U.S. patent application number 12/404748 was filed with the patent office on 2010-03-18 for asphalt shingle recycling system and method.
Invention is credited to Kirk J. Frey, Thomas B. Harmon.
Application Number | 20100064937 12/404748 |
Document ID | / |
Family ID | 41061569 |
Filed Date | 2010-03-18 |
United States Patent
Application |
20100064937 |
Kind Code |
A1 |
Harmon; Thomas B. ; et
al. |
March 18, 2010 |
ASPHALT SHINGLE RECYCLING SYSTEM AND METHOD
Abstract
A method of recycling asphalt roofing material is provided. The
asphalt roofing material is delivered into a treatment chamber of a
processor. A heat source is provided to the treatment chamber. Heat
energy is transferred from the heat source to the asphalt roofing
material to produce a heated product, and the heated product is
removed from the treatment chamber.
Inventors: |
Harmon; Thomas B.; (Odessa,
FL) ; Frey; Kirk J.; (Sulphur, LA) |
Correspondence
Address: |
GREENBERG TRAURIG (HOU);INTELLECTUAL PROPERTY DEPARTMENT
1000 Louisiana Street, Suite 1800
Houston
TX
77002
US
|
Family ID: |
41061569 |
Appl. No.: |
12/404748 |
Filed: |
March 16, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61069435 |
Mar 14, 2008 |
|
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|
Current U.S.
Class: |
106/273.1 ;
241/107; 241/23; 241/29; 241/65 |
Current CPC
Class: |
Y02W 30/625 20150501;
C08L 95/00 20130101; B29C 48/03 20190201; E01C 19/104 20130101;
Y02W 30/62 20150501; B29B 17/04 20130101; C10C 3/007 20130101; C10C
3/12 20130101; B29C 48/00 20190201; E01C 19/1004 20130101; B09B
3/00 20130101; B29K 2095/00 20130101; B29L 2031/108 20130101; B29K
2105/251 20130101 |
Class at
Publication: |
106/273.1 ;
241/23; 241/29; 241/65; 241/107 |
International
Class: |
C09D 195/00 20060101
C09D195/00; C08J 11/06 20060101 C08J011/06; B02C 25/00 20060101
B02C025/00 |
Claims
1. A method of recycling asphalt roofing material, the method
comprising the steps of: delivering the asphalt roofing material
into a treatment chamber of a processor; passing a heat source
through a jacket at least partially surrounding the treatment
chamber; transferring heat energy from the heat source to the
asphalt roofing material until the asphalt roofing material forms a
liquefied slurry; and removing the liquefied slurry from the
treatment chamber.
2. The method of claim 1, further comprising the step of utilizing
heated oil as the heat source.
3. The method of claim 1, further comprising the step of adding
liquid asphalt to the asphalt roofing material in the treatment
chamber.
4. The method of claim 1, further comprising the step of agitating
the asphalt roofing material in the treatment chamber.
5. The method of claim 1, further comprising the step of heating
the asphalt roofing material to a temperature in the range from 200
degrees Fahrenheit to 650 degrees Fahrenheit within the treatment
chamber.
6. The method of claim 1, further comprising the step of milling
the liquefied slurry after it has been removed from the treatment
chamber to form a final recycled product.
7. The method of claim 1, further comprising the step of cooling
the liquefied slurry after it exits the treatment chamber.
8. The method of claim 7, further comprising the step of cooling
the liquefied slurry to the range of approximately 90 degrees
Fahrenheit to 110 degrees Fahrenheit.
9. The method of claim 1, further comprising the step of passing
the liquefied slurry through a hammer mill after the liquefied
slurry exits the treatment chamber.
10. A processor for recycling asphalt roofing material, the
processor comprising: a treatment chamber; an inlet disposed on the
treatment chamber for allowing untreated asphalt roofing material
to enter the treatment chamber; an outlet disposed on the treatment
chamber for allowing treated asphalt roofing material to exit the
treatment chamber; and a jacket at least partially surrounding the
treatment chamber, the jacket having a outer wall, an inner wall,
and a passageway therebetween for allowing a heat source to pass
therethrough.
11. The processor of claim 10, further comprising an agitator arm
disposed within the treatment chamber, the agitator arm having a
shaft and one or more paddles positioned thereon that contact the
contents of the treatment chamber.
12. The processor of claim 10, further comprising a screw conveyer
disposed adjacent to the inlet for delivering untreated asphalt
roofing material to the treatment chamber.
