Polymer modified asphalt for industrial applications
View Patent ↗This invention provides for a method for producing polymer modified asphalt using base asphalt (bitumen) blended with partially air blown (“puffed”) asphalt which is further modified with polymers and additives to attain desired properties for industrial applications. The partially blown or blown asphalt is oxidized to a target softening point to suit the application. In another embodiment, the base asphalt is blended with hard PEN asphalt (“Zero PEN Asphalt”) which is further modified with polymers and additives to attain desired properties. By using the partially oxidized asphalt or blending the base asphalt with partially oxidized asphalt or hard PEN asphalt, the amount of polymers and additives needed to achieve desired properties and performance are significantly reduced. This technique can be used to attain polymer modified asphalt having a highly desirable combination of characteristics not otherwise attainable using the base asphalt.
1. An industrial asphalt composition consisting of:
a base asphalt, wherein the base asphalt is asphalt flux, and wherein the base asphalt is not air blown,
a partially blown asphalt, wherein the partially blown asphalt is asphalt flux,
a polymer modifier,
at least one wax,
optionally, one or more fillers,
optionally, one or more stabilizers,
optionally, one or more recycled tire rubber,
optionally, one or more recycled engine oil,
optionally, one or more recycled plastics,
optionally, one or more softeners,
optionally, one or more antifungal agents, and
optionally, one or more biocides,
and
wherein the industrial asphalt composition has softening point which is within the range of 130° F. to 260° F., a penetration at 77° F. which is within the range of 12 dmm to 40 dmm, and a rotational viscosity which is within the range of 90 cP to 700 cP at 400° F.
2. The industrial asphalt composition of claim 1 wherein the partially blown asphalt has a softening point which is within the range of 120° F. to 230° F., wherein the partially blown asphalt has a penetration value which is within the range of 5 dmm to 30 dmm at 77° F., wherein the partially blown asphalt has a rotational viscosity which is within the range of 120 cP to 450 cP at 400° F.
3. The industrial asphalt composition of claim 1 wherein the industrial asphalt composition includes 5 weight percent to 95 weight percent of the partially blown asphalt and from 5 weight percent to 95 weight percent of the base asphalt.
4. The industrial asphalt composition of claim 1 wherein the polymer modifier is present at a level which is within the range of 0.5 weight percent to 12 weight percent, and wherein the wax is present at a level which is within the range of 0.5 weight percent to 5 weight percent.
5. The industrial asphalt composition of claim 1 wherein the polymer modifier is selected from the group consisting of SBS, SEBS, copolymers of functionalized reactive elastomers (RET) or glycidyl acrylate copolymers of methyl, ethyl, butyl acrylates, and polyolefin homo-polymers and copolymers.
6. The industrial asphalt composition of claim 1 wherein the wax has a softening point which is within the range of 200° F. to 330° F., a penetration value at 77° F. which is within the range of 0.5 dmm to 15 dmm, and a rotational viscosity which is within the range of 2 cP to 100 cP at 400° F., and COC flash point of greater than 400° F.
7. An industrial asphalt composition consisting of:
a base asphalt, wherein the base asphalt is asphalt flux,
a hard PEN asphalt, wherein the hard PEN asphalt is asphalt flux,
a polymer modifier,
at least one wax,
optionally, one or more fillers,
optionally, one or more stabilizers,
optionally, one or more recycled tire rubber,
optionally, one or more recycled engine oil,
optionally, one or more recycled plastics,
optionally, one or more softeners,
optionally, one or more antifungal agents, and
optionally, one or more biocides,
wherein the hard PEN asphalt has a penetration value which is within the range of 0.2 dmm to 15 dmm at 77°, and
wherein the industrial asphalt composition has softening point which is within the range of 130° F. to 260° F., a penetration at 77° F. which is within the range of 12 dmm to 40 dmm, and a rotational viscosity which is within the range of 90 cP to 700 cP at 400° F.
