Sulfur additives for paving binders and manufacturing methods

Abstract

Sulfur, useable in as an additive to asphalt in the preparation of asphalt binders can be plasticized by addition of carbon and further treated with amyl acetate. This plasticized sulfur can be formed into solid particles and then added to asphalt as either a minority or majority component to create desired paving binder compositions. The solid plasticized sulfur has non-stick non-flow properties within a wide range of ambient temperatures, and it can be stored solid for subsequent use in paving applications.

1. A plasticized sulfur product, comprising:
 a plasticized sulfur composition obtained by mixing liquid sulfur with carbon and amyl acetate, wherein at least a portion of said liquid sulfur is plasticized.   
     
     
       2. A plasticized sulfur product according to  claim 1  wherein said carbon is added at a weight percent concentration above about 0.25%. 
     
     
       3. A plasticized sulfur product according to  claim 1  wherein said carbon is added at a weight percent concentration between about 0.25% and about 1.0%. 
     
     
       4. A plasticized sulfur product according to  claim 1  wherein said carbon is added at a weight percent concentration between about 0.4% and about 0.8%. 
     
     
       5. A plasticized sulfur product according to  claim 1  wherein said amyl acetate is added at a weight percent concentration above about 0.08%. 
     
     
       6. A plasticized sulfur product according to  claim 1  wherein said amyl acetate is added at a weight percent concentration between about 0.1% and about 1.5%. 
     
     
       7. A plasticized sulfur product according to  claim 1  wherein said amyl acetate is added at a weight percent concentration between about 0.2% and about 0.4%. 
     
     
       8. A process for plasticizing sulfur, comprising:
 mixingmaking solid particles of a plasticized sulfur composition by forming a mixture consisting essentially of liquid sulfur withand a carbon and allowing said sulfur to polymerize to form said solid particles. 
 
     
     
       9. A process for plasticizing sulfur according to  claim 8  wherein said sulfur, is maintained during the forming step at a temperature of between about 120° F C. and about 150° F C. 
     
     
       10. A process for plasticizing sulfur according to  claim 8  wherein said process further comprises cooling said plasticized sulfur into said solid particles. 
     
     
       11. A process for plasticizing sulfur according to  claim 10  wherein said solid particles exhibit no agglomeration at temperatures under 175° F. 
     
     
       12. A sulfur-rich paving binder obtained by mixing the substances comprising:
 (a) hydrocarbon-based material; 
 (b) a fine mineral constituent; and 
 (c) a plasticized sulfur product obtained by mixing forming a mixture consisting essentially of liquid sulfur with and carbon and allowing said liquid sulfur to polymerize. 
 
     
     
       13. A sulfur-rich paving binder according to  claim 12  wherein said plasticized sulfur product is incorporated into the mixture sulfur-rich paving binder in a weight percentage of at least 60%. 
     
     
       14. A sulfur-rich paving binder according to  claim 12  wherein said fine mineral constituent comprises at least one of the materials in the group consisting of fly ash, silica material, and mixtures thereof. 
     
     
       15. A sulfur-rich paving binder according to  claim 12  obtained by forming a mixture by mixing the substances comprising a hydrocarbon-based material; a fine mineral constituent; and a plasticized sulfur product obtained by mixing liquid sulfur with a plasticizer consisting essentially of carbon and allowing said sulfur to polymerize wherein said plasticized sulfur product is incorporated into the said mixture in a weight percentage of about 70% at least 60%, said hydrocarbon-based material is incorporated into the said mixture in a weight percentage of about 15% at least 10% and said fine mineral constituent is incorporated into the mixture in a weight percentage of about 15% at least 10%. 
     
     
       16. A sulfur-rich paving binder according to  claim 15  wherein said solid particles exhibit no agglomeration at temperatures under 175° F. 
     
     
       17. A sulfur-rich paving binder according to  claim 12  wherein said sulfur-rich paving binder is formed into solid particles. 
     
     
       18. A sulfur-rich paving binder according to  claim 12 , wherein the plasticized sulfur product further comprises amyl acetate, wherein the amyl acetate improves the handling and odor characteristics of the plasticized sulfur product. 
     
