Method for producing bituminous compositions

Abstract

This invention relates to bituminous compositions and methods of producing the same. More particularly, the invention relates to the production of bituminous compositions formulated with performance-graded bitumen-containing solvent-free bitumen emulsions which exhibit controllable, temperature-dependent interfacial rheology. When employed in paving applications, these bituminous compositions develop adhesive strength and load-bearing strength properties at rates comparable to traditional hot mix paving compositions and at rates faster than traditional cold mix paving compositions.

1 . A method for producing a bituminous composition comprising bitumen emulsion and aggregate by the steps of: 
 (A) preparing a solvent-free bitumen emulsion comprising: 
 ( 1 ) bitumen, in an amount from about 50.0% to about 75.0% by total weight of the bitumen emulsion,  
 ( 2 ) an emulsifier in an amount from about 0.05% to about 2.0% active by total weight of the bitumen emulsion, and  
 ( 3 ) water in an amount to complete the bitumen emulsion, and  
   (B) producing the bituminous composition having a temperature from about 50° C. to about 140° C. by mixing: 
 ( 1 ) the bitumen emulsion of step (A), having a temperature from about 25° C. to about 95° C., in an amount from about 2.0% to about 10.0% by total weight of the bituminous composition, and  
 ( 2 ) aggregate, having a temperature from about 60° C. to about 140° C., in an amount from about 90.0% to about 98.0% by total weight of the bituminous composition.  
   
   
   
       2 . The method of  claim 1  wherein said bitumen emulsion contains at least one bitumen selected from the group consisting of unmodified bitumens, modified bitumens, and combinations thereof.  
   
   
       3 . The method of  claim 1  wherein said bitumen emulsion contains from about 60.0% to about 70.0% by total weight of the emulsion of at least one bitumen selected from the group consisting of bitumens, modified bitumens, and combinations thereof and from about 0.08% to about 0.75% by total weight of the emulsion of at least one ionic emulsifier.  
   
   
       4 . The method of  claim 2  wherein said modified bitumen contains at least one member selected from the group consisting of natural rubbers, synthetic rubbers, plastomers, thermoplastic resins, thermosetting resins, elastomers, and combinations thereof.  
   
   
       5 . The method of  claim 4  wherein said modified bitumen contains at least one member selected from the group consisting of styrene-butadiene-styrene, styrene-butadiene-rubber, polyisoprene, polybutylenes, butadiene-styrene rubbers, vinyl polymers, ethylene vinyl acetate, ethylene vinyl acetate derivatives, sulfur-modified bituminous, acid-modified bituminous and combinations thereof.  
   
   
       6 . The method of  claim 1  wherein said bitumen emulsion contains from about 0.1% to about 0.5% active by total weight of said emulsion of at least one ionic emulsifier.  
   
   
       7 . The method of  claim 1  wherein said emulsifier is a member selected from the group consisting of amphoteric emulsifiers, cationic emulsifiers, nonionic emulsifiers and combinations thereof.  
   
