Vertical Asphalt Reactor with Bottom Impeller
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Solution Overview
Problem
Existing asphalt blending systems are unsuitable for modified asphalts due to inadequate dispersion and heating efficiency, leading to non-uniform composition and increased energy costs, and are not suitable for continuous operation or compact transportation.
Innovation Solution
A vertically oriented reactor with a bottom-mounted axial flow impeller and internal cylindrical circulation tube, equipped with a heating jacket and a unique recirculation path, allowing for high internal circulation rates and efficient dispersion and heating of modifiers and reactants, enabling continuous operation and compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a separate blender and reaction tank system is used, then blending and heating can be performed, but the system occupies excessive space and cannot be transported compactly
Solution Approach 1:
The patent combines the blender and reaction tank into a single integrated reactor vessel. The reaction tank is equipped with an impeller system that performs both blending and heating functions within one unit, eliminating the need for separate equipment and enabling compact transportation while maintaining full functionality.
Solution Approach 2:
The reactor vessel is designed to perform multiple functions simultaneously: it serves as both the blending chamber and the heating chamber. The impeller system provides both mixing action and facilitates heat transfer, making the single device universal for both operations.
2Manufacturing precision
If basic vertical reactors are used without modification, then the structure is simple, but dispersion and heating efficiency are inadequate leading to non-uniform composition
Solution Approach 1:
The reactor interior is segmented into multiple circulation zones using internal baffles or circulation tubes. This segmentation creates multiple flow paths that enhance mixing efficiency and ensure uniform heat distribution throughout the reaction mixture, preventing dead zones and improving composition uniformity.
Solution Approach 2:
The reactor employs a dynamic impeller system that creates active circulation patterns within the reaction mixture. The impeller design generates turbulent flow and continuous movement of the mixture, which enhances both dispersion of reactants and heat transfer efficiency, leading to uniform composition.
3Productivity
If mild agitation is used in the reaction tank, then the structure is simple, but blending efficiency is insufficient for modified asphalts
Solution Approach 1:
The agitation system uses a dynamically designed impeller that creates intense circulation and turbulent mixing. The impeller geometry and rotation speed are optimized to generate sufficient shear forces and flow patterns that efficiently blend modified asphalt components, achieving high productivity through active dynamic mixing rather than static or mild agitation.
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 solution achieves highly uniform composition and temperature, reduces energy costs, and allows for compact, efficient production of asphalt rubber binders with improved physical properties, suitable for continuous operation and easy transportation, overcoming the limitations of existing systems.
Implementation Method 1
The outer shell is provided with a heating jacket using thermal heat transfer oil
Implementation Method 2
The impeller pulls the vessel contents downward through the core of the circulation tube, discharging into the hydraulic head, which is designed to smoothly channel the flow upward through the annulus
Data Source
AI summary
A modified asphalt Contactor reactor for blending and reacting asphalt cement and modifiers is described; for example, a vertically oriented vessel having an outer shell having an internal surface and an external surface, a lower end and a flat flanged top; an internal circulation tube having a base, a top and an outside surface, wherein the outside surface of the internal circulation tube and the internal surface of the outer shell forms an annulus; a heating jacket having heating oil inlet and a heating oil outlet coupled to the external surface of the outer shell for circulation of heating oil; and a hydraulic head assembly having an impeller coupled to the lower end the vertically oriented vessel wherein the impeller is located near the base of the internal circulation tube, wherein the impeller and the annulus are of sufficient size to facilitate the flow of high viscosity fluids.