     
       19. A paving product obtained by mixing substances comprising:
 (a) a plasticized sulfur product obtained by mixing forming a mixture consisting essentially of liquid sulfur with and carbon and allowing said liquid sulfur to polymerize; and 
 (b) hydrocarbon-based material. 
 
     
     
       20. A sulfur-rich paving binder according to  claim 19 , wherein the plasticized sulfur product further comprises amyl acetate, wherein the amyl acetate improves the handling and odor characteristics of the plasticized sulfur product. 
     
     
       21. A sulfur-rich paving binder obtained by forming a mixture by mixing
 (a) a hydrocarbon-based material;   (b) a fine mineral constituent; and   (c) a plasticized sulfur product obtained by mixing liquid sulfur with carbon and allowing said sulfur to polymerize and to form solid particles,   wherein said plasticized sulfur product is incorporated into said mixture in a weight percentage of at least 60%, said hydrocarbon-based material is incorporated into said mixture in a weight percentage of at least 10% and said fine mineral constituent is incorporated into the mixture in a weight percentage of at least 10%, and wherein said solid particles exhibit no agglomeration at temperatures below 175° F.   
     
     
       22. A sulfur-rich paving binder obtained by mixing the substances comprising:
 (a) hydrocarbon-based material;   (b) a fine mineral constituent; and   (c) a plasticized sulfur product obtained by mixing liquid sulfur with carbon and allowing said sulfur to polymerize,   wherein the plasticized sulfur product further comprises amyl acetate, wherein the amyl acetate improves the handling and odor characteristics of the plasticized sulfur product.   
     
     
       23. A paving product obtained by mixing substances comprising:
 (a) a plasticized sulfur product obtained by mixing liquid sulfur with carbon and allowing said sulfur to polymerize;   (b) hydrocarbon-based material, and   (c) amyl acetate,   wherein the amyl acetate improves the handling and odor characteristics of the plasticized sulfur product.   
     
     
       24. A composition, comprising: a plasticized sulfur product obtained by forming a mixture by mixing liquid sulfur and an amount of carbon, wherein said amount of carbon is in the range of from about 0.25% to about 1.0% of said mixture and allowing plasticization of at least a portion of said liquid sulfur, and wherein said forming of said mixture further includes mixing an amount of amyl acetate with said liquid sulfur and said amount of carbon, wherein said amount of amyl acetate is in the range of at least about 0.08% of said mixture. 
     
     
       25. A composition as recited in claim 24, wherein said amount of amyl acetate is in the range of from about 0.1% to about 1.5% of said mixture. 
     
     
       26. A composition as recited in claim 25, wherein said amount of amyl acetate is in the range of from about 0.2% to about 0.4% of said mixture. 
     
     
       27. A composition as recited in claim 26, wherein said liquid sulfur of said forming step is at a temperature in the range of from about 120° C. to about 150° C. 
     
     
       28. A composition as recited in claim 27, wherein said forming step further includes cooling said mixture having at least a portion of said liquid sulfur that is plasticized to thereby form solid particles of said plasticized sulfur product. 
     
     
       29. A composition as recited in claim 28, wherein said solid particles have characteristics such as to exhibit no agglomeration at temperatures under 79° C. (175° F.). 
     
     
       30. A composition as recited in any one of claims 24 through 29, further comprising: a hydrocarbon-based material and a fine mineral constituent. 
     
     
       31. A composition as recited in any one of claims 24 through 29, further comprising: a hydrocarbon-based material and a fine mineral constituent, wherein said plasticized sulfur product is present in said composition in an amount of at least 60 weight percent of said composition, wherein said hydrocarbon-based material is present in said composition in an amount of at least 10 weight percent of said composition, and wherein said fine mineral constituent is present in said composition in an amount of at least 10 weight percent. 
     