13. The processor of claim 12, wherein the screw conveyer comprises
a plurality of variable speed conveyors for regulating the flow of
untreated asphalt roofing material to the treatment chamber.
14. The processor of claim 10, wherein the heat source is heated
oil, and the heated oil circulates through the jacket.
15. An apparatus for recycling asphalt roofing material, the
apparatus comprising: a jacketed agitated processor for heating the
asphalt roofing material to produce a partially liquefied product;
a heating skid for supplying a heat source to the jacket of the
agitated processor; and a hammer mill for reducing the particle
size of solid particles present in the partially liquefied
product.
16. The apparatus of claim 15, further comprising a sizing unit for
reducing the particle size of solid particles present in the
partially liquefied product before the partially liquefied product
is delivered to the hammer mill.
17. The apparatus of claim 15, further comprising a screw conveyer
for delivering asphalt roofing material to the processor.
18. The apparatus of claim 17, wherein the screw conveyer comprises
a plurality of variable speed conveyors for regulating the flow of
untreated asphalt roofing material to the treatment chamber.
19. The apparatus of claim 15, further comprising one or more
temperature measuring devices disposed at the outlet of the
jacketed agitated processor.
20. The apparatus of claim 15, further comprising one or more
cooling devices between the outlet of the jacketed agitated
processor and the inlet of the hammer mill.
21. A method of recycling asphalt roofing material, the method
comprising the steps of: delivering the asphalt roofing material
into a treatment chamber of a processor; supplying a heat source to
the treatment chamber; transferring heat energy from the heat
source to the asphalt roofing material to produce a heated solid
product; and removing the heated solid product from the treatment
chamber.
22. The method of claim 21, further comprising the step of
utilizing heated oil as the heat source.
23. The method of claim 21, further comprising the step of adding
liquid asphalt to the asphalt roofing material in the treatment
chamber.
24. The method of claim 21, further comprising the step of
agitating the asphalt roofing material in the treatment
chamber.
25. The method of claim 21, further comprising the step of heating
the asphalt roofing material to a temperature in the range from 150
degrees Fahrenheit to 650 degrees Fahrenheit within the treatment
chamber.
26. The method of claim 21, further comprising the step of grinding
the heated solid product after it has been removed from the
treatment chamber to form a recycled product.
27. The method of claim 21, further comprising the step of cooling
the heated solid product after it exits the treatment chamber.
28. The method of claim 27, further comprising the step of cooling
the heated solid product to the range of approximately 90 degrees
Fahrenheit to 140 degrees Fahrenheit.
29. The method of claim 21, further comprising the step of passing
the heated solid product through a hammer mill after the heated
solid product exits the treatment chamber.
30. The method of claim 21, further comprising the step of passing
the heat source through a jacket that at least partially surrounds
the treatment chamber.
31. A method of recycling asphalt roofing material, the method
comprising: delivering the asphalt roofing material into a
treatment chamber of a processor; supplying a heat source to the
treatment chamber; transferring heat energy from the heat source to
the asphalt roofing material to produce a heated product; removing
the heated product from the treatment chamber; determining a
desired temperature for the heated product exiting the treatment
chamber; measuring the actual temperature of the heated product
exiting the treatment chamber; and automatically adjusting at least
one operational parameter for the processor until the desired
temperature and the actual temperature of the heated product
exiting the treatment chamber are substantially the same.
32. The method of claim 31, further comprising the step of
utilizing heated oil as the heat source.
33. The method of claim 31, further comprising the step of adding
liquid asphalt to the asphalt roofing material in the treatment
chamber.
34. The method of claim 31, further comprising the step of
agitating the asphalt roofing material in the treatment
chamber.
35. The method of claim 31, further comprising the step of heating
the asphalt roofing material to a temperature in the range from 150
degrees Fahrenheit to 650 degrees Fahrenheit within the treatment
chamber.
36. The method of claim 31, further comprising, the step of
grinding the heated product after it has been removed from the
treatment chamber to form a recycled product.
37. The method of claim 31, further comprising the step of cooling
the heated product after it exits the treatment chamber.
38. The method of claim 37, further comprising the step of cooling
the heated product to the range of approximately 90 degrees
Fahrenheit to 140 degrees Fahrenheit.
39. The method of claim 31, further comprising the step of passing
the heated product through a hammer mill after the heated product
exits the treatment chamber.
