The present invention relates to a process for continuously heating an asphalt surface.

BACKGROUND ART

As used throughout this specification, the term "asphalt" is meant to encompass macadam and tarmac. As is known in the art, asphalt paved road surfaces typically comprise a mixture of asphalt cement (typically a black, sticky, petrochemical binder) and an aggregate comprising appropriately sized stones, gravel and/or sand. The asphalt concrete mixture is usually laid, compressed and smoothed to provide an asphalt paved road surface.

Over time, an asphalt paved road surface can deteriorate as a result of a number of factors. For example, seasonal temperature fluctuations can cause the road surface to become brittle and/or cracked. Erosion or compaction of the road bed beneath the road surface may also result in cracking. Moreover, certain of the chemical constituents incorporated in fresh asphalt are gradually lost over time or their properties changed with time, further contributing to brittleness and/or cracking of the road surface. Where concentrated cracking occurs, pieces of pavement may become dislodged. This dislodgement can create traffic hazards, and accelerates the deterioration of adjacent pavement and highway substructure. Even if cracking and the loss of pavement pieces do not occur, the passage of traffic can polish the upper highway surface, and such a surface can be slippery and dangerous. In addition, traffic-caused wear can groove, trough, rut and crack a highway surface. Under wet highway conditions, water can collect in these imperfections and set up dangerous vehicle hydro-planing phenomena. Collected water also contributes to the further deterioration of the pavement.

Prior to about the 1970's, available methods for repairing old asphalt- paved road surfaces included: spot treatments such as patching or sealing, paving with new materials over top of the original surface, and removal of

some of the original surface and replacement with new materials. Each of these methods has inherent drawbacks and limitations.

Since about the early 1970's, with increasing raw material, oil and energy costs, there has been a growing interest in trying to recycle the original asphalt. The world's highways have come to be recognized as a very significant renewable resource.

Early recycling techniques involved removing some of the original surface and transporting it to a centralized, stationary recycling plant where it would be mixed with new asphalt and/or rejuvenating chemicals. The rejuvenated paving material would then be trucked back to the work site and laid. These techniques had obvious limitations in terms of delay, transportation costs and the like.

Subsequently, technology was developed to recycle the old asphalt at the worksite in the field. Some such processes involved heating and are frequently referred to as "hot-in-place recycling" (hereinafter referred to as HIPR).

This technology comprises many known processes and machines in the prior art for recycling asphalt paved surfaces where the asphalt has broken down. Generally, these processes and machines operate on the premise of (i) heating the paved surface (typically by using large banks of heaters) to facilitate softening or plasticization of an exposed layer of the asphalt; (ii) mechanically breaking up (typically using devices such as rotating, toothed grinders; screw auger/mills; and rake-like scarifiers) the heated surface; (iii) applying fresh asphalt or asphalt rejuvenant to the heated, broken asphalt; (iv) distributing the mixture from (iii) over the road surface; and (v) compacting or pressing the distributed mixture to provide a recycled asphalt paved surface. In some cases, the heated, broken material can be removed altogether from the road surface, treated off the road surface and then returned to the surface and pressed into finished position. Much of the prior art relates to variations of some kind on this premise.

Over time, HIPR has had to address certain problems, some of which still exist today. For example, asphalt concrete (especially the asphalt cement

within it) is susceptible to damage from heat. Thus, the road surface has to be heated to the point where it was sufficiently softened for practical rupturing, but not to the point of harming it. Furthermore, it was recognized that asphalt concrete is increasingly hard to heat as the depth of the layer being heated increases. Another problem results from excess and/or smoking of the asphalt surface which can lead to a negative impact on the environment. Many patents have attempted to address these problems. See, for example, the following patents:

US 3,361,042 (Cutler) US 3,970,404 (Benedetti)

US 3,843,274 (Gutman et al.) US 3,989,401 (Moench)

US 4,011 ,023 (Cutler) US 4, 124,325 (Cutler)

US 4,129,398 (Schoelkopf) US 4,335,975 (Schoelkopf)

US 4,226,552 (Moench) US 4,534,674 (Cutler) US 4,545,700 (Yates) US 4,711,600 (Yates)

US 4,784,518 (Cutler) US 4,793,730 (Butch)

US 4,929,120 (Wiley et al.) US 4,850,740 (Wiley)

As is apparent from these prior patents, many efforts have been made in the prior art to deal with the inherent difficulty of adequately and uniformly heating an asphalt surface in an efficient manner while minimizing or eliminating burning and smoking of the asphalt surface. To the Applicant's knowledge, much of this effort has involved utilizing relatively complicated means to distribute heat through the asphalt surface after rupturing thereof. This has involved treating the ruptured surface on or off the asphalt surface, and thereafter reapplying and pressing the ruptured surface to create a recycled asphalt surface. For example, it is believed that most of the prior art techniques require further heating of the ruptured asphalt surface to facilitate heat distribution therethrough. Such complicated processing means are typically cumbersome and large yet are necessary due to the inability to preheat the unruptured asphalt surface adequately without overheating thereof.

