Modified Bitumen Composition Using Petrocoke and Extract Additives
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Solution Overview
Problem
Existing bitumen compositions used in asphalt-coated roads are prone to thermal cracks, fatigue cracks, and rutting, especially in high vehicle density areas and extreme climate conditions, and current additives like fly ash can be toxic and contribute to air pollution.
Innovation Solution
A modified bitumen composition incorporating petrocoke and a base oil unit by-product as additives, with petrocoke comprising at least 55% by weight and the extract comprising 2-5% by weight, which increases the resistance of bitumen and asphalt coatings without subjecting the additives to combustion, thereby enhancing performance grading and reducing environmental harm.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fly ash is added to bitumen to increase resistance to cracks and potholes, then the mechanical properties of asphalt are improved, but toxic materials are released causing air pollution and unsafe working conditions
Solution Approach 1:
The patent converts the harmful combustion process of fly ash into a beneficial non-combustion mixing process. By eliminating the burning step that causes toxic emissions, the patent maintains the crack-resistant properties of fly ash while removing the air pollution and safety hazards associated with combustion.
Solution Approach 2:
The patent extracts the harmful combustion step from the fly ash application process. Instead of burning fly ash to improve asphalt properties, the patent directly incorporates unburned or pre-processed fly ash into the bitumen, separating the beneficial mechanical reinforcement from the harmful emissions.
2Reliability
If fly ash is combusted to improve asphalt performance, then resistance to crack formation increases, but air pollution and pollutant emissions are caused
Solution Approach 1:
The patent transforms the harmful combustion process into a beneficial non-thermal processing approach. By using mechanical mixing instead of combustion to incorporate fly ash into bitumen, the patent achieves crack formation resistance without generating air pollution or pollutant emissions.
3Ease of manufacture
If conventional bitumen is used in asphalt-coated roads, then the basic binding function is provided, but thermal cracks, fatigue cracks, and rutting occur over time
Solution Approach 1:
The patent creates a composite material by combining conventional bitumen with fly ash and other additives. This composite structure provides both the basic binding function of bitumen and the enhanced crack resistance and rutting prevention properties of the incorporated materials.
Solution Approach 2:
The patent modifies the physical and chemical parameters of bitumen by adding fly ash and other substances. These parameter changes include increased viscosity, improved tensile strength, and enhanced resistance to thermal and fatigue cracking, while maintaining the fundamental binding properties.
Data Source
AI summary
The present invention relates to a modified bitumen composition used in asphalt-coated roads as a binding raw material and comprising petrocoke, a derivative of carbon based crude oil, and extract, a base oil unit by-product, as additives, and to a method of producing the same. The modified bitumen composition of the invention contains at least 55% by weight of bitumen with a penetration in the range of 40 to 110 as per EN 1426 standard, and 1%-40% by weight of petrocoke with a particle size preferably less than 300 micrometers, and 2% to 5% by weight of extract, a base oil unit by-product, as additives. The present invention includes determination of the amount of the additives petrocoke and extract to be added to the bitumen, optimum values of such parameters as mixing temperature and mixing rate required for them to distribute in the bitumen homogenously and the conditions at which the modified bitumen may be stored and/or transported without losing its improved properties.