40. The method of claim 31, further comprising: measuring the
actual temperature of the heated product exiting the treatment
chamber a plurality of times over a defined time period;
calculating an average temperature for the heated product exiting
the treatment chamber over the defined time period; and adjusting
at least one operational parameter for the processor until the
desired temperature and the average temperature of the heated
product exiting the treatment chamber are substantially the
same.
41. The method of claim 31, wherein the treatment chamber contains
one or more paddles for mixing the asphalt roofing material, and
the operational parameter is the rotational speed of the one or
more paddles.
42. The method of claim 31, wherein the operational parameter is
the rate at which the asphalt roofing material is delivered to the
treatment chamber.
43. The method of claim 31, wherein the operational parameter is
the amount of time that the asphalt roofing material is retained in
the treatment chamber.
44. The method of claim 31, wherein the heated product is a heated
solid product.
45. The method of claim 31, further comprising passing the heat
source through a jacket that at least partially surrounds the
treatment chamber.
46. An apparatus for recycling asphalt roofing material, the
apparatus comprising: a processor for heating the asphalt roofing
material to produce a heated solid product, the processor having an
inlet and an outlet; a heating skid for supplying a heat source to
the processor; at least one hammer mill for reducing the particle
size of solid particles present in the heated product, the hammer
mill having an inlet and an outlet; a measurement device for
measuring the temperature of the heated product; an operational
control device for controlling one or more operational parameters
of the processor based upon the temperature indicated by the
measurement device; one or more cooling devices disposed between
the outlet of the processor and the inlet of the hammer mill for
cooling the heated product; and a screw conveyer for delivering
asphalt roofing material to the processor, the screw conveyer
comprising a plurality of variable speed conveyors for regulating
the flow of asphalt roofing material to the processor.
47. The apparatus of claim 46, further comprising an agitator arm
disposed within the processor, the agitator arm having a shaft and
one or more paddles positioned thereon that contact the contents of
the processor.
48. The apparatus of claim 46, wherein the heat source is heated
oil, and the heated oil transfers heat energy to the asphalt
roofing material.
49. The apparatus of claim 46, wherein the asphalt roofing material
is heated to a temperature in the range from 150 degrees Fahrenheit
to 650 degrees Fahrenheit within the processor.
50. The apparatus of claim 46, wherein the heated product is cooled
to a temperature in the range of approximately 90 degrees
Fahrenheit to 140 degrees Fahrenheit in the cooling device.
51. The apparatus of claim 46, further comprising a jacket disposed
around the processor for receiving the heat source.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit, and priority benefit,
of U.S. Patent Application Ser. No. 61/069,435, filed Mar. 14,
2008, titled "Asphalt Shingle Recycling System and Method."
BACKGROUND
[0002] 1. Field of Invention
[0003] The invention relates generally to recycling of asphalt
shingles, and in particular, to a system and method for recycling
of asphalt shingles utilizing heat treatment.
[0004] 2. Description of the Related Art
[0005] Asphalt concrete pavement is commonly used in roadway
construction. The asphalt concrete pavement typically comprises
liquid asphalt cement combined with aggregate. The aggregate is
usually a mixture of sand, gravel, and stone. The aggregate and
liquid asphalt cement are mixed and heated to form an asphalt
paving composition. The crushed gravel and stone particles of the
aggregate provide sharp edges which, when combined with the liquid
asphalt cement, create an aggregate interlock which improves the
strength of the composition.
[0006] Liquid asphalt cement can be expensive. Shredded asphalt
roofing shingles are often used as a substitute for liquid asphalt
cement. The asphalt roofing shingles are "recycled" and
incorporated into the asphalt pavement composition.
[0007] It is difficult to regulate the consistency of the asphalt
pavement composition using shredded asphalt roofing shingles
produced by existing recycling processes. Also, air emissions from
existing recycling processes can be detrimental to the
atmosphere.
SUMMARY OF THE INVENTION
[0008] In accordance with the illustrative embodiments hereinafter
described, a system and method for recycling asphalt roofing
shingles is described. In an embodiment, scrap and tear-off
shingles from roofing materials are heat treated and liquefied to
produce a slurry that can be formed into a finished product. The
composition of the slurry can be regulated with a relatively high
degree of consistency. Further, many of the air emissions concerns
that existed in previous asphalt shingle recycling processes are
eliminated.
