Separate-Stream Oxidized Bitumen Processing for Lower CO2-Equivalent Emissions
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Solution Overview
Problem
Existing methods for producing oxidized bitumen are time-consuming and energy-intensive, leading to high emissions of filterable particulate, total organic compounds, carbon monoxide, HCl, VOC, and NOx.
Innovation Solution
A process involving separate feed streams of preheated bitumen and polymeric modifier into an oxidizer, with controlled oxygen flow and temperature, forming a bituminous composition with reduced CO2-equivalent emissions by avoiding premixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If bitumen and polymeric modifier are premixed before oxidation, then mixing is thorough, but process time and energy consumption increase
Solution Approach 1:
The patent divides the feeding process into separate streams: bitumen is fed through a first feed stream and polymeric modifier through a second feed stream, which are then mixed within the oxidizer. This segmentation eliminates the need for separate pre-mixing equipment and reduces overall process time while maintaining effective mixing during the oxidation process.
Solution Approach 2:
The patent combines the mixing and oxidation operations into a single integrated oxidizer unit. The separate feed streams are introduced into the oxidizer where they mix and undergo oxidation simultaneously, eliminating the need for separate pre-mixing step and reducing total process time and energy consumption.
2Manufacturing precision
If oxidation is performed for extended periods to achieve desired properties, then penetration and softening point are optimized, but energy consumption and emissions increase
Solution Approach 1:
The patent optimizes oxidation parameters including temperature (maintained between 400-550°F), oxygen flow rate (at least 5 l/min per kg of bitumen), and feed stream ratios (1-25 parts by weight of polymeric modifier to 100 parts by weight of bitumen). These parameter changes enable achieving desired penetration and softening point within reduced time frames, lowering energy consumption and emissions.
3Productivity
If separate feed streams are used instead of premixing, then process time is reduced, but mixing effectiveness may be compromised
Solution Approach 1:
The bitumen is preheated to at least 275°F before entering the oxidizer, and the polymeric modifier is prepared as a separate feed stream. This preliminary preparation ensures that both materials are in the appropriate state for immediate effective mixing and reaction within the oxidizer, maintaining mixing effectiveness while enabling faster processing.
Solution Approach 2:
The oxidizer acts as an intermediary zone where the separate feed streams of bitumen and polymeric modifier are introduced, mixed, and reacted simultaneously with oxygen. This intermediary function allows effective mixing and oxidation to occur in one unit, eliminating the need for separate pre-mixing equipment and maintaining composition stability.
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
Reduces CO2-equivalent emissions by at least 10% and shortens oxidation time, achieving desired penetration and softening point properties in bitumen.
Implementation Method 1
blowing an oxygen-containing gas (e.g., air, oxygen or an oxygen-inert gas mixture) through the bitumen feedstock at an elevated temperature
Implementation Method 2
maintaining the temperature of the oxidizer in a range of 400-550° F.
Data Source
AI summary
The disclosure relates to a process for the production of an oxidized bituminous compound. The process includes providing bitumen and a polymeric modifier in separate feed streams and blowing oxygen-containing gas through the bitumen and polymeric modifier in an oxidizer. The process for preparing the bituminous composition reduces CO2-equivalent by at least 10% compared to a process involving premixing bitumen and polymeric modifier, and/or oxidation of the bitumen alone.