Bitumen Fractionation via Solvent Dissolution and Flotation
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Solution Overview
Problem
Current recycling processes for bitumen-containing materials, such as asphalt roofing shingles, do not economically process non-comminuted materials and fail to efficiently separate and utilize the individual fractions, resulting in lower market value for recycled products compared to separate components.
Innovation Solution
A system comprising a dissolution vessel, tumbler, and solvent distributor facilitates the dissolution of bitumen-containing materials into solvents, followed by solid-liquid and solvent-fraction separation, allowing for the extraction of bitumen-rich streams comprising asphaltenes and maltenes, enabling the production of specific bitumen products with desired ratios and characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If bitumen-containing materials are ground and mixed into hot mix paving asphalt, then recycling is achieved, but the market value is substantially less than the total value of separate individual fractions
Solution Approach 1:
The patent applies segmentation by separating bitumen-containing materials into individual fractions (asphalt cement, aggregate, sand, gravel, granules) rather than grinding and mixing them together. This allows each fraction to be recovered and sold separately, maximizing the total market value while maintaining recycling efficiency.
2Quantity of substance
If bitumen-containing materials are separated into individual fractions, then market value is maximized, but the processing complexity increases
Solution Approach 1:
The patent replaces complex mechanical separation systems with a flotation-based separation process. By using flotation tanks with air bubbles and selective reagents, the system automatically separates different fractions based on their surface properties, significantly reducing mechanical complexity while maintaining high separation efficiency and market value.
3Stability of the object's composition
If non-comminuted bitumen-containing materials are processed, then material integrity is preserved, but current recycling processes cannot economically process them
Solution Approach 1:
The patent changes the processing parameters by using flotation separation instead of mechanical comminution. This allows non-comminuted materials to be processed economically while preserving material integrity, as the flotation process separates fractions based on surface chemistry rather than physical size reduction, making the recycling process economically viable.
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
This method enables the economic and efficient recycling of bitumen-containing materials, producing stronger, more durable bitumen products by separating and blending bitumen fractions, thereby increasing the market value of recycled products.
Implementation Method 1
The tumbler is configured to agitate the bitumen-containing materials and facilitate wetting the bitumen-containing materials with the at least one solvent
Implementation Method 2
apparatus to facilitate dissolution of at least one fraction of bitumen-containing materials into at least one solvent
Implementation Method 3
a solid-liquid separator configured to separate the mixed-materials stream to provide a liquid-rich stream and a solids-rich stream
Implementation Method 4
a solvent-fraction separator configured to separate the liquid-rich stream to provide a solvent-rich stream and a bitumen-rich stream
Data Source
AI summary
Method and apparatus to facilitate recycling of at least one fraction of bitumen-containing materials. This can be accomplished by dissolving the at least one fraction, for example, maltenes or asphaltenes in roofing shingles, into at least one solvent. In one aspect, the apparatus comprises a dissolution vessel, a tumbler positioned therein, and at least one solvent distributor. The tumbler is configured to facilitate wetting the bitumen-containing materials with solvent. In a second aspect, a system comprises the apparatus, a solid-liquid separator, for example, a vibratory screen, and at least one solvent-fraction separator, for example, a flash drum. The at least one solvent can comprise one or more solvents useful to extract the at least one fraction. In a third aspect, a first fraction is extracted from the bitumen-containing materials with a first solvent composition, then a second fraction is extracted from the remaining bitumen-containing materials with a second solvent composition.