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Title:
ASPHALT MODIFIER AND METHOD OF MANUFACTURE
Document Type and Number:
WIPO Patent Application WO/2000/055257
Kind Code:
A1
Abstract:
Processed used motor oil containing motor oil additives is distilled at relatively high temperature and relatively low pressure to provide still bottoms having the motor oil additives contained therein which are then utilized as an asphalt modifier. Additional chemical agents selected from the group including: 1) Polymethacrylates; 2) Ethylene-Propylene copolymers; 3) Styrene-Diene copolymers; 4) Styrene-Ester copolymers; 5) Wax Alkylated Naphthalene; 6) Cross Linked Wax Alkylated Phenols; and/or 7) Vinyl Acetate/Fumaric Acid Ester Copolymers and/or other asphalt modifiers such as pulverized latex may be added to the still bottoms prior to the use thereof as an asphalt modifier. Alternatively, a petroleum product not containing motor oil additives may be distilled at relatively high temperature and relatively low pressure to provide still bottoms which are subsequently enhanced by the addition of one or more chemical agents thereto. The enhanced still bottoms are then utilized as an asphalt modifier either singlely or in combination with other asphalt modifiers.

Inventors:
SHERMAN JEFFREY H (US)
Application Number:
PCT/US2000/002603
Publication Date:
September 21, 2000
Filing Date:
February 01, 2000
Export Citation:
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Assignee:
AVISTA RESOURCES INC (US)
SHERMAN JEFFREY H (US)
International Classes:
C08L95/00; C09D195/00; C10C3/00; C10C3/02; (IPC1-7): C08L95/00; C09D195/00; C10C3/06; C10M175/02
Foreign References:
US6048447A2000-04-11
US6007701A1999-12-28
US6068759A2000-05-30
Attorney, Agent or Firm:
O'neil, Michael A. (P.C. Suite 1030 5949 Sherry Lane Dallas, TX, US)
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Claims:
I CLAIM:
1. A method of manufacturing asphalt modifiers including the steps of: providing a quantity of used motor oil having motor oil additives contained therein; distilling the used motor oil under conditions of relatively high temperature and relatively low pressure and thereby formulating a quantity of still bottoms containing the motor oil additives from the used motor ca1 and characterized by a relatively high viscosity.
2. The method of Claim 1 wherein the distillation step is carried out at a temperature of between about 325°C and about 375°C and at a pressure of about. 05mm and about .001mm.
3. The method of Claim 2 wherein the distillation step is further characterized by the separation of at least one relatively low viscosity component from the still bottoms.
4. The asphalt modifier resulting from the method of Claim 3.
5. The method of Claim 1 further including the subsequent step of mixing the still bottoms into a quantity of straight run asphalt to improve the quality thereof.
6. The method of Claim 3 wherein the still bottoms are added to the straight run asphalt at a predetermined percentage which is within the range of between about. 5% and 5%.
7. The method as of Claim 3 including the subsequent steps of adding a predetermined asphalt modifier to the still bottoms and subsequently mixing the still bottoms having the asphalt modifier added thereto with a quantity of straight run asphalt.
8. The method of making asphalt modifiers including the steps of: providing a quantity of used motor oil including at least one motor oil additive selected from the group including pour point depressants and viscosity index improvers; distilling the used motor oil at a temperature of between about 325°C and about 375°C and at a pressure of between about. 05mm and about. 001mm and thereby separatlsg the used motor oil into at least one relatively low viscosity component and relatively high viscosity still bottoms having the motor oil additives contained therein.
9. The method according to Claim 8 including the subsequent step of enhancing the still bottoms having the motor oil additives contained therein by the addition thereto of at least one chemical agent selected from the group including: 1. Polymethacrylates; 2. EthylenePropylene copolymers; 3. StyreneDiene copolymers; 4. StyreneEster copolymers; 5. Wax Alkylated Naphthalene; 6. Cross Linked Wax Alkylated Phenols; and/or 7. Vinyl Acetate/Fumaric Acid Ester Copolymers.
10. The asphalt modifier resulting from the process of Claim 9.
11. The method according to Claim 8 including the subsequent step of mixing the still bottoms having the motor oil additives contained therein into a quantity of straight run asphalt.
12. The method according to Claim 11 wherein the still bottoms having the motor oil additives contained therein are added to the straight run asphalt at a ratio of between about. 5% and about 5%.
13. The method according to Claim 12 including the additional step of adding at least one asphalt modifier to the still bottoms having the motor oil additives contained therein prior to adding the still bottoms to the straight run asphalt.
14. The method of making asphalt modifiers including the steps of: providing a quantity of a predetermined petroleum product; distilling the petroleum product at a temperature of between about 325°C and about 375°C and at a pressure of between. 05mm and about. 001mm, and thereby separating the petroleum product into at least one relatively high viscosity component and still bottoms having a relatively low viscosity; subsequently enhancing the still bottoms by adding thereto at least one chemical agent.
15. The method of making asphalt modifiers according to Claim 14 wherein the step of enhancing the still bottoms is carried out by adding at least one motor oil additive selected from the group including pour point depressants and viscosity index improvers to the still bottoms.
