Rejuvenation of reclaimed asphalt pavement

Patent metadata

Field	Value
Publication number	US-12221381-B2
Application number	US-202217743977-A
Country	US
Kind code	B2
Filing date	May 13, 2022
Priority date	May 13, 2022
Publication date	Feb 11, 2025
Grant date	Feb 11, 2025

Abstract

A method of rejuvenating reclaimed asphalt pavement (RAP) is provided. The method includes mixing the RAP with oil sludge, at least one asphalt binder, and at least one aggregate at a temperature of 100-200° C. to form a mixture. The method further includes compacting the mixture to form a rejuvenated paving material. The oil sludge is 60-80 wt. % water, 10-30 wt. % sediments, and 5-30 wt. % hydrocarbon oils based on a total weight of the water, sediments, and hydrocarbon oils.

First claim

The invention claimed is:

1. A method of rejuvenating reclaimed asphalt pavement (RAP), the method comprising:
mixing RAP, oil sludge, at least one asphalt binder, and at least one aggregate at a temperature in a range of from 100 to 200° C. to form a mixture; and
compacting the mixture to form a rejuvenated paving material,
wherein the oil sludge comprises water in a range of from 60 to 80 wt. %, sediments in a range of from 10 to 30 wt. %, and hydrocarbon oils in a range of from 5 to 30 wt. %, based on a total weight of the oil sludge,
wherein the mixture comprises the oil sludge in a range of from 1.5 to 2 wt. %, based on a total weight of the RAP,
wherein the at least one asphalt binder is at least one selected from the group consisting of PG58-22, PG64-10, PG64-16, PG64-28, and PG70-10, the at least one asphalt binder being present in a range of from 20 to 25 wt. %, based on the total weight of the RAP,
wherein the at least one aggregate is at least one selected from the group consisting of limestone, granite, syenite, diorite, basalt, diabase, and gabbro, sandstone, chert, shale, gneiss, schist, slate, quartzite, marble, and serpentine, a balance of the mixture being the at least one aggregate and new asphalt pavement,
wherein the mixture comprises the RAP in a range of from 20 to 40 wt. %, based on a total weight of the mixture, and
wherein the rejuvenated paving material has a retained Marshall stability of in a range of from 75 to 85%, the retained Marshall stability being measured according to AASHTO: T245 (2019) on a first set of 3 samples being saturated and conditioned at 60° C. in water bath for 35 minutes prior to measuring Marshall stability, a second set of 3 samples of the same AC-mix being subjected to saturation and conditioning at 60° C. in water bath for 24 hours, the Marshall stability of the second set of samples being measured and corrected according to heights of the 3 samples according to equation (1):

RS
=

MS
f

MS
o

×
100

,

(
1
)

wherein an average corrected stability of the first set of samples is M S an average corrected stability of the second set of samples is MS f , and the retained Marshall stability is RS.

2. The method of claim 1 , wherein the sediments in the oil sludge are sulfur, calcium oxide, iron rust, and copper oxide.

3. The method of claim 1 , wherein the sediments in the oil sludge have sulfur in a range of from 1 to 15 wt %, calcium oxide in a range of from 25 to 50 wt. %, iron rust in a range of from 5 to 25 wt. %, and copper oxide in a range of from 5 to 25 wt. %, based on the total weight of the sulfur, calcium oxide, iron rust, and copper oxide.

4. The method of claim 1 , wherein the oil sludge comprises carbon, hydrogen, oxygen, sulfur, calcium, iron, sodium, magnesium, silicon, chlorine, mercury, copper, bromine, molybdenum, vanadium, cadmium, chromium, lead, zinc, and nickel.

5. The method of claim 1 , wherein the oil sludge further comprises nickel in a range of from 1 to 8000 mg, per kg of the oil sludge.

6. The method of claim 1 , wherein the oil sludge further comprises vanadium in a range of from 1 to 100 mg, per kg of the oil sludge.

7. The method of claim 1 , wherein the at least one aggregate is at least one selected from the group consisting of limestone, granite, syenite, diorite, basalt, diabase, and gabbro.

8. The method of claim 1 , wherein the rejuvenated paving material leaches less than 5 mg/L of mercury, cadmium, chromium, lead, copper, nickel, zinc, and/or iron.

9. The method of claim 1 , wherein the RAP has an average asphalt binder content of 5.5±0.5%.

10. The method of claim 9 , wherein the RAP is obtained from a pavement initially comprising a PG64-10 asphalt binder and a limestone aggregate.

11. The method of claim 10 , wherein the oil sludge comprises the water in 69 wt. %, the sediments in 23 wt. %, and the hydrocarbon oils in 8 wt. %,
wherein the sediments are sulfur, calcium oxide, iron rust, and copper oxide, and
wherein the oil sludge comprises carbon, hydrogen, oxygen, sulfur, calcium, iron, sodium, magnesium, silicon, chlorine, mercury, copper, bromine, molybdenum, vanadium, cadmium, chromium, lead, zinc, and nickel.

12. The method of claim 11 , wherein the at least one aggregate is limestone.

13. The method of claim 12 , wherein the at least one asphalt binder is a PG64-10 asphalt binder.

14. The method of claim 13 , comprising 20 wt. % of the RAP, based on a total weight of the mixture, and
wherein the retained Marshall stability is 85%.

15. The method of claim 13 , comprising 40 wt. % of the RAP, based on a total weight of the mixture, and
wherein the retained Marshall stability is 75%.

Assignees

• Univ Imam Abdulrahman Bin Faisal

Inventors

• Dalhat Muhammad Abubakar
• Osman Sami Abdullah

Classifications

• C04B26/26

  Bituminous materials, e.g. tar, pitch {(C08L95/00 takes precedence)} · CPC title

• C04B2111/0075

  for road construction · CPC title

• C04B2111/1075

  Chromium-free or very low chromium-content materials · CPC title

• E01C19/05

  Crushing, pulverising or disintegrating apparatus ({preparing and placing involving breaking E01C19/466} ; in general B02C); Aggregate screening, cleaning, {drying} or heating apparatus; {Dust-collecting arrangements specially adapted therefor} · CPC title

• C04B2111/10

  Compositions or ingredients thereof characterised by the absence or the very low content of a specific material · CPC title