   
       8 . The method of  claim 7  wherein said cationic emulsifier is a member selected from the group consisting of fatty imidazolines derived from C-12 to C-24 fatty acids, fatty imidoamines derived from C-12 to C-24 fatty acids, rosin acids, and combinations thereof modified with maleic anhydride, fumaric acid, and/or other ene- and dieneophiles and further reacted with polyalkylenepolyamines; fatty amidoamines derived from C-12 to C-24 fatty acids, rosin acids and combinations thereof modified with acrylic acid, maleic anhydride, fumaric acid, and/or other ene- and dieneophiles and further reacted with polyalkylenepolyamines; saturated C-12 to C-24 alkyl monoamines, unsaturated C-12 to C-24 alkyl monoamines, saturated C-12 to C-24 alkyl polypropylenepolyamines; unsaturated C-12 to C-24 alkyl polypropylenepolyamines; saturated C-12 to C-24 alkyl monoamines modified by reaction with ethylene oxide and/or propylene oxide to give polyoxyethylene derivatives; unsaturated C-12 to C-24 alkyl monoamines modified by reaction with ethylene oxide and/or propylene oxide to give polyoxyethylene derivatives; saturated C-12 to C-24 alkyl polypropylenepolyamines modified by reaction with ethylene oxide and/or propylene oxide to give polyoxyethylene derivatives; unsaturated C-12 to C-24 alkyl polypropylenepolyamines modified by reaction with ethylene oxide and/or propylene oxide to give polyoxyethylene derivatives; saturated C-12 to C-24 alkyl aryl monoamines, unsaturated C-12 to C-24 alkyl aryl monoamines; saturated C-12 to C-24 alkyl aryl polypropylenepolyamines, unsaturated C-12 to C-24 alkyl aryl polypropylenepolyamines; C-12 to C-24 quaternary amines; C-12 to C-24 alkyl ether amines; C-12 to C-24 alkylether polyamines; C-12 to C-24 alkyl polypropylene polyamine N-oxides; amine derivatives of tannins, amine derivatives of phenolic resins; amine derivatives of lignins, amine-modified polyacrylates; and combinations thereof. It is preferred that the cationic emulsifier be a member selected from the group consisting of saturated C-12 to C-24 alkyl monoamines, unsaturated C-12 to C-24 alkyl monoamines, saturated C-12 to C-24 alkyl polypropylenepolyamines, unsaturated C-12 to C-24 alkyl polypropylenepolyamines, and combinations thereof.  
   
   
       9 . The method of  claim 7  wherein said amphoteric emulsifier is a member selected from the group consisting of C-12 to C-24 fatty acids, rosin acids, and combinations thereof modified with acrylic acid, maleic anhydride, fumaric acid, and/or other ene- and dieneophiles and further reacted with polyethylene polyamines, lithium C-12 to C-24 alkyl amidopropyl halide methyl carboxylate betaines, sodium C-12 to C-24 alkyl amidopropyl halide methyl carboxylate betaines, potassium C-12 to C-24 alkyl amidopropyl halide methyl carboxylate betaines, lithium C-12 to C-24 alkyl amidopropyl halide phosphate betaines, sodium C-12 to C-24 alkyl amidopropyl halide phosphate betaines, potassium C-12 to C-24 alkyl amidopropyl halide phosphate betaines, lithium C-12 to C-24 alkyl amidopropyl halide sulphate betaines, sodium C-12 to C-24 alkyl amidopropyl halide sulphate betaines, and potassium C-12 to C-24 alkyl amidopropyl halide sulphate betaines.  
   
   
       10 . The method of  claim 1  wherein said bituminous composition is produced having a temperature in the range of about 55° C. to about 120° C.  
   
   
       11 . The method of  claim 1  wherein said bituminous composition is produced having a temperature in the range of about 60° C. to about 80° C.  
   
   
       12 . The method of  claim 1  wherein said bitumen emulsion of step (B) ( 1 ) has a temperature in the range of about 60° C. to about 80° C. and said aggregate of step (B) ( 2 ) has a temperature in the range of about 60° C. to about 120° C.  
   
   
       13 . The method of  claim 1  wherein said aggregate is a member selected from the group consisting of dense-graded aggregate, gap-graded aggregate, open-graded aggregate, reclaimed asphalt pavement, and combinations thereof.  
   
   
       14 . A bitumenous composition for road paving comprising a solvent-free bitumen emulsion blended with an aggregate, 
 wherein said bitumen emulsion is from about 2.0% to about 10.0% by total weight of the bituminous composition, and is characterized by from about 50.0% to about 75.0% bitumen by total weight of the bitumen emulsion, and from about 0.05% to about 2.0% of at least one active emulsifier by total weight of the bitumen emulsion, and    an amount of water in an amount to complete the bitumen emulsion, and    said aggregate is from about 90.0% to about 98.0% by total weight of the bituminous composition, and    wherein the bituminous composition is characterized by a temperature of from about 50° C. to about 140° C. prior to paving the road.    
   
   
       15 . The bitumenous composition of  claim 14  wherein said bitumen emulsion contains from about 60.0% to about 70.0% by total weight of the emulsion of at least one bitumen selected from the group consisting of bitumens, modified bitumens, and combinations thereof and from about 0.08% to about 0.75% by total weight of said at least one active emulsifier.  
   
   
       16 . The bitumenous composition of  claim 15  wherein said modified bitumen contains at least one member selected from the group consisting of natural rubbers, synthetic rubbers, plastomers, thermoplastic resins, thermosetting resins, elastomers, and combinations thereof.  
   
   
       17 . The bitumenous composition of  claim 15  wherein said modified bitumen contains at least one member selected from the group consisting of styrene-butadiene-styrene, styrene-butadiene-rubber, polyisoprene, polybutylenes, butadiene-styrene rubbers, vinyl polymers, ethylene vinyl acetate, ethylene vinyl acetate derivatives, sulfur-modified bituminous, acid-modified bituminous and combinations thereof.  
   
   
       18 . The bitumenous composition of  claim 14  wherein said bitumen emulsion contains from about 0.1% to about 0.75% by total weight of said emulsion of at least one ionic emulsifier.  
   
   
       19 . The bitumenous composition of  claim 14  wherein said emulsifier is a member selected from the group consisting of amphoteric emulsifiers, cationic emulsifiers, nonionic emulsifiers and combinations thereof.  
   
   
       20 . The bitumenous composition of  claim 19  wherein said cationic emulsifier is a member selected from the group consisting of fatty imidazolines derived from C-12 to C-24 fatty acids, fatty imidoamines derived from C-12 to C-24 (preferably C-16 to C-18) fatty acids, rosin acids, and combinations thereof modified with maleic anhydride, fumaric acid, and/or other ene- and dieneophiles and further reacted with polyalkylenepolyamines; fatty amidoamines derived from C-12 to C-24 (preferably C-16 to C-18) fatty acids, rosin acids and combinations thereof modified with acrylic acid, maleic anhydride, fumaric acid, and/or other ene- and dieneophiles and further reacted with polyalkylenepolyamines; saturated C-12 to C-24 alkyl monoamines, unsaturated C-12 to C-24 alkyl monoamines, saturated C-12 to C-24 alkyl polypropylenepolyamines; unsaturated C-12 to C-24 alkyl polypropylenepolyamines; saturated C-12 to C-24 alkyl monoamines modified by reaction with ethylene oxide and/or propylene oxide to give polyoxyethylene derivatives; unsaturated C-12 to C-24 alkyl monoamines modified by reaction with ethylene oxide and/or propylene oxide to give polyoxyethylene derivatives; saturated C-12 to C-24 alkyl polypropylenepolyamines modified by reaction with ethylene oxide and/or propylene oxide to give polyoxyethylene derivatives; unsaturated C-12 to C-24 alkyl polypropylenepolyamines modified by reaction with ethylene oxide and/or propylene oxide to give polyoxyethylene derivatives; saturated C-12 to C-24 alkyl aryl monoamines, unsaturated C-12 to C-24 alkyl aryl monoamines; saturated C-12 to C-24 alkyl aryl polypropylenepolyamines, unsaturated C-12 to C-24 alkyl aryl polypropylenepolyamines; C-12 to C-24 quaternary amines; C-12 to C-24 alkyl ether amines; C-12 to C-24 alkylether polyamines; C-12 to C-24 alkyl polypropylene polyamine N-oxides; amine derivatives of tannins, amine derivatives of phenolic resins; amine derivatives of lignins, amine-modified polyacrylates; and combinations thereof. It is preferred that the cationic emulsifier be a member selected from the group consisting of saturated C-12 to C-24 alkyl monoamines, unsaturated C-12 to C-24 alkyl monoamines, saturated C-12 to C-24 alkyl polypropylenepolyamines, unsaturated C-12 to C-24 alkyl polypropylenepolyamines, and combinations thereof.