16. The method according to Claim 14 wherein the chemical agent that is added to the still bottoms is selected from the group including: 1. Polymethacrylates; 2. EthylenePropylene copolymers; 3. StyreneDiene copolymers; 4. StyreneEster copolymers; 5. Wax Alkylated Naphthalene; 6. Cross Linked Wax Alkylated Phenols; and/or 7. Vinyl Acetate/Fumaric Acid Ester Copolymers.
17. The asphalt modifier resulting from the process of Claim 16.
18. The method according to Claim 13 including the subsequent step of mixing the still bottoms having the chemical agent included therein with straight run asphalt in accordance with a predetermined ratio.
19. The method according to Claim 18 wherein the predetermined ratio comprises a range of between about. 5% and about 5%.
20. The method according to Claim 18 including the step of mixing a predetermined asphalt modifier with the still bottoms prior to adding the still bottoms to the straight run asphalt.
21. AMENDED CLAIMS [received by the International Bureau on 20 July 2000 (20.07.00); new claims 2136 added; other claims unchanged; (4 pages)].
22. A process for manufacturing asphalt modifiers, comprising the steps of: providing a predetermined quantity of used motor oil containing additives selected from the group consisting of pour point depressants and viscosity index improvers; processing said used motor oil in accordance with the method of copending application No. 09/250,741 the disclosure of which is included herein by reference; distilling said processed used motor oil; and recovering the high viscosity still bottoms from the distillation step for use as an asphalt modifier.
23. The process for manufacturing asphalt modifiers as recited in Claim 21 comprising the additional step of : adding chemical agents selected from the group consisting of polymethacrylates, ethylenepropylene copolymers, styrenediene copolymers, styreneester copolymers, wax alkylated naphthalene, cross linked wax alkylated phenols, and vinyl acetate/fumaric acid ester copolymers.
24. The process for manufacturing asphalt modifiers as recited in Claim 21 wherein the distillation step takes place at a temperature of between about 325 °C and about 375 °C.
25. The process for manufacturing asphalt modifiers as recited in Claim 23 wherein the distillation takes place at a pressure of between about 0.05 mm and about 0.001 mm 25. A process for manufacturing asphalt modifiers, comprising the steps of: providing a predetermined quantity of used motor oil; processing said used motor oil in accordance with the method of copending application No.
26. 09/250,741 the disclosure of which is included herein by reference; distilling said processed used motor oil; and recovering the high viscosity still bottoms from the distillation step for use as an asphalt modifier.
27. The process for manufacturing asphalt modifiers as recited in Claim 25 comprising the additional step of: adding chemical agents selected from the group consisting of polymethacrylates, ethylenepropylene copolymers, styrenediene copolymers, styreneester copolymers, wax alkylated naphthalene, cross linked wax alkylated phenols, and vinyl acetate/fumaric acid ester copolymers.
28. The process for manufacturing asphalt modifiers as recited in Claim 21 wherein the distillation takes place at a temperature of between about 325 °C and about 375 °C.
29. A process for manufacturing asphalt modifiers, as recited in Claim 23., wherein the distillation takes place at a pressure of between about 0.05 mm and about 0.001 mm 29.
30. A process for manufacturing asphalt modifiers, comprising the steps of: providing a predetermined quantity of used motor oil having had contaminants removed therefrom, said predetermined quantity of used motor oil containing additives selected from the group consisting of pour point depressants and viscosity index improvers; distilling said used motor oil; and recovering the high viscosity still bottoms resulting.
31. The process for manufacturing asphalt modifiers as recited in Claim 29 from the distillation step for use as an asphalt modifier comprising the additional step of: adding chemical agents selected from the group consisting of polymethacrylates, ethylenepropylene copolymers, styrenediene copolymers, styreneester copolymers, wax alkylated naphthalene, cross linked wax alkylated phenols, and vinyl acetate/fumaric acid ester copolymers, to said still bottoms.
32. The process for manufacturing asphalt modifiers as recited in Claim 29 wherein the distillation takes place at a temperature of between about 325 °C and about 375 °C.
33. The process for manufacturing asphalt modifiers, as recited in Claim 29., wherein the distillation takes place at a pressure of between about 0.05 mm and about 0.001 33.
34. A process for manufacturing asphalt modifiers, comprising the steps of: providing a predetermined quantity of used motor oil having had contaminants removed therefrom; distilling said used motor oil; and recovering the high viscosity still bottoms resulting from the distillation step for use as an asphalt modifier.
35. The process for manufacturing asphalt modifiers as recited in Claim 33 comprising the additional step of: adding chemical agents selected from the group consisting of polymethacrylates, ethylenepropylene copolymers, styrenediene copolymers, styreneester copolymers, wax alkylated naphthalene, cross linked wax alkylated phenols, and vinyl acetate/fumaric acid ester copolymers, to said still bottoms.
36. The process for manufacturing asphalt modifiers as recited in Claim 33 wherein said distillation takes place at a temperature of between about 325 °C and about 375 °C.
37. The process for manufacturing asphalt modifiers as recited in Claim 33 wherein said distillation takes place at a pressure of between about 0.05 mm and about 0.001 mm.
Description:
APPLICATION ASPHALT MODIFIER AND METHOD OF MANUFACTURE TECHNICAL FIELD This invention relates generally to asphalt modifiers, and more particularly to an improved asphalt modifier which is also useful as a solubilizing agent or compatibilizer for other asphalt modifiers, and to a method of manufacturing the improved asphalt modifier.

