Electric Resistance Heating for Low-Carbon Asphalt Production
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Solution Overview
Problem
Conventional warm mix asphalt (WMA) and hot mix asphalt (HMA) production processes rely on fossil fuels for heat, leading to high carbon emissions, aggregate degradation, and safety hazards due to rapid heating, which also results in reduced asphalt pavement strength and blue smoke issues.
Innovation Solution
A system and method for storing and time-shifting renewable electrical power to generate low-carbon heat using thermally insulated storage subsystems and furnaces, preheating asphalt components, and mixing subsystems to produce WMA or HMA, reducing the need for fossil fuels and minimizing aggregate degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If fossil fuel combustion is used to generate high flame temperature for rapid aggregate heating, then production throughput is improved, but carbon emissions increase and aggregate degradation occurs
Solution Approach 1:
The patent changes the fundamental parameter of heating method from combustion-based thermal heating to electric resistance heating. This allows precise control of heating temperature and rate, enabling aggregate to be heated to the required temperature without excessive flame temperatures that cause degradation and emissions. The electric heating system maintains productivity while eliminating the harmful effects of fossil fuel combustion.
Solution Approach 2:
The patent replaces the mechanical/chemical combustion system with an electrical heating system. Instead of using fossil fuels to generate combustion heat, the system uses electric current passing through resistance heaters to generate heat directly. This substitution eliminates carbon emissions from the heating process while maintaining the ability to rapidly heat aggregate to required temperatures for asphalt production.
2Speed
If very high flame temperature is used to rapidly heat aggregate, then heating speed is improved, but aggregate particles explode and worker safety is compromised
Solution Approach 1:
The patent changes the heating parameter from uncontrolled flame temperature to controlled electric resistance heating temperature. The electric heating system provides uniform heat distribution and allows precise temperature control, heating aggregate rapidly to the required temperature without creating the extreme localized temperatures that cause particle explosion. This maintains heating speed while eliminating the safety hazard.
3Productivity
If high temperature heating is used to process asphalt binder, then mixing efficiency is improved, but volatization and oxidation of binder occur, reducing pavement ductility
Solution Approach 1:
The patent changes the heating method for asphalt binder from high-temperature combustion heating to controlled electric resistance heating. This allows the binder to be heated to the necessary temperature for proper mixing while avoiding excessive temperatures that cause volatization and oxidation. The controlled heating maintains mixing efficiency while preserving binder properties and resulting pavement ductility.
4Use of energy by moving object
If conventional combustion heating is used for asphalt production, then energy supply is sufficient, but blue smoke is created causing environmental concerns
Solution Approach 1:
The patent replaces the combustion-based energy conversion system with direct electric resistance heating. This substitution provides sufficient energy supply for all heating requirements in asphalt production without creating blue smoke emissions. The electric heating elements convert electrical energy directly to thermal energy without combustion, eliminating the harmful emissions while maintaining adequate energy supply for efficient asphalt manufacturing.
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 approach enables low-carbon production of asphalt mixtures by reducing carbon emissions, improving aggregate strength, minimizing dust and blue smoke, and enhancing the sustainability of asphalt manufacturing processes.
Implementation Method 1
a first thermally insulated storage subsystem containing a quantity of an asphalt paving material manufacturing component, and a first furnace configured to heat the asphalt paving material manufacturing component using an available supplemental energy source
Implementation Method 2
a first furnace configured to heat the asphalt paving material manufacturing component using an available supplemental energy source
Data Source
AI summary
The present disclosure relates to a system for storing and time-shifting at least one of electrical power, excess electrical power, or renewable electrical power, to create low-carbon heat for future use in assisting with a production of asphalt paving material. The system makes use of a first thermally insulated storage subsystem containing a quantity of an asphalt paving material manufacturing component, and a first furnace configured to heat the asphalt paving material manufacturing component using an available supplemental energy source. A second thermally insulated storage subsystem is used to store a quantity of asphalt binder, and a second furnace is used to heat the quantity of asphalt binder. An air blower is used to supply a quantity of air to the first furnace to assist in a heating during a heat-charge phase of operation of the system in which both the quantity of asphalt paving material manufacturing component and the quantity of asphalt binder are pre-heated.