Further, the need for complicated processing means increases the capitol cost

associated with the process and dictates the need for highly skilled operators.

It would be desirable to have a process of heating an asphalt surface in a manner which facilitated subsequent recycling thereof. Ideally, such an asphalt surface heating process could be conducted utilizing conventional asphalt heaters and coupled with a relatively simple recycling system to provide a recycled asphalt surface. Preferably, the process would be capable of heating the unruptured asphalt surface to a sufficient extent such that the requirement further heating after rupturing could be obviated or mitigated.

This would result in the ability to reduce the amount of equipment necessary to effect recycling of the asphalt surface and thereby reduce the capital cost associated with the overall recycling process.

DISCLOSURE OF THE INVENTION

It is an object of the present invention to provide a novel process for heating an asphalt surface.

It is another object of the present invention to provide a process for heating an asphalt surface which obviates or mitigates at least one of the foregoing disadvantages of the prior art.

The present inventors have discovered that it is possible to achieve relatively uniform and efficient heating of an asphalt surface to a desired depth if preheating of the asphalt surface is accomplished in a particular manner. Generally, it has been discovered that vastly improved preheating of the asphalt surface, with miriimal or no overheating thereof, can be achieved by reciprocating the motion of heating. More specifically, by cyclically translating the heating means over the asphalt surface a first distance and thereafter backtracking the heating means a second distance which is less than the first distance, the asphalt surface may be heated uniformly to a desired depth in an efficient manner. By preheating the asphalt surface in this manner, it has been further discovered that heating can be accomplished efficiently, relatively uniformly and to a desired depth while obviating or mitigating damage to the asphalt surface associated with overheating thereof.

Further, the present process can be used while minimizing or eliminating burning and/or smoking of the asphalt surface.

Accordingly, in one of its aspects, the present invention provides a process for continuously heating an asphalt surface comprising the steps of: (i) providing asphalt surface heating means on the asphalt surface;

(ii) translating the heating means a first distance along the asphalt surface;

(iii) reversing the direction of and translating the heating means a second distance along the asphalt surface in a direction substantially opposite to that in Step (ii);

(iv) reversing the direction of and translating the heating means a first distance along the asphalt surface in a direction substantially the same as that in Step (ii); and

(v) repeating Steps (iii) and (iv) in a cyclic manner to provide a heated asphalt surface; wherein the ratio of the second distance to the first distance is in the range of from about 0.10 to about 0.90.

In another of its aspects, the present invention provides a process for continuously heating an asphalt surface comprising the steps of: (i) providing asphalt surface heating means comprising a leading heater and a trailing heater arranged in series on the asphalt surface;

(ii) translating the heating means a first distance along the asphalt surface;

(iii) reversing the direction of and translating the heating means a second distance along the asphalt surface in a direction substantially opposite to that in Step (ii);

(iv) reversing the direction of and translating the heating means a first distance along the asphalt surface in a direction substantially the same as that in Step (ii); and (v) repeating Steps (iii) and (iv) in a cyclic manner to provided a heated asphalt surface;

wherein the ratio of the second distance to the first distance is in the range of from about 0.10 to about 0.90.

Preferably, in this embodiment of the invention, the heating means further comprises at least one intermediate heater between the leading heater and the trailing heater.

In a preferred aspect of the invention, the process further comprises the steps of:

(vi) rupturing the heated asphalt surface to a depth of at least about 1.5 inches to provide a ruptured upper surface and an unruptured surface therebelow;

(vii) mixing the ruptured upper surface while it is on the unruptured surface to produce a ruptured upper surface which is substantially free of moisture; and

(viii) pressing the heated, ruptured upper surface to provide a recycled asphalt surface.

In yet a further preferred aspect of the present invention, the process further comprises the steps of:

(vi) rupturing the heated asphalt surface to a desired depth, the ruptured surface overlying a remaining unruptured portion of the asphalt surface;

(vii) mixing at least some of the ruptured surface on the unruptured portion asphalt surface; and

(viii) pressing the ruptured surface to form a recycled asphalt surface.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the present invention will be described with reference to the accompanying drawings, in which:

Figure 1 is a graphic illustration of the temperature/time relationship for a conventional asphalt heating process and the present process; Figure 2 is a graphic illustration of the temperature/time relationship for an asphalt surface at various depths utilizing the present process;

Figure 3 (comprising Figures 3 A and 3B) is an illustration of a remixer capable of being used in conjunction with the present process; and

Figure 4 (comprising Figures 4A and 4B) is an illustration of the embodiment of the invention where an aggregate is heated with the asphalt surface.

