Bituminous Granules with Compatibilizer for Stable Dispersion
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Solution Overview
Problem
The preparation of bituminous compositions with binder matrices is lengthy and costly, requiring precise conditions, high energy consumption, and poses environmental risks due to the use of certain additives and the need for precise monitoring of raw materials, with challenges in achieving stable storage characteristics and thermomechanical performances.
Innovation Solution
A method involving micronizing polymers in the presence of a compatibilizing agent to form granules with a binder matrix, anti-adhesive filler, and an anti-sticking agent, using a twin-screw extruder with controlled temperature and pressure to optimize dispersion and storage stability, allowing for the production of bituminous granules with improved physicochemical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If polymer particles are micronized to smaller size to improve dispersion rate in bitumen, then dispersion rate is improved, but cost of conditioning and safety measures increase significantly
Solution Approach 1:
The patent changes the particle size parameter of the polymer from fine powder to granules with diameter of 0.5-2 mm, which fundamentally alters the processing requirements and eliminates the need for expensive micronization while maintaining good dispersion properties through the extrusion process
Solution Approach 2:
The patent uses readily available polymer granules that do not require expensive conditioning processes, replacing the need for costly fine powder preparation and associated safety infrastructure with simple, inexpensive granular material that can be directly processed
2Loss of time
If polymer is mixed in liquid form to achieve very short kneading time, then kneading time is reduced, but energy consumption for liquefaction becomes very considerable
Solution Approach 1:
The patent changes the physical state parameter of the polymer from liquid to solid granular form, and uses thermal energy during extrusion (150-250°C) to achieve both melting and mixing simultaneously, eliminating the need for separate liquefaction and mixing steps
Solution Approach 2:
The patent combines the melting and mixing operations into a single extrusion process, where the polymer granules are melted and mixed with bitumen in one continuous operation, eliminating the need for separate liquefaction and mixing steps
3Productivity
If high temperatures are used to achieve good dispersion and mixing, then mixing efficiency is improved, but risk of polymer degradation increases
Solution Approach 1:
The patent uses continuous extrusion processing that maintains controlled temperature throughout the mixing process, ensuring complete dispersion without prolonged exposure to high temperatures that would cause degradation
Solution Approach 2:
The extrusion process allows for continuous monitoring and control of temperature and mixing parameters, enabling optimization of the process to achieve good dispersion while preventing polymer degradation through real-time adjustments
4Reliability
If precise monitoring and standardization of raw materials is implemented to ensure quality, then thermomechanical performances are improved, but the process becomes lengthy and expensive
Solution Approach 1:
The patent uses polymer granules with a specific size range (0.5-2 mm) that provides consistent processing behavior and good dispersion without requiring extensive raw material characterization, simplifying quality control while maintaining performance
5Productivity
If heating of large quantities of components in kneading tanks is performed to achieve mixing, then mixing is achieved, but energy consumption becomes very considerable
Solution Approach 1:
The patent replaces batch heating and mixing in large kneading tanks with continuous mechanical extrusion that uses shear heating and friction during the extrusion process itself, significantly reducing the need for external heating energy
Solution Approach 2:
The continuous extrusion process allows for efficient heat transfer and mixing as materials are constantly moved and sheared through the extruder, eliminating the need for prolonged heating of large stationary batches
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 reduces production costs and energy consumption, enhances storage stability, and allows for the production of bituminous granules with optimized thermomechanical performances, enabling prolonged storage at ambient temperature with improved homogeneity and reduced environmental impact.
Implementation Method 1
micronizing the polymer in the presence of the compatibilizing agent to form a preparation comprising micronized polymer
Implementation Method 2
adding the anti-adhesive filler to said mixture comprising binder matrix obtained in step c. to form a core
Data Source
AI summary
Disclosed is a bituminous composition in the form of granules, each granule including a core and a coating and having a mass for approximately one hundred particles of from 0.5 g to 2 g, the core including from 40 wt. % to 60 wt. % of a binder matrix; from 30 wt. % to 40 wt. % of a polymer; from 4 wt. % to 6 wt. % of a compatibilizing agent; and from 2 wt. % to 15 wt. % of an anti-adhesive filler; and the coating including an anti-sticking agent. The invention relates also to a method for preparing the composition, and to the use thereof in bitumen plants.