     
       32. A composition as recited in any one of claims 24 through 29, further comprising a hydrocarbon-based material and a fine mineral constituent selected from the group of aggregates consisting of fly ash and silica material, and wherein said plasticized sulfur product is present in said composition in an amount of at least 60 weight percent of said composition, wherein said hydrocarbon-based material is present in said composition in an amount of at least 10 weight percent of said composition, and wherein said fine mineral constituent is present in said composition in an amount of at least 10 weight percent. 
     
     
       33. A composition, comprising: a plasticized sulfur product obtained by forming a mixture by mixing liquid sulfur and an amount of carbon, wherein said amount of carbon is in the range of from about 0.25% to about 1.0% of said mixture and allowing plasticization of at least a portion of said liquid sulfur; a hydrocarbon-based material; and a fine mineral constituent, wherein said plasticized sulfur product is present in said composition in an amount of at least 60 weight percent of said composition, wherein said hydrocarbon-based material is present in said composition in an amount of at least 10 weight percent of said composition, and wherein said fine mineral constituent is present in said composition in an amount of at least 10 weight percent. 
     
     
       34. A composition as recited in claim 33, wherein said forming of said mixture further includes mixing an amount of amyl acetate with liquid sulfur and said amount of carbon, wherein said amount of amyl acetate is in the range of at least about 0.08% of said mixture. 
     
     
       35. A composition as recited in claim 34, wherein said amount of amyl acetate is in the range of from about 0.1% to about 1.5% of said mixture. 
     
     
       36. A composition as recited in claim 35, wherein said amount of amyl acetate is in the range of from about 0.2% to about 0.4% of said mixture. 
     
     
       37. A composition as recited in claim 36, wherein said liquid sulfur of said forming step is at a temperature in the range of from about 120° C. to about 150° C. 
     
     
       38. A composition as recited in claim 37, wherein said forming step further includes cooling said mixture having at least a portion of said liquid sulfur that is plasticized to thereby form solid particles of said plasticized sulfur product. 
     
     
       39. A composition as recited in claim 38, wherein said solid particles have characteristics such as to exhibit no agglomeration at temperatures under 79° C. (175° F.). 
     
     
       40. A composition, comprising: a plasticized sulfur product obtained by forming a mixture by mixing liquid sulfur and an amount of carbon, wherein said amount of carbon is in the range of from about 0.25% to about 1.0% of said mixture and allowing plasticization of at least a portion of said liquid sulfur; a hydrocarbon-based material; and a fine mineral constituent selected from the group of aggregates consisting of fly ash and silica material, and wherein said plasticized sulfur product is present in said composition in an amount of at least 60 weight percent of said composition, wherein said hydrocarbon-based material is present in said composition in an amount of at least 10 weight percent of said composition, and wherein said fine mineral constituent is present in said composition in an amount of at least 10 weight percent. 
     
     
       41. A composition as recited in claim 40, wherein said forming of said mixture further includes mixing an amount of amyl acetate with liquid sulfur and said amount of carbon, wherein said amount of amyl acetate is in the range of at least about 0.08% of said mixture. 
     
     
       42. A composition as recited in claim 41, wherein said amount of amyl acetate is in the range of from about 0.1% to about 1.5% of said mixture. 
     
     
       43. A composition as recited in claim 42, wherein said amount of amyl acetate is in the range of from about 0.2% to about 0.4% of said mixture. 
     
     
       44. A composition as recited in claim 43, wherein said liquid sulfur of said forming step is at a temperature in the range of from about 120° C. to about 150° C. 
     
     
       45. A composition as recited in claim 44, wherein said forming step further includes cooling said mixture having at least a portion of said liquid sulfur that is plasticized to thereby form solid particles of said plasticized sulfur product. 
     
     
       46. A composition as recited in claim 45, wherein said solid particles have characteristics such as to exhibit no agglomeration at temperatures under 79° C. (175° F.). 
     
     
       47. A composition as recited in claim 46, wherein said concentration of carbon is 0.4 weight % to about 0.8 weight %. 
     
     
       48. A composition as recited in claim 47, wherein said composition mixture further comprises a hydrocarbon-based material. 
     