BACKGROUND AND SUMMARY OF THE INVENTION As is well known, modern motor oils frequently include a variety of additives, including pour point depressants and viscosity index improvers. Pour point depressants are used to reduce the temperature at which the motor oil becomes solid and is therefore no longer pourable.

Viscosity index improvers broaden the temperature range over which the viscosity of the motor oil remains relatively stable.

The assignee of the present application is the exclusive licensee of co-pending application Serial Number 09/250,741 filed February 16,1999, and entitled METHOD OF REMOVING CONTAMINANTS FROM USED OIL. In accordance with the method of the co-pending application, used motor oil is processed and is thereafter distilled at high temperature and low pressure. This results in the separation of the processed used motor oil into light base oil, medium base oil, heavy base oil, and still bottoms.

The still bottoms contain the additives, particularly including the pour point depressants and the viscosity index improvers, that were present in the motor oil at the time it was originally sold and used.

It is also well known that asphalt is a residual product generated in the process of refining crude oil.

Asphalt is used literally worldwide in a variety of applications, including road paving materials, roof coatings and shingles, and industrial coatings. For example, when asphalt is mixed with aggregates, such as sand and/or gravel, the resulting mixture forms an ideal road paving material. In fact, over 35,000,000 tons of asphalt are used annually in the construction and repair of roads and highways in the United States alone.

The quality of asphalt is defined in terms of temperature range, that is, the range of temperatures over which the asphalt is neither too soft nor too brittle to perform successfully for the intended purpose.

Unfortunately, most straight run asphalts are of relatively poor quality. It has therefore become common practice to use asphalt modifiers such as synthetic rubbers and other chemicals, to improve asphalt quality. Although generally successful in raising the high end of the temperature range at which asphalt is useful, presently available asphalt modifiers also raise the low end of the temperature range, thereby causing the asphalt to become brittle at unacceptably high temperatures.

In accordance with the present invention it has been found that the still bottoms resulting from the practice of the above-identified co-pending application comprise an

asphalt modifier which is vastly superior to any currently available asphalt modifier in improving the quality of straight run asphalt by expanding the temperature range thereof both upwardly and downwardly. The asphalt modifier of the present invention can be used singlely, that is, without the addition of other materials. The asphalt modifier of the present invention can also be used as a solubilizer or compatibilizer to facilitate the use of other asphalt modifiers.

The present invention further comprises a method of manufacturing asphalt modifiers. In accordance with one embodiment of the method, used motor oil is processed in accordance with the method of the above-identified co- pending application during which the processed used motor oil is distilled at high temperature and low pressure to provide light base oil, medium base oil, heavy base oil, and still bottoms, with the still bottoms comprising the improved asphalt modifier of the present invention.

Preferably, the composition of the still bottoms, which includes the additives from the used oil, is supplemented by the addition of chemical agents selected from the group including: 1. Polymethacrylates; 2. Ethylene-Propylene copolymers;

3. Styrene-Diene copolymers; 4. Styrene-Ester copolymers; 5. Wax Alkylated Naphthalene; 6. Cross Linked Wax Alkylated Phenols; and/or 7. Vinyl Acetate/Fumaric Acid Ester Copolymers.

In accordance with a second embodiment of the method, petroleum products not having additives contained therein are distilled at high temperature and low pressure to provide various distillates and still bottoms. Chemical agents of the types and kinds which are utilized as additives in virgin motor oils are then added to the still bottoms to provide the asphalt modifier of the present invention.

Asphalt modifiers made in accordance with any of the foregoing embodiments can be used singlely, that is, without adding further materials. Alternatively, any of the foregoing embodiments can be used as a solubilizing agent or compatibilizer for other asphalt modifiers, such as ground or pulverized latex rubber.

DETAILED DESCRIPTION In accordance with the first embodiment of the invention, virgin motor oil is provided with one or more additives, including but not limited to, one or more pour point depressants and one or more viscosity index improvers. The virgin motor oil having the additives contained therein is utilized as a lubricant in automobile engines and similar applications. Following a predetermining period of operation of the engine or other apparatus in which the motor oil is used, the now-used motor oil is recovered.

The used motor oil still having the pour point depressant and viscosity index improver additives contained therein is accumulated, in some instances from a variety of sources. The used motor oil is then processed in accordance with the method of co-pending application Serial Number 09/250,741 filed February 16,1999, which is incorporated herein by reference. At the conclusion of the process of the co-pending application, the processed used motor oil is distilled under conditions of high temperature and low pressure. Preferably, the distillation takes place at a temperature of between about 325°C and about 375°C, and at a pressure of between about. 05mm and about. 001mm.

The distillation process yields one or more relatively low

viscosity products, and results in a high viscosity product known as still bottoms which contain the pour point depressant and viscosity index improver additives of the virgin motor oil.

The still bottoms resulting from the method of the co- pending application are then employed as an asphalt modifier. The asphalt modifier of the present invention is added to straight run asphalt at levels of between about . 5% and about 5% depending upon the requirements of particular applications of the invention. In the actual practice it has been determined that the use of the asphalt modifier of the present invention is significantly superior to currently available asphalt modifiers in improving the performance of straight run asphalt. For example, the United States Department of Transportation established a program, known as the Strategic Highway Research Program, which in turn created a program known as Superpave.