[0009] In one illustrative embodiment, a method of recycling
asphalt roofing material is provided. The asphalt roofing material
may be delivered into a treatment chamber of a processor. A heat
source may be passed through a jacket that at least partially
surrounds the treatment chamber. Heat energy is transferred from
the heat source to the asphalt roofing material until the asphalt
roofing material forms a liquefied slurry. The liquefied slurry may
be then removed from the treatment chamber. Heated oil can be used
as the heat source. Liquid asphalt can be added to the asphalt
roofing material in the treatment chamber in a specific embodiment,
although this step is not required. The asphalt roofing material in
the treatment chamber can be agitated to promote mixing. The
asphalt roofing material can be heated to a temperature in the
range from approximately 200 degrees Fahrenheit to 650 degrees
Fahrenheit within the treatment chamber. The liquefied slurry can
be cooled after it exits the treatment chamber, preferably to a
temperature in the range of approximately 90 degrees Fahrenheit to
110 degrees Fahrenheit. The liquefied slurry can be passed through
a hammer mill after some point after exiting the treatment chamber.
Preferably, the liquefied slurry passes through the hammer mill
after cooling has occurred.
[0010] In another illustrative embodiment, a processor for
recycling asphalt roofing material is provided. The processor can
include a treatment chamber, an inlet disposed on the treatment
chamber for allowing untreated asphalt roofing material to enter
the treatment chamber, an outlet disposed on the treatment chamber
for allowing treated asphalt roofing material to exit the treatment
chamber, and a jacket at least partially surrounding the treatment
chamber, the jacket having a outer wall, an inner wall, and a
passageway therebetween for allowing a heat source to pass
therethrough. A feature of the processor is that an agitator arm
can be disposed within the treatment chamber. The agitator arm can
have a shaft and one or more paddles positioned thereon that
contact the contents of the treatment chamber. A screw conveyer can
be disposed adjacent to the inlet for delivering untreated asphalt
roofing material to the treatment chamber. The screw conveyer can
include a plurality of variable speed conveyors for regulating the
flow of untreated asphalt roofing material to the treatment
chamber. The heat source can be heated oil, and the heated oil can
circulate through the jacket.
[0011] In another illustrative embodiment, an apparatus for
recycling asphalt roofing material is provided. The apparatus can
include a jacketed agitated processor for heating the asphalt
roofing material to produce a partially liquefied product, a
heating skid for supplying a heat source to the jacket of the
agitated processor, and a hammer mill for reducing the particle
size of solid particles present in the partially liquefied product.
The apparatus can also include a sizing unit for reducing the
particle size of solid particles present in the partially liquefied
product before the partially liquefied product is delivered to the
hammer mill. A screw conveyer can be utilized for delivering
asphalt roofing material to the processor. The screw conveyer can
include a plurality of variable speed conveyors for regulating the
flow of untreated asphalt roofing material to the treatment
chamber. One or more temperature measuring devices can be disposed
at the outlet of the jacketed agitated processor. Further, one or
more cooling devices can be positioned between the outlet of the
jacketed agitated processor and the inlet of the hammer mill for
measuring and regulating temperature at the processor outlet.
[0012] In another illustrative embodiment, a method of recycling
asphalt roofing material is provided whereby the asphalt roofing
material may be delivered into a treatment chamber of a processor.
A heat source may be supplied to the treatment chamber. Heat energy
can be transferred from the heat source to the asphalt roofing
material to produce a heated solid product. The heated solid
product may then be removed from the treatment chamber.
[0013] The heat source may be passed through a jacket at least
partially surrounding the treatment chamber. Heated oil may be used
as the heat source. Liquid asphalt can be added to the asphalt
roofing material in the treatment chamber. The processor can be
agitated to mix the asphalt roofing material in the treatment
chamber. The asphalt roofing material may be heated to a
temperature in the range from 150 degrees Fahrenheit to 650 degrees
Fahrenheit within the treatment chamber. The heated product may be
ground, milled and/or passed through a hammer mill after it exits
the treatment chamber. The heated product can be cooled to a
temperature in the range from 90 degrees Fahrenheit to 140 degrees
Fahrenheit after it exits the treatment chamber.
[0014] In another illustrative embodiment, a method of recycling
asphalt roofing material is provided whereby the asphalt roofing
material may be delivered into a treatment chamber of a processor.
A heat source can be supplied to the processor. Heat energy may be
transferred from the heat source to the asphalt roofing material to
produce a heated product, and the heated product can be removed
from the treatment chamber. The heated product may be a heated
solid product.
[0015] A desired temperature may be determined for the heated
product exiting the treatment chamber. The actual temperature of
the heated product exiting the treatment chamber may be measured,
and at least one operational parameter for the processor may be
automatically adjusted until the desired temperature and the actual
temperature of the heated product exiting the treatment chamber are
substantially the same.
[0016] Further, the actual temperature of the heated product
exiting the treatment chamber can be measured a plurality of times
over a defined time period, and an average temperature for the
heated product exiting the treatment chamber can be calculated over
the defined time period. Then, at least one operational parameter
for the processor can be adjusted until the desired temperature and
the average temperature of the heated product exiting the treatment
chamber are substantially the same.
[0017] The operational parameter for the processor can be, for
example, the amount of time that the asphalt roofing material is
retained in the treatment chamber, the rate at which the asphalt
roofing material is delivered to the treatment chamber, or the
rotational speed of the one or more paddles in the processor.
[0018] A heat source may be passed through a jacket at least
partially surrounding the treatment chamber. Heated oil may be used
as the heat source. Liquid asphalt can be added to the asphalt
roofing material in the treatment chamber. The processor can be
agitated to mix the asphalt roofing material in the treatment
chamber. The asphalt roofing material may be heated to a
temperature in the range from 150 degrees Fahrenheit to 650 degrees
Fahrenheit within the treatment chamber. The heated product may be
ground, milled and for passed through a hammer mill after it exits
the treatment chamber. The heated product can also be cooled to a
temperature in the range from 90 degrees Fahrenheit to 140 degrees
Fahrenheit after it exits the treatment chamber.
[0019] In another illustrative embodiment, an apparatus for
recycling asphalt roofing material is provided. The apparatus can
include an processor for heating the asphalt roofing material to
produce a heated product. A jacket may be disposed around the
processor. A heating skid can be used to supply a heat source to
the jacket. At least one hammer mill can be used to reduce the
particle size of solid particles present in the heated product. A
measurement device can be utilized to measure the temperature of
the heated product.
[0020] The apparatus can also include an operational control device
for controlling one or more operational parameters of the processor
based upon the temperature indicated by the measurement device, as
well as one or more cooling devices disposed between the outlet of
the processor and the inlet of the hammer mill for cooling the
heated product. A screw conveyer can be utilized for delivering
asphalt roofing material to the processor. The screw conveyer can
include a plurality of variable speed conveyors for regulating the
flow of asphalt roofing material to the processor.
[0021] An agitator arm can be disposed within the processor. The
agitator arm can have a shaft and one or more paddles positioned
thereon that contact the contents of the processor. A jacket may be
disposed around the processor for receiving the heat source. The
heat source for the processor may be heated oil, and the heated oil
can transfer heat energy to the asphalt roofing material. The
asphalt roofing material may be heated to a temperature in the
range from 150 degrees Fahrenheit to 650 degrees Fahrenheit within
the processor. The heated product may be cooled to a temperature in
the range of approximately 90 degrees Fahrenheit to 140 degrees
Fahrenheit in the cooling device.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a schematic side view of equipment utilized in a
specific embodiment of an asphalt shingle recycling system and
method.
[0023] FIG. 2 is a schematic side view of a processor utilized in a
specific embodiment of an asphalt shingle recycling system and
method.
[0024] FIG. 3 is a schematic top view of an agitator arm and a
plurality of paddles utilized in a specific embodiment of an
asphalt shingle recycling system and method.
[0025] FIG. 4 is a schematic side view of additional equipment
utilized in a specific embodiment of an asphalt shingle recycling
system and method.
[0026] FIG. 5 is a schematic top view of additional equipment
utilized in a specific embodiment of an asphalt shingle recycling
system and method.
[0027] FIG. 6 is a schematic side view of equipment utilized in
another specific embodiment of an asphalt shingle recycling system
and method.
[0028] While certain embodiments will be described in connection
with the preferred illustrative embodiments, it will be understood
that it is not intended to limit the invention to those
embodiments. On the contrary, it is intended to cover all
alternatives, modifications, and equivalents, as may be included
within the spirit and scope of the invention as defined by the
appended claims.
DETAILED DESCRIPTION
[0029] Referring now to FIGS. 1-5, an illustrative embodiment of an
asphalt roofing shingle recycling system and method is provided.