8. The industrial asphalt composition of claim 7 wherein the hard PEN asphalt has a softening point which is within the range of 140° F. to 240° F., wherein the hard PEN asphalt has a penetration value which is within the range of 0.2 dmm to 10 dmm at 77° F., and wherein the hard PEN asphalt has a rotational viscosity which is within the range of 25 cP to 450 cP at 400° F.
9. The industrial asphalt composition of claim 7 wherein the industrial asphalt composition includes 5 weight percent to 95 weight percent of the hard PEN asphalt and from 5 weight percent to 95 weight percent of the base asphalt.
10. The industrial asphalt composition of claim 7 wherein the polymer modifier is present at a level which is within the range of 0.5 weight percent to 12 weight percent, and wherein the wax is present at a level which is within the range of 0.5 weight percent to 5 weight percent.
11. The industrial asphalt composition of claim 7 wherein the polymer modifier is selected from the group consisting of SBS, SEBS, copolymers of functionalized reactive elastomers (RET) or glycidyl acrylate copolymers of methyl, ethyl, butyl acrylates, and polyolefin homo-polymers and copolymers.
12. The industrial asphalt composition of claim 7 wherein the wax has a softening point which is within the range of 200° F. to 330° F., a penetration value at 77° F. which is within the range of 0.5 dmm to 15 dmm, and a rotational viscosity which is within the range of 2 cP to 100 cP at 400° F., and COC flash point of greater than 400° F.
13. The industrial asphalt composition of claim 7 wherein the industrial asphalt composition has softening point which is within the range of 130° F. to 260° F., a penetration at 77° F. which is within the range of 12 dmm to 40 dmm, and a rotational viscosity which is within the range of 90 cP to 700 cP at 400° F.
14. A method for producing an industrial asphalt composition comprising blending into an asphalt base materials consisting of:
a partially blown asphalt or a hard PEN asphalt,
a polymer modifier,
at least one wax,
optionally, one or more fillers,
optionally, one or more stabilizers,
optionally, one or more recycled tire rubber,
optionally, one or more recycled engine oil,
optionally, one or more recycled plastics,
optionally, one or more softeners,
optionally, one or more antifungal agents, and
optionally, one or more biocides,
wherein the asphalt base is not air blown, wherein the base asphalt is asphalt flux, wherein the partially blown asphalt or hard PEN asphalt is asphalt flux, and
wherein the industrial asphalt composition has softening point which is within the range of 130° F. to 260° F., a penetration at 77° F. which is within the range of 12 dmm to 40 dmm, and a rotational viscosity which is within the range of 90 cP to 700 cP at 400° F.
15. The method of claim 14 wherein partially blown asphalt is blended into the asphalt base, wherein the partially blown asphalt has a softening point which is within the range of 120° F. to 230° F., wherein the partially blown asphalt has a penetration value which is within the range of 5 dmm to 30 dmm at 77° F., and wherein the partially blown asphalt has a rotational viscosity which is within the range of 120 cP to 450 cP at 400° F.
16. The method of claim 14 wherein the hard PEN asphalt is blended into the asphalt base, wherein the hard PEN asphalt has a softening point which is within the range of 140° F. to 240° F., wherein the hard PEN asphalt has a penetration value which is within the range of 0.5 dmm to 15 dmm at 77° F., and wherein the hard PEN asphalt has a rotational viscosity which is within the range of 25 cP to 450 cP at 400° F.
17. The method of claim 14 wherein 20 weight percent to 80 weight percent of the hard PEN asphalt is blended into 20 weight percent to 80 weight percent of the base asphalt, wherein the hard PEN asphalt has a penetration value which is within the range of 0.2 dmm to 10 dmm at 77° F., wherein a polymer modifier is further blended into the asphalt base at a level which is within the range of 0.5 weight percent to 12 weight percent, and wherein a wax is further blended into the asphalt base at a level which is within the range of 0.5 weight percent to 5 weight percent.