Superpave was designed to develop better and longer lasting asphalt pavements. One of the primary aspects of Superpave was the establishment of a series of analysis procedures, by which asphalt binders could be objectively tested to predict the performance of the binder as a road pavement ingredient. Using the Superpave test procedures the

asphalt modifier of the present invention has been shown to improve the performance qualities of asphalt binders.

Asphalt modifiers produced in accordance with the method of the first embodiment of the invention may be utilized singlely, that is, without incorporation of other materials. Asphalt modifiers produced in accordance with the first embodiment of the invention can also be used as solubilizers or compatibilizers for other asphalt modifiers. For example, the pulverized latex materials which are currently used as asphalt modifiers are sometimes insoluble in asphalt. However, when first combined with the asphalt modifier of the present invention and then combined with straight run asphalt, pulverized latex and other currently used asphalt modifiers are thoroughly dissolved in the straight run asphalt and do not separate therefrom during use.

In accordance with a variation of the first embodiment of the invention, the still bottoms resulting from the practice of the method of the above-identified co-pending application are enhanced by the incorporation of additional chemical agents therein. For example, one or more chemical agents selected from the group including: 1. Polymethacrylates; 2. Ethylene-Propylene copolymers;

3. Styrene-Diene copolymers; 4. Styrene-Ester copolymers; 5. Wax Alkylated Naphthalene; 6. Cross Linked Wax Alkylated Phenols; and/or 7. Vinyl Acetate/Fumaric Acid Ester Copolymers may be added to the. still bottoms prior to utilization thereof as an asphalt modifier. Other variations in the practice of the first embodiment of the invention will readily suggest themselves to those skilled in the art.

In accordance with the second embodiment of the invention, one or more petroleum products not having motor oil additives contained therein are distilled in conditions of high temperature and low pressure. The distillation process is preferably carried out at a temperature of between about 325°C and about 375°C, and at a pressure of about. 05mm and about. 001mm. The distillation process separates the petroleum product or products into at least one component having relatively low viscosity and still bottoms having relatively high viscosity.

In accordance with a variation of the second embodiment of the invention, the still bottoms resulting from the distillation process are enhanced by the addition of pour point depressants and/or viscosity index improvers thereto. The pour point depressants and/or viscosity index

improvers which are utilized in the enhancement of the still bottoms comprise the same materials which are presently utilized as motor oil additives, including: 1. Polymethacrylates; 2. Ethylene-Propylene copolymers; 3. Styrene-Diene copolymers; 4. Styrene-Ester copolymers; 5. Wax Alkylated Naphthalene; 6. Cross Linked Wax Alkylated Phenols; and/or 7. Vinyl Acetate/Fumaric Acid Ester Copolymers.

Such materials are added to the still bottoms in percentages which are within the ranges at which the additives are added to virgin motor oils.

Regardless of which of the foregoing variations are employed, the enhanced still bottoms are then utilized as an asphalt modifier. Preferably, the enhanced still bottoms are added to straight run asphalt in percentages of between about. 5% and 5% depending on the requirements of particular applications of the invention. The improvements in the quality of straight run asphalt deriving from use of the asphalt modifier prepared in accordance with the process of the second embodiment of the invention are comparable with those achieved in the use of

the asphalt modifier prepared in accordance with the first embodiment of the invention.

The asphalt modifier of the second embodiment of the invention may be used singlely, that is, without the addition of other chemical agents thereto. The asphalt modifier of the second embodiment of the invention may also be utilized as a solubilizer or compatibilizer for currently used asphalt modifiers. For example, when the asphalt modifier of the second invention is used as..a. solubilizer or compatibilizer for pulverized latex materials of the type currently used as asphalt modifiers, such materials are fully dissolved in the straight run asphalt and do not separate therefrom during use.

Although preferred embodiments of the invention have been described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications, and substitutions of parts and elements without departing from the spirit of the invention.