Scrap asphalt shingles (not shown) are collected and deposited in
hopper 10. Hopper 10 is preferably of carbon steel construction and
may have at least a three cubic yard storage capacity. In a
specific embodiment, hopper 10 can have hinged doors 11 at or near
its top end 12 through which scrap asphalt shingles may be loaded.
Alternatively, scrap asphalt shingles may be loaded into hopper 10
by other means not requiring the use of hinged doors 11 as shown in
the embodiment of FIG. 6, or by any feed, loader, or supply device
capable of supplying scrap asphalt shingles into the shingle
recycling system.
[0030] The contents of hopper 10 can empty onto a screw conveyer 20
by opening bottom doors 13. Screw conveyer 20 preferably has at
least a ten ton-per-hour capacity and may be driven by any suitable
motor, such as a variable frequency drive ("VFD") motor, which may
be a VFD motor of at least 60 horsepower.
[0031] Screw conveyer 20 delivers the scrap asphalt shingles from
hopper 10 to processor 40. In an illustrative embodiment, processor
40 is formed of carbon steel, and includes an inlet 42 on its top
43 for receiving the scrap asphalt shingles from screw conveyer 20.
If desired, temperature reading and moisture reading devices can be
installed at or near inlet 42 to allow for monitoring by a process
operator. Further, screw conveyer 20 can have a dual delivery
system, if desired, to prevent clogging and to feed the asphalt
shingles into processor 40 in an even and consistent manner.
Shingles can be loaded into hopper 10 and then pulled from hopper
10 by a short variable speed conveyor 20a that feeds onto an longer
variable speed conveyor 20b. By adjusting the speeds of the two
conveyors 20a and 20b, the flow of shingles into processor 40 can
be regulated which will reduce or eliminate clogging of conveyer 20
or hopper 10. Alternatively, one or more augers may be utilized to
load the asphalt shingles into hopper 10.
[0032] The scrap asphalt shingles are heated in a treatment chamber
55 disposed within processor 40 until the shingles reach the
desired composition or consistency. In an illustrative embodiment,
the shingles are at least partially liquefied. For example, a
substantial portion of the scrap asphalt can take the form of a
slurry after being heated in treatment chamber 55 of processor 40.
Alternatively, in another illustrative embodiment, the heated
shingles can remain in solid form and not take the form of a slurry
in treatment chamber 55. The heated shingles can take the form of
solid heated, or "toasted," shingles. Producing a heated solid
product, or heated shingles, in solid form reduces the heating
requirements for the system.
[0033] In an illustrative embodiment, processor 40 can be similar
in construction to those processors originally designed by the
Dupps Company of Germantown, Ohio for rendering animal protein
products. Processor 40 has been adapted according to embodiments of
the present system and method to recycle asphalt shingles. For
example, processor 40 can utilize hot oil instead of steam (as
intended in animal protein rendering applications) as a heating
source. Hot oil is preferably utilized as the heat supplying stream
due to its capacity for reaching higher temperatures than steam,
although steam or other heat sources may also be utilized.
Alternatively, processor 40 can be constructed or obtained from
other sources while still falling within the scope of the
embodiments of the present invention. For example, other apparatus
that apply direct or indirect heat to the shingles that results in
the shingles being brought within the desired temperature range and
consistency, whether a heated product in solid form or liquefied
slurry form, would be in accordance with those of the present
illustrative embodiments.
[0034] A jacket 65 can at least partially surround processor 40 in
certain illustrative embodiments. Jacket 65 preferably comprises an
outer wall 50 and an inner wall 60 with a passageway formed
therebetween. The hot oil (not shown), or heat source, circulates
within the passageway of jacket 65 and flows around the exterior of
processor 40. The hot oil, or heat source, delivers heat energy to
the scrap asphalt shingles contained within treatment chamber 55 of
processor 40. Jacket 65 allows for transfer of heat over a large
surface area within processor 40. Alternatively, other heat sources
and apparatus for supplying heat to processor 40 may be utilized to
heat the shingles treated by processor 40.
[0035] In an illustrative embodiment, the scrap asphalt shingles
are heated to a temperature in the range from approximately 200
degrees Fahrenheit to 650 degrees Fahrenheit, more preferably about
350 degrees Fahrenheit, within treatment chamber 55 of processor 40
to form a heated product. In another illustrative embodiment, the
scrap asphalt shingles may be heated to a temperature in the range
from approximately 150 degrees Fahrenheit to 650 degrees
Fahrenheit. To the extent the scrap asphalt shingles heated within
these temperature ranges form a liquid slurry, the heated product
will flow relatively easily. To the extent the scrap asphalt
shingles heated within these temperature ranges form a solid
heated, or "toasted," shingle, the heated product is sufficiently
brittle to be easily ground in one or more hammer mills.
[0036] The hot oil is initially stored in a heating tank 120, as
illustrated in FIG. 4. Heating tank 120 is preferably associated
with a thermal fluid heater skid 90. Skid 90 also includes a supply
pump 130 and expansion tank 140 associated with heating tank 120.
The hot oil is delivered to processor 40 via heat inlet stream 70
and exits processor 40 via heat outlet stream 80, and is
recirculated through skid 90.
[0037] In a specific illustrative embodiment, liquid asphalt
additive can be added to the asphalt shingles in processor 40. The
liquid asphalt additive can be, for example, virgin non-oxidized
asphalt. The liquid asphalt additive further liquefies the asphalt
shingles in processor 40, and can affect other characteristics such
as melt point. The liquid asphalt additive can be delivered to
processor 40 via additive inlet stream 100 and pump 105, as
illustrated in FIG. 4. The liquid asphalt additive can be heated in
heater 310 prior to being introduced into processor 40. In
alternate illustrative embodiments in which a solid heated product
is desired, it is not necessary to introduce liquid asphalt
additive into processor 40.
[0038] In an illustrative embodiment as shown in FIGS. 2-3, the
contents of treatment chamber 55 of processor 40 can be agitated in
order to promote mixing. In an illustrative embodiment, processor
40 includes a motor 41 such as a 75 horsepower motor and an
agitator arm 111 that is operationally connected to motor 41 and
extends within processor 40. One or more paddles 110 are positioned
along the length of agitator arm 111. Paddles 110 turn and contact
the material within treatment chamber 55 of processor 40 as
agitator arm 111 rotates to stir and mix the treatment chamber's
contents until they are of the desired consistency. The shaft of
agitator arm 111 can turn clockwise or counterclockwise (as viewed
from the vantage point "a" on FIGS, 2-3) within processor 40.
Preferably, shaft of agitator arm 111 turns clockwise during mixing
and counterclockwise during discharge of the material from
processor 40.
[0039] In an illustrative embodiment, processor 40 does not include
any milling elements to grind, crush or abrade the scrap asphalt
shingles during treatment therein, as these shingles will be
adequately processed by heating and/or agitation alone. Further, it
is not necessary for the scrap asphalt shingles to be shredded,
milled or otherwise broken apart prior to treatment in processor
40, or for liquid asphalt additive to be added to the contents of
processor 40.
[0040] In general, the viscosity and consistency of the mixture in
processor 40 are controlled by monitoring a variety of parameters
such as the temperature of the heated product exiting processor 40
and the amount of time the mixture is treated in processor 40. In
certain illustrative embodiments, the amount of liquid asphalt
additive included in the mixture may also be a relevant factor.
[0041] Upon heating, a certain portion of the asphalt mixture
within processor 40 may take a gaseous/vapor form. This gas or
vapor may also include steam or water vapor within processor 40. A
gas/vapor buildup within processor 40 could increase the pressure
within processor 40 to undesirable levels. Vapor outlet stream 160
can be utilized to allow these gases/vapors to exit the top of
processor 40. Vapor outlet stream 160 is preferably directed to
condenser 220, which condenses the gas/vapor stream to liquid form.
A scrubber 221 may also be utilized to remove undesired pollutants
from vapor outlet stream 160 (See FIG. 6). Condenser 220 is cooled
by a recycled glycol stream 250 which is supplied by packaged
chiller 260. The glycol stream returns to packaged chiller via
return stream 270. The liquid from condenser 220 is collected in
receiver 230.
[0042] In an illustrative embodiment, processor 40 includes an
outlet 44 on its bottom 45 whereby the heated product can exit
processor 40 via processor outlet stream 46. If desired, one or
more temperature measurement devices 68 (FIG. 1) can be positioned
at or near outlet 44 of processor 40 to measure and/or monitor the
temperature of the exiting heated product. In an illustrative
embodiment, temperature measurement device can be an infrared
temperature reader 68' as shown in the embodiment of FIG. 6.
