Modified Bitumen Mixture with Petroleum Coke and Paraffin Wax
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Solution Overview
Problem
Bitumen used in asphalt pavements fails to meet performance criteria in extreme climates and high-traffic areas, leading to heat- and fatigue-induced cracks and rutting, and the use of imported polymers increases costs and energy consumption due to viscosity issues and grinding challenges.
Innovation Solution
A modified bituminous mixture comprising bitumen with a styrene-conjugated diene triblock copolymer, paraffin wax as a viscosity-lowering agent, and carbon-based solid petroleum coke of larger particle sizes, processed using a method that includes fluidization, grinding, and an aging process to achieve low viscosity and homogeneity without energy-intensive grinding of small particles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If imported polymeric additives are used to improve temperature sensitivity, then the performance of bitumen in extreme climates is improved, but the cost and importation costs increase
Solution Approach 1:
The patent replaces expensive imported polymeric additives with locally available, cheaper materials including petroleum coke (a refinery byproduct), paraffin wax, and natural minerals. These domestic materials achieve similar performance improvements in temperature sensitivity and durability without the high costs associated with imported polymers, directly addressing the cost-performance contradiction
Solution Approach 2:
The patent changes the material parameters by using petroleum coke with controlled particle sizes (0.063-2.0 mm) and specific carbon content (85-95%), combined with paraffin wax and natural minerals in optimized proportions. This parameter optimization allows achieving the desired temperature sensitivity and climate resistance using local materials instead of expensive imported polymers
2Stability of the object's composition
If small particle size additives are used to modify bitumen, then the homogeneity of the mixture is improved, but the energy consumption for grinding increases
Solution Approach 1:
The patent optimizes the particle size parameter of petroleum coke to a specific range (0.063-2.0 mm, preferably 0.2-1.0 mm), which achieves adequate homogeneity in the bitumen mixture without requiring excessive grinding energy. This parameter optimization balances homogeneity requirements with energy consumption constraints
Solution Approach 2:
The patent extracts and utilizes the fine fraction of petroleum coke (0.063-2.0 mm) that naturally exists as a byproduct of delayed coking units, eliminating the need for energy-intensive grinding of larger particles. By taking out and utilizing this pre-fractionated material, the patent achieves homogeneity without the high energy costs of extensive size reduction
3Ease of manufacture
If bitumen is used in asphalt pavements, then the basic paving function is fulfilled, but the resistance to heat- and fatigue-induced cracks and rutting is insufficient
Solution Approach 1:
The patent creates a composite modified bitumen material by combining bitumen with petroleum coke (5-20% by weight), paraffin wax (2-10% by weight), and natural minerals (3-15% by weight). This composite structure provides both the basic paving functionality of bitumen and enhanced resistance to heat-induced cracks, fatigue cracks, and rutting through the synergistic effects of the combined materials
Solution Approach 2:
The patent uses paraffin wax as an intermediary material that enhances the bonding between bitumen and aggregate particles, improving the overall cohesion and resistance to rutting. The wax acts as a mediator that strengthens the interface between different components, thereby improving durability without compromising the basic paving function
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 results in durable asphalt products with reduced energy costs and improved resistance to rutting and fatigue-induced cracks, while utilizing larger petroleum coke particles without homogeneity issues, achieving high performance in hot and cold climates.
Implementation Method 1
fluidizing the bitumen by heating the same preferably to 135°C
Implementation Method 2
subjecting the mixture from the second grinder to an aging process at 180°C and 250 rpm stirring speed for 1-4 hours bearing in mind the chemical structure of bitumen
Data Source
AI summary
A modified bituminous mixture developed according to the present invention comprises bitumen with a penetration value from 40 to 100 dmm, a styrene-conjugated diene triblock copolymer as a first additive, a viscosity-lowering agent as a second additive comprising zeolite derivatives and/or paraffin wax composed of aliphatic hydrocarbon chains comprising C40-C120 carbon obtained by Fisher-Tropsch method, and a carbon-based solid petroleum coke as a third additive, with a particle size above 300 microns, which is a product of delayed coking units of refineries.