Asphalt Shingle Pyrolysis for High-Content Asphalt Mixtures
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Solution Overview
Problem
Conventional asphalt roofing shingle recycling methods are inefficient, as they cannot utilize more than 5% of the material by weight in road asphalt without degrading its quality, leading to excess disposal and the need for fresh materials.
Innovation Solution
A method involving pyrolysis of asphalt binder in asphalt roofing shingles to produce a coke layer, allowing the processed solid components to be used in asphalt mixtures up to 30% by weight, enhancing the recycling efficiency and reducing waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If untreated asphalt roofing shingles are used in road asphalt, then recycling is achieved, but the quality of road asphalt deteriorates when more than 5% by weight is composed of untreated shingles
Solution Approach 1:
The patent applies parameter changes by heating the asphalt roofing shingles to a specific temperature range (400-1000°F) to alter the physical and chemical properties of the aged asphalt binder. This thermal treatment transforms the brittle, aged binder into a more workable state that can be effectively reused in road asphalt mixtures at higher concentrations (5-30% by weight) without compromising road asphalt quality
Solution Approach 2:
The patent creates a composite material by combining processed asphalt roofing shingle components with fresh asphalt binder and aggregate. The processed shingle material, which has been thermally treated to modify its properties, is integrated with fresh materials to form a composite mixture that maintains the desired performance characteristics of road asphalt while incorporating recycled content at elevated levels
2Quantity of substance
If aged asphalt binder in used asphalt roofing shingles is present, then the shingles retain useful components, but the utilization of these components is limited to less than 5% by weight in road asphalt
Solution Approach 1:
The patent applies parameter changes by heating the asphalt roofing shingles to a specific temperature range (400-1000°F) to alter the physical and chemical properties of the aged asphalt binder. This thermal treatment transforms the brittle, aged binder into a more workable state that can be effectively reused in road asphalt mixtures at higher concentrations (5-30% by weight) without compromising road asphalt quality
Solution Approach 2:
The patent converts the harmful effect of aged, brittle asphalt binder into a beneficial resource. By applying thermal treatment, the previously unusable aged binder is transformed into a valuable component that can be reused in road asphalt. The aging process, which initially renders the binder unusable, is reversed through heating to create a material that contributes positively to the performance and sustainability of road asphalt
3Reliability
If fresh materials are acquired to maintain road asphalt quality, then asphalt quality is maintained, but waste asphalt roofing shingles must be disposed of in landfills
Solution Approach 1:
The patent implements discarding and recovering by extracting and reprocessing the useful components from discarded asphalt roofing shingles. Instead of landfilling the entire shingle material, the process recovers the asphalt binder and aggregate components, processes them to restore usability, and reintroduces them into road asphalt production. This circular approach eliminates landfill disposal while maintaining road asphalt quality
Solution Approach 2:
The patent applies universality by creating a multi-functional processing system that simultaneously achieves multiple objectives: it recycles waste shingles, produces usable road asphalt material, reduces landfill disposal, and maintains road asphalt quality. The same thermal processing apparatus serves to both rehabilitate the aged binder and prepare the material for reuse, making the system efficiently multi-functional
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
Enables the effective recycling and reuse of asphalt roofing shingles in asphalt mixtures, reducing waste and production costs while maintaining asphalt quality, thereby extending the material's useful life and reducing landfill disposal.
Implementation Method 1
heating the asphalt roofing shingles at a temperature of 1,100° F. or higher in an anaerobic environment within the thermal reactor to produce a residual material of the asphalt roofing shingles, the residual material including of a plurality of particles having one or more different particle sizes, and at least a portion of the plurality of particles include coke formed thereon
Data Source
AI summary
The present invention is directed to a method, apparatus and system that are configured to process asphalt roofing shingles so that solid constituent components of such asphalt roofing shingles may be used in asphalt mixtures. The present invention may include pyrolysis of asphalt binder present in the asphalt roofing shingles in order to develop a layer of coke on the solid constituent components, so that the solid constituent components may be suitable for use in the asphalt mixtures in quantities of 5 to 30% by weight of the total weight of the asphalt mixtures. The present invention is also directed to the asphalt mixtures that include 5 to 30% by weight of the solid constituent components of the asphalt roofing shingles that have been processed in accordance with the method, apparatus and/or system of the present invention.