BEST MODE FOR CARRYING OUT THE INVENTION

One of the advantages accruing from the present process is the ability to use conventional asphalt surface heaters to effect, in some cases, all of the heating necessary for recycling prior to rupture of the asphalt surface. Thus, the choice of asphalt surface heating means is not particularly restricted and use may be made of radiant heaters (e.g. infrared heaters), hot air heaters, convection heaters, microwave heaters, direct flame heaters and the like. Generally, the heater is an independent, self-propelled vehicle which comprises a series of rows of elongate heaters extending transversely across the asphalt surface. The preferred heating means for use in the present process is a series of propane or diesel fired infrared heaters. Such heaters are well known in the art.

Generally, it is preferred that the vehicular heating means used in the present process may be readily switched from forward to reverse operation, and vice versa. The manner by which this is accomplished is not particularly restricted and is within the purview of those of skill in the art.

The asphalt surface heating means is: moved forward a first distance; reversed; and thereafter moved backward in an opposite direction a second distance. The ratio of the second distance to the first distance is in the range of from about 0.10 to about 0.90. Thus, when the ratio is 0.90, for every 10 units of distance the asphalt surface heating means is moved forward, it is moved backwards 9 units of distance. Similarly, when the ratio is 0.10, for every 10 units of distance the asphalt surface heating means is moved forward, it is moved backwards 1 unit of distance.

Preferably, the ratio of the second distance to the first distance is in the range of about 0.30 to about 0.90, more preferably in the range of from about 0.50 to about 0.90.

It is well known in the art that overheating of the asphalt surface must be avoided since this can result in ignition of and/or damage to the asphalt surface. Specifically, it is well known in the art that an asphalt mixture to a temperature above about 160°C can result in damage to the asphalt cement. It is also well known in the art that the surface of asphalt pavement in need of recycle may heated to a temperature approaching the flashpoint of the asphalt since, typically, the surface oil has been worn off, washed away or severely oxidized. Typically, the flash point of an asphalt surface is at a temperature exceeding about 210°C. Using the process of the present invention, it is possible to heat an unruptured asphalt surface to a temperature close to but not exceeding the flash point of the asphalt surface. Moreover, it is possible to maintain the unruptured asphalt surface at substantially this temperature. Thus, it is particularly preferred in the present process that the asphalt surface is heated to a temperature less than about 200 °C, more preferably a temperature in the range of from about 100°C to about 190°C, most preferably in the range of from about 130°C to about 190°C. The ability to achieve such uniform and steady-state heating of the asphalt surface is illustrated in Figure 1. Specifically, curve A is a representative temperature/time relationship associated with passing an infrared heater over an asphalt surface in the conventional manner (i.e. moving the heater in a single direction at a substantially constant speed). As is apparent, the temperature of the asphalt surface peaks between 2 and 3 minutes after initiating of heating to a temperature above the flashpoint of the asphalt surface. In comparison, curve B is representative of the temperature/time relationship obtained using the process of the present process (i.e. reciprocating movement of the heater in an unbalance manner). As illustrated, the temperature of the asphalt surface is increased to but does not exceed 200°C, i.e. below the flashpoint of the asphalt surface.

This point is further illustrated with reference to Figure 2 which provides individual temperature/time relationship curves for the asphalt surface at the following depths: 0 cm, 1 cm, 2 cm, 3 cm, 4 cm and 5 cm. As can be seen, the temperature varies from 200 °C at 0 cm (on the asphalt surface itself) to 80°C 5 centimetres (approximately 2 inches) below the surface. The average temperature of the 5 centimetre layer is approximately 120°C. This time/temperature profile is highly advantageous and simplifies recycling of the asphalt surface.

A particularly preferred embodiment of the present invention is the use of an asphalt surface heating means comprising at least two independent heaters. Ideally, the heaters are arranged in series, with a leading heater and a trailing heater. More preferably, at least one intermediate heater is disposed between the leading heater and the trailing heater. When two or more independent heaters are used, it is preferred that the above-described uneven reciprocating translation thereof is conducted in a uniform manner.

When two or more independent heaters are used in the present process, it is preferred that they be connected to each other to facilitate uniform translation of all of the heaters.

It is further preferred that, when two or more independent heaters are used, each heater be operated at a different temperature. Further, it is preferred that operation of the independent heaters at a different temperature creates a temperature gradient (i.e. of the heat output by the heaters) as the heating means in its entirety is translated along the asphalt surface. More preferably, the temperature gradient is a decrease in operation temperature of from leading heater to the trailing heater. A particularly advantageous manner of utilizing the temperature gradient associated with this embodiment of the invention is, for each independent heater, to vary the temperature depending on whether the heater is being translated in Step (iii) (i.e. relatively backward stroke) or Step (iv) (i.e. relatively forward stroke). Specifically, for each independent heater, it is most preferred, to have greater heater operational temperature in relatively forward stroke than the heater operational

temperature in the relatively backward stroke while maintain the overall preferred temperature gradient between individual heaters.

One of the key advantages of the present process is that it may comprