System and method for manufacturing asphalt products with recycled asphalt shingles

Abstract

A method for manufacturing a processed asphalt suspension is provided. The method includes dry grinding shingle waste material to a particle size of less than 1 cm, forming ground recycled shingle material, introducing virgin asphalt into a heated slurry tank and mixing the ground recycled shingle material with the virgin asphalt in the heated slurry tank, forming a mixed asphalt slurry, introducing the mixed asphalt slurry into a wet grinding machine, and recovering a processed asphalt suspension comprising particles having a size no greater than about 200 microns. Roofing and paving products manufactured from the processed asphalt suspension are also provided.

1 . A method for manufacturing a processed asphalt suspension composition comprising:
 dry grinding shingle waste material to a particle size of less than 1 cm, forming ground recycled shingle material;   introducing virgin asphalt into a slurry tank heated to a temperature between about 150-260° C.;   adding said ground recycled shingle material to said heated slurry tank and mixing said ground recycled shingle material with said virgin asphalt in said heated slurry tank, forming a mixed asphalt slurry;   introducing said mixed asphalt slurry into a wet grinding machine; and   recovering a processed asphalt suspension comprising particles having a size no greater than about 200 microns.   
     
     
         2 . The method of  claim 1 , wherein said virgin asphalt is oxidized prior to mixing with the ground recycled shingle material. 
     
     
         3 . The method of  claim 1 , further including adding an antifoam agent is added to said virgin asphalt prior to the addition of said ground recycled shingle material. 
     
     
         4 . The method of  claim 1 , wherein the wet grinding machine comprises an attritor. 
     
     
         5 . The method of  claim 1 , wherein said processed asphalt suspension comprises particles having a size no greater than about 150 microns. 
     
     
         6 . The method of  claim 5 , wherein said processed asphalt suspension comprises particles having a size no greater than about 100 microns. 
     
     
         7 . The method of  claim 1 , wherein 90% of the particles in the processed asphalt suspension are smaller than 150 microns and 50% of the particles are smaller than 50 microns. 
     
     
         8 . The method of  claim 1 , wherein said particles comprise at least one of granules, fillers, and fiberglass. 
     
     
         9 . The method of  claim 1 , comprising combining together:
 5-65 wt. % of the ground recycled shingle component; and   35-95 wt. % of the virgin asphalt component.   
     
     
         10 . The method of  claim 1 , further including a step of incorporating additives into said processed asphalt suspension. 
     
     
         11 . The method of  claim 1 , wherein said mixed asphalt slurry remains in said wet grinding mill until the ground recycled shingle material is fully integrated in the virgin asphalt. 
     
     
         12 . The method of  claim 1 , wherein said ground recycled shingle material comprises a powder having no more than 3% moisture content. 
     
     
         13 . The method of  claim 1 , wherein said processed asphalt suspension includes about 10-60% processed shingle material. 
     
     
         14 . The method of  claim 1 , further including manufacturing a roofing product incorporating said processed asphalt suspension. 
     
     
         15 . The method of  claim 14 , wherein said roofing products include one or more of hot roofing adhesive, modified shingle adhesive, asphalt shingles, modified bitumen membranes, asphalt coated glass plies and base sheets, asphaltic protector board, organic roofing felt, mastics, coatings, and sealants. 
     
     
         16 . The method of  claim 14 , wherein said virgin asphalt composition is selected according to the specific roofing product to be manufactured. 
     
     
         17 . The method of  claim 1 , further including adding an aggregate material into the wet grinding machine and manufacturing a paving product incorporating said processed asphalt suspension. 
     
     
         18 . The method of  claim 17 , wherein said paving products include one or more of hot mix asphalt paving applications, warm mix asphalt, and cold mix asphalt. 
     
     
         19 . The method of  claim 17 , wherein said virgin asphalt composition is selected according to the specific paving product to be manufactured. 
     
     
         20 . A processed asphalt suspension comprising:
 a ground recycled shingle component derived from recycled asphalt based roofing materials; and   a virgin asphalt component, wherein the ground recycled shingle component comprises particles of the recycled asphalt based roofing materials which have been reduced in size to have an average particle size of less than about 200 microns.   
     
     
         21 . The processed asphalt suspension of  claim 20 , wherein the particles have an average particle size of less than about 150 microns. 
     
     
         22 . The processed asphalt suspension of  claim 21 , wherein the particles have an average particle size of less than about 100 microns. 
     
     
         23 . The processed asphalt suspension of  claim 20 , wherein the particles comprise at least one of granules, filler and fiberglass. 
     
     
         24 . The processed asphalt suspension of  claim 20 , wherein said processed asphalt suspension provides improved durability to asphalt compositions. 
     
     
         25 . The processed asphalt suspension of  claim 20 , wherein said processed asphalt suspension provides improved fatigue and stiffness to asphalt pavements. 
     
     
         26 . The processed asphalt suspension of  claim 20 , comprising:
 5-65 wt. % of the ground recycled shingle component; and   35-95 wt. % of the virgin asphalt component.   
     
     
         27 . The processed asphalt suspension of  claim 20 , wherein 90% of the particles in the processed asphalt suspension are smaller than 150 microns and 50% of the particles are smaller than 50 microns. 
     
     
         28 . A roofing product comprising:
 a processed asphalt suspension comprising:
 a ground recycled shingle component derived from recycled asphalt based roofing materials; and 
 a virgin asphalt component, wherein the ground recycled shingle component comprises particles of the recycled asphalt based roofing materials which have been reduced in size to have an average particle size of less than about 200 microns. 
   
     
     
         29 . The roofing product of  claim 28 , wherein said processed asphalt suspension provides improved durability and shelf-life to said roofing product. 
     
     
         30 . An asphalt paving composition comprising:
 a processed asphalt suspension comprising:
 a ground recycled shingle component derived from recycled asphalt based roofing materials; and 
 a virgin asphalt component, wherein the ground recycled shingle component; and 
   an aggregate material, wherein said processed asphalt suspension comprises particles of the recycled asphalt based roofing materials which have been reduced in size to have an average particle size of less than about 200 microns.   
     
     
         31 . The asphalt paving composition of  claim 30 , wherein said processed asphalt suspension provides improved fatigue behavior and dynamic modulus to said asphalt paving composition. 
     
     
         32 . An asphalt pavement made from the asphalt paving composition of  claim 29 .