System and method for producing asphalt using exhaust from a generator

Abstract

A system for producing hot mix asphalt includes a generator having an exhaust port; a dryer drum having an inlet; a duct connecting the exhaust port to the inlet, the duct conveying a first flow of hot gas from the exhaust port; an exhaust bypass vent conveying a second flow of hot gas diverging from the first flow of hot gas; and a valve disposed at a junction between the duct and the exhaust bypass vent for adjusting a flow rate of the second flow of hot gas. The dryer drum produces hot mix asphalt from asphalt materials using a third flow of hot gas diverging from the first flow of hot gas and entering the dryer drum through the inlet.

What is claimed is: 
     
         1 . A system for producing hot mix asphalt, comprising:
 a generator having an exhaust port;   a dryer drum having an inlet;   a duct connecting the exhaust port to the inlet, the duct being configured to convey a first flow of hot gas from the exhaust port;   an exhaust bypass vent configured to convey a second flow of hot gas diverging from the first flow of hot gas; and   a valve disposed at a junction between the duct and the exhaust bypass vent, the valve being configured to adjust a flow rate of the second flow of hot gas,   wherein the dryer drum is configured to produce hot mix asphalt from asphalt materials using a third flow of hot gas diverging from the first flow of hot gas and entering the dryer drum through the inlet.   
     
     
         2 . The system of  claim 1 , wherein the exhaust bypass vent is in fluid communication with atmosphere. 
     
     
         3 . The system of  claim 1 , wherein the generator is a gas turbine generator. 
     
     
         4 . The system of  claim 1 , wherein the valve is a gate valve. 
     
     
         5 . The system of  claim 1 , wherein the dryer drum is further configured to produce the hot mix asphalt by rotating the dryer drum with the asphalt materials inside the dryer drum and the third flow flowing through the dryer drum. 
     
     
         6 . The system of  claim 1 , wherein a flow rate of the first flow is equal to the flow rate of the second flow plus a flow rate of the third flow. 
     
     
         7 . The system of  claim 1 , wherein the valve is further configured to decrease a flow rate of the third flow by increasing the flow rate of the second flow. 
     
     
         8 . The system of  claim 1 , wherein the valve is further configured to increase a flow rate of the third flow by decreasing the flow rate of the second flow. 
     
     
         9 . The system of  claim 1 , further comprising an air intake structure configured to convey ambient air into the generator. 
     
     
         10 . The system of  claim 1 , wherein the asphalt materials include virgin asphalt and recycled asphalt. 
     
     
         11 . The system of  claim 1 , wherein the dryer drum is tilted such that a first axial end of the dryer drum is at a lower elevation than a second axial end of the dryer drum. 
     
     
         12 . The system of  claim 11 , wherein the inlet is disposed at the first axial end. 
     
     
         13 . The system of  claim 12 , wherein the dryer drum includes an opening at the second axial end for loading the asphalt materials into the dryer drum. 
     
     
         14 . The system of  claim 12 , wherein
 the dryer drum includes an exhaust structure, and an outlet at the second axial end,   the exhaust structure is connected to the outlet, and   the third flow flows through the dryer drum, through the outlet, through the exhaust structure, and into a baghouse.   
     
     
         15 . The system of  claim 1 , further comprising:
 a support structure configured to support the dryer drum; and   a drive system configured to axially rotate the dryer drum.   
     
     
         16 . The system of  claim 1 , wherein the generator is in electrical communication with a power grid to provide electrical energy to the power grid. 
     
     
         17 . The system of  claim 1 , wherein the generator is configured to provide electrical energy to equipment on a manufacturing site comprising the system. 
     
     
         18 . A power generation apparatus, comprising:
 a generator having an exhaust port;   a dryer drum having an inlet;   a duct connecting the exhaust port to the inlet, the duct being configured to convey a first flow of hot gas from the exhaust port;   an exhaust bypass vent configured to convey a second flow of hot gas diverging from the first flow of hot gas; and   a valve disposed at a junction between the duct and the exhaust bypass vent, the valve being configured to adjust a flow rate of the second flow of hot gas,   wherein the dryer drum is configured to produce hot mix asphalt from asphalt materials using a third flow of hot gas diverging from the first flow of hot gas and entering the dryer drum through the inlet, and   wherein the generator is configured to provide electrical energy to a power grid or equipment on a manufacturing site including the power generation apparatus.   
     
     
         19 . A method of producing hot mix asphalt and providing electrical energy, the method comprising:
 providing a generator having an exhaust port;   providing a dryer drum having an inlet;   providing an exhaust bypass vent;   connecting the exhaust port to the inlet using a duct;   installing a valve at a junction between the duct and the exhaust bypass vent;   running the generator to produce hot gas such that a first flow of the hot gas flows through the duct, the first flow of the hot gas diverging into a second flow of the hot gas and a third flow of the hot gas, the second flow of the hot gas flowing through the exhaust bypass vent, and the third flow of the hot gas flowing through the inlet and into the dryer drum;   controlling a flow rate of the third flow of the hot gas by controlling the valve to control a flow rate of the second flow of the hot gas;   producing hot mix asphalt from asphalt materials in the dryer drum using the third flow of the hot gas; and   providing, to a power grid or to equipment on a manufacturing site having the generator, electrical energy generated by the running of the generator.   
     
     
         20 . The method of  claim 19 , wherein the hot gas is exhaust gas produced by the running of the generator. 
     
     
         21 . The method of  claim 19 , wherein the producing of the hot mix asphalt and the providing of the electrical energy occur simultaneously.