     
       49. A composition as recited in claim 48, wherein said composition further comprises an aggregate having been mixed with said composition mixture in liquefied form. 
     
     
       50. A composition as recited in claim 49, wherein said hydrocarbon-based material is selected from the group consisting of asphalt, heavy crude oil, and fuel oil. 
     
     
       51. A composition as recited in claim 46, wherein said solid particles are of the type that includes pastilles, slates, pellets, chips, and briquettes. 
     
     
       52. A composition as recited in claim 51, wherein said composition mixture further comprises a hydrocarbon-based material. 
     
     
       53. A composition as recited in claim 52, wherein said composition further comprises an aggregate having been mixed with said composition mixture in liquefied form. 
     
     
       54. A composition as recited in claim 53, wherein said composition has a concentration of carbon of at least 0.25 weight %, with the weight % being based on the weight of said plasticized sulfur composition. 
     
     
       55. A composition as recited in claim 54, further comprising aggregate. 
     
     
       56. A composition as recited in claim 53, wherein said composition has a concentration of carbon of from about 0.25 weight % to about 1.0 weight %, with the weight % being based on the weight of said plasticized sulfur composition. 
     
     
       57. A composition as recited in claim 56, further comprising aggregate. 
     
     
       58. A composition as recited in claim 53, wherein said composition has a concentration of carbon of from about 0.4 weight % to about 0.8 weight %, with the weight % being based on the weight of said plasticized sulfur composition. 
     
     
       59. A composition as recited in claim 58, further comprising aggregate. 
     
     
       60. A composition as recited in claim 53, wherein said composition contains between about 20 weight % and 60 weight % of said plasticized sulfur composition based on the weight of said plasticized sulfur composition and said hydrocarbon-based material. 
     
     
       61. A composition as recited in claim 53, further comprising aggregate. 
     
     
       62. A composition as recited in claim 46, wherein said solid particles are of the size that units thereof expose a surface area within the range of from about 0.25 in 2  to about 4 in 2 . 
     
     
       63. A composition as recited in claim 46, wherein said composition mixture includes between about 20% and 60% said plasticized sulfur composition. 
     
     
       64. A composition as recited in claim 63, wherein said hydrocarbon-based material is selected from the group consisting of asphalt, heavy crude oil, and fuel oil. 
     
     
       65. A composition as recited in claim 46, wherein said composition mixture further comprises a hydrocarbon-based material. 
     
     
       66. A composition as recited in claim 65, wherein said composition further comprises an aggregate having been mixed with said composition mixture in liquefied form. 
     
     
       67. A composition as recited in claim 66, wherein said hydrocarbon-based material is selected from the group consisting of asphalt, heavy crude oil, and fuel oil. 
     
     
       68. A composition, comprising: a plasticized sulfur composition obtained by forming a mixture comprising liquid sulfur and a concentration of carbon, under conditions wherein at least a portion of said liquid sulfur is plasticized, to thereby provide said plasticized sulfur composition; and a hydrocarbon-based material selected from the group consisting of asphalt, heavy crude oil, and fuel oil. 
     
     
       69. A composition as recited in claim 68, further comprising aggregate. 
     
     
       70. A composition, comprising:
 a composition mixture comprising solid particles of a plasticized sulfur composition obtained by forming a sulfur mixture consisting essentially of liquid sulfur and a concentration of carbon of from about 0.25 weight % to about 1.0 weight %, with the weight % being based on the weight of said plasticized sulfur composition, under conditions wherein at least a portion of said liquid sulfur is plasticized to thereby provide said plasticized sulfur composition, and wherein said solid particles are formed from said plasticized sulfur composition.   
     
     
       71. A composition as recited in claim 70, wherein said composition mixture further comprises a hydrocarbon-based material. 
     
     
       72. A composition as recited in claim 71, wherein said composition further comprises an aggregate having been mixed with said composition mixture in liquefied form. 
     
     
       73. A composition as recited in claim 72, wherein said hydrocarbon-based material is selected from the group consisting of asphalt, heavy crude oil, and fuel oil.