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 - 32 . (canceled) 
     
     
         33 . A method for manufacturing a processed asphalt suspension composition comprising:
 providing a ground recycled shingle material that is substantially free of granules and has a moisture content of less 3%;   introducing virgin asphalt into a slurry tank heated to a temperature between about 150-260° C.;   adding the 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 to form a mixed asphalt slurry;   processing the mixed asphalt slurry in a wet grinding machine to provide a processed asphalt suspension composition; and   recovering the processed asphalt suspension composition, wherein the processed asphalt suspension composition comprises particles having a size no greater than about 150 microns.   
     
     
         34 . The method of  claim 33 , wherein the ground recycled shingle material comprises fine fillers and asphalt. 
     
     
         35 . The method of  claim 33 , wherein the wet grinding machine comprises a stirred ball mill or an attritor. 
     
     
         36 . The method of  claim 33 , wherein said processed asphalt suspension is comprised of:
 0-100% ground recycled shingle fines; and   0-100% ground recycled shingle asphalt particles.   
     
     
         37 . The method of  claim 33 , further including adding an antifoam agent to the virgin asphalt prior to the addition of said ground recycled shingle feedstock. 
     
     
         38 . The method of  claim 33 , wherein aged asphalt derived from the ground recycled shingle material is rejuvenated in the wet grinding machine by mixing with the virgin asphalt. 
     
     
         39 . The method of  claim 33 , wherein the wet grinding machine is an attritor. 
     
     
         40 . The method of  claim 33 , wherein the processed asphalt suspension comprises particles having a size no greater than about 100 microns. 
     
     
         41 . The method of  claim 33 , wherein 90% of the particles in the processed asphalt suspension are smaller than 100 microns and 50% of the particles are smaller than 50 microns. 
     
     
         42 . The method of  claim 33 , wherein the ground recycled shingle material is derived from ground shingle waste comprising particles that include moisture and at least one of granules, fillers, or fiberglass in addition to asphalt. 
     
     
         43 . The method of  claim 42 , wherein the ground recycled shingle material is derived from a process comprising the use of a milling or impactor device. 
     
     
         44 . The method of  claim 42 , wherein the ground shingle waste comprises granules, and the granules comprise no more than 5% by weight of the processed asphalt suspension. 
     
     
         45 . The method of  claim 33 , comprising combining together:
 5-65% wt. % of the ground recycled shingle material component; and   35-95% wt. % of the virgin asphalt component.   
     
     
         46 . The method of  claim 33 , further including a step of incorporating an additive into said processed asphalt suspension. 
     
     
         47 . The method  claim 46  wherein the additive comprises at least one of a polymer, a wax, or an oil. 
     
     
         48 . The method of  claim 33 , wherein said ground recycled shingle material comprises a powder having no more than 3% moisture content. 
     
     
         49 . The method of  claim 33 , further comprising manufacturing a roofing product from the processed asphalt suspension. 
     
     
         50 . The method of  claim 49 , wherein the roofing product includes at least one 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, or sealants.