μm diameter). These parameter specifications transform the complex material selection process into a systematic approach based on measurable physical and chemical properties, enabling improved durability and upper temperature performance while maintaining controllable processing complexity
Solution Approach 2:
The patent creates composite asphalt materials by blending purified coal products with asphalt feedstock. The composite mixture comprises at least 0.1 wt% and at most 50 wt% PCP, combining the beneficial properties of coal fines (stiffness, high-temperature performance) with asphalt (adhesion, flexibility). This composite approach resolves the contradiction by achieving enhanced reliability through material composition optimization rather than increasing processing complexity
2Strength
If purified coal products are used to enhance asphalt stiffness and high-temperature performance, then resistance to deformation under heavy loads is improved, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-processing coal fines into purified coal products with controlled particle size distribution (at least 90% by volume no greater than 25 μm diameter) and controlled ash content (<10 wt%) before blending with asphalt. This preliminary preparation of the coal product ensures optimal performance characteristics while simplifying the subsequent manufacturing process, as the material is ready for direct incorporation without additional processing steps during asphalt production
Solution Approach 2:
The patent optimizes manufacturing simplicity by establishing specific parameter ranges for the PCP-asphalt blend ratio (0.1-50 wt% PCP). This parameter specification allows for straightforward manufacturing processes while achieving the desired resistance to deformation under heavy loads, eliminating the need for complex process control and multiple processing stages
3Loss of substance
If coal fines are utilized as asphalt additives, then waste management benefits are achieved, but the quality consistency of the additive may be compromised
Solution Approach 1:
The patent resolves the contradiction between waste utilization and quality consistency by establishing strict parameter specifications for purified coal products: ash content <10 wt%, water content <5 wt%, and particle size distribution with at least 90% by volume no greater than 25 μm diameter. These parameter controls ensure that waste coal fines are transformed into a consistent, high-quality additive suitable for asphalt applications, maintaining both environmental benefits and compositional stability
Solution Approach 2:
The patent applies extraction by separating and removing unwanted components from coal fines through purification processes. By extracting impurities (reducing ash content to <10 wt% and water content to <5 wt%), the patent produces a consistent purified coal product that maintains waste utilization benefits while achieving the quality consistency required for reliable asphalt performance
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The use of purified coal products improves asphalt binder properties, increasing durability and performance under varying climatic conditions, while providing a sustainable solution to coal mining waste.
Implementation Method 1
asphalt-in-water emulsions stabilised by a solid stabilizer... the emulsion is stabilised by a solid stabilizer, suitably purified coal product (PCP) particles
Data Source
AI summary
An oil-in-water emulsion comprising an asphalt and purified coal product (PCP) is provided, wherein the PCP is in particulate form, and wherein at least about 90% by volume (% v) of the particles are no greater than about 25 μm in diameter; wherein the PCP has an ash content of less than about 10 wt %. Methods are also provided for the use of PCP as a stabilizing additive in the manufacture of asphalt containing emulsions.