Methods and systems for producing ethanol based warm foam mix asphalt

1. A method of producing a warm foam mix asphalt, comprising:

injecting a substantially ethanol additive into a stream of asphalt binder having a temperature below the auto ignition point of ethanol to form a foamed asphalt stream including both ethanol and asphalt binder;

adding said foamed asphalt stream including both ethanol and asphalt binder to a mixing zone;

adding at least one of aggregate and reclaimed asphalt pavement to said mixing zone;

heating at least one of said mixing zone and said at least one of aggregate and reclaimed asphalt pavement; and

mixing said foamed asphalt stream and said at least one of aggregate and reclaimed asphalt pavement to form a warm foam mix asphalt.

2. The method according to claim 1 , further comprising:

mixing a predetermined amount of said ethanol additive with said binder until said foamed asphalt stream has a predetermined viscosity and a predetermined volume.

3. The method according to claim 2 , wherein said foamed asphalt stream includes about one to two percent ethanol by mass.

4. The method according to claim 2 , wherein said foamed asphalt stream includes an amount of said ethanol additive that causes it to have a second viscosity that is about 85 to 100 percent less than a first viscosity of said asphalt binder prior to mixing with said ethanol additive.

5. The method according to claim 1 , wherein said asphalt binder has a temperature of about 300 to about 355 degrees Fahrenheit.

6. The method according to claim 1 , wherein said at least one of aggregate and reclaimed asphalt pavement is heated to a temperature of about 190 to about 260 degrees Fahrenheit.

7. The method according to claim 1 , further comprising:

collecting emissions from said mixing zone, said emissions including ethanol vapors; and

recycling said emissions to said mixing zone.

8. The method according to claim 1 , further comprising:

adding sodium bicarbonate to said mixing chamber; and

adding at least one of carbon dioxide and sodium blowing gases to said mixing chamber.

9. A system for producing warm foam mix asphalt, said system comprising:

a mixing chamber including a mixing zone, an outlet for dispensing warm foam mix asphalt and an outlet for releasing emissions;

a supply of asphalt binder in fluid communication with said mixing chamber;

a supply of ethanol additive in fluid communication with said supply of asphalt binder;

a supply of aggregate in fluid communication with said mixing chamber;

a source of heat for heating at least one of said mixing chamber, said supply of aggregate, and said supply of asphalt binder; and

an emission collection and treatment module for collecting, treating, and recycling emissions generated in said mixing chamber via said outlet and back to said mixing chamber.

10. The system according to claim 9 , further comprising:

a supply of reclaimed asphalt pavement in fluid communication with said mixing chamber.

11. The system according to claim 9 , further comprising:

a temperature control module for monitoring temperatures of said mixing chamber, said supply of aggregate, and said supply of asphalt binder; and

an automatic control mechanism for automatically adjusting said source of heat so that said asphalt binder and said supply of aggregate are heated to predetermined temperatures.

12. The system according to claim 11 , wherein said predetermined temperature of said supply of asphalt binder is about 300 to about 355 degrees Fahrenheit.

13. The system according to claim 11 , wherein said predetermined temperature of said supply of aggregate is about 190 to about 260 degrees Fahrenheit.

14. The system according to claim 9 , further comprising:

a viscosity control module for monitoring a viscosity of a stream including said supply of asphalt binder and said supply of ethanol additive; and

an automatic control mechanism for automatically adjusting an amount of said ethanol additive added to said stream so that said stream has a viscosity substantially equal to a predetermined viscosity.

15. The system according to claim 14 , wherein said predetermined viscosity is about 85 to 100 percent lower than a viscosity of said supply of asphalt binder before adding said supply of ethanol additive.

16. A method of producing a warm foam mix asphalt, comprising:

injecting a substantially ethanol additive into a stream of asphalt binder having a temperature below the auto ignition point of ethanol to form a foamed asphalt stream including both ethanol and asphalt binder;

adding said foamed asphalt stream including both ethanol and asphalt binder to a mixing zone;

adding at least one of aggregate and reclaimed asphalt pavement to said mixing zone;

adding a foaming agent to said mixing chamber;

heating at least one of said mixing zone and said at least one of aggregate and reclaimed asphalt pavement;

mixing said foamed asphalt stream and said at least one of aggregate and reclaimed asphalt pavement to form a warm foam mix asphalt;

collecting emissions from said mixing zone, said emissions including ethanol vapors; and

recycling said emissions to said mixing zone.

17. The method according to claim 16 , wherein said foamed asphalt stream includes about one to two percent ethanol by mass.

18. The method according to claim 16 , wherein said foamed asphalt stream includes an amount of said ethanol additive that causes it to have a second viscosity that is about 85 to 100 percent less than a first viscosity of said asphalt binder prior to mixing with said ethanol additive.

19. The method according to claim 16 , wherein said asphalt binder has a temperature of about 300 to about 355 degrees Fahrenheit.

20. The method according to claim 16 , wherein said at least one of aggregate and reclaimed asphalt pavement is heated to a temperature of about 190 to about 260 degrees Fahrenheit.