Temperature measurement device 68' can be linked to a operational
control device 49 for processor 40, as shown in FIG. 6. Operational
control device 49 can automatically adjust one or more parameters
relating to the operation of processor 40, based upon the
temperature reading obtained from device 68', as shown in FIG. 6.
Examples of the parameters that can be adjusted for processor 40 to
achieve a desired temperature reading at or near outlet 44 can
include, but are not limited to, the rate at which scrap asphalt
shingles are fed into inlet 42, the rate at which paddles 110
and/or agitator arm 111 rotate within processor 40 and the amount
of time that the shingles are retained in processor 40.
[0043] At times, the heated product in processor 40 may become
stuck or clumped together and form an aggregation. This aggregation
can cause a distinct variation in the temperature reading measured
by temperature measurement device 68. For example, an aggregation
passing through outlet 44 can cause the temperature reading on
device 68 to shift by fifty degrees Fahrenheit or more. In an
illustrative embodiment, temperature measurement device 68' is
capable of taking temperature readings at or near outlet 44 over a
defined period of time and then averaging the readings to determine
an average temperature for the heated product. The average
temperature is reported to variable control system 49 instead of
the actual temperature reading. This prevents any unnecessary
fluctuations to the operational parameters of processor 40 caused
by variable control system 49.
[0044] If desired, a cooling device 69 can be utilized so that the
temperature of the contents of processor 40 in outlet stream 46 can
be reduced such as, for example, in elevated summer temperatures.
In an illustrative embodiment, cooling device 69 can accept a
heated product and preferably cool it down to the range of
approximately 90 degrees Fahrenheit to 110 degrees Fahrenheit. In
another embodiment, cooling device 69 may cool heated shingles down
to the range of approximately 90 degrees Fahrenheit to 140 degrees
Fahrenheit. Cooling device 69 can utilize water mist, fans and/or
tumbling action to cool the liquefied slurry or heated shingles,
although other cooling means may also be utilized. Also, the
contents of outlet stream 46 can be cooled by ambient air, without
the need for cooling device 69.
[0045] Processor outlet stream 46 is ultimately directed from
processor 40 to sizing unit 150. Sizing unit 150 preferably
includes motor 151 such as a 75 horsepower VFD motor, and can
accommodate 10,000 pounds per hour of materials. In an illustrative
embodiment, sizing unit 150 is utilized to remove thick asphalt or
other undesired materials that may be present in processor outlet
stream 46. Sizing unit 150 is preferably able to grind or reduce a
solid heated product without clogging or other similar
disruption.
[0046] After treatment in sizing unit 150, the heated product can
be delivered to hammer mill 200 via a belt conveyer 210.
Alternately, an auger 400 may be used to deliver the heated product
to hammer mill 200, as shown in FIG. 6. Hammer mill 200 preferably
includes a totally enclosed fan cooled ("TEFC") motor (not shown)
and can accommodate at least 10,000 pounds per hour of materials.
The hammer mill 200 reduces the asphalt shingle material into even
smaller particles, preferably able to pass through a one inch
screen. If desired, temperature reading and moisture reading
devices can be installed at or near the inlet to hammer mill 200 to
allow for monitoring by a process operator. In an illustrative
embodiment, a finishing hammer mill 300 can be utilized to further
reduce the asphalt shingle material exiting hammer mill 200, as
shown in FIG. 6.
[0047] The particles in hammer mill 200 can be formed into a
desired final product. For example, the final product can be
extruded, formed into a pellet, or can have the consistency of
coffee grounds or even finer, such as a powder. Further, the
particles can be allowed to harden before entering hammer mill 200
and then crushed to size.
[0048] The final product can be utilized, for example, as an
additive for pavement or roofing materials or as a raw material for
shingle manufacturing. Further, grease zerts can be installed on
all bearings and other related items in the system to facilitate
prolonged periods of use. Additional screening, bagging and loading
systems (not shown) may be provided, depending upon the size of,
and intended use for, the final product, as would be well
understood by one of ordinary skill in the art.
[0049] In the drawings and specification, there has been disclosed
and described typical illustrative embodiments, and although
specific terms are employed, the terms are used in a descriptive
sense only and not for purposes of limitation. It will be apparent
that various modifications and changes can be made within the
spirit and scope of the invention as described in the foregoing
specification. Accordingly, the invention is therefore to be
limited only by the scope of the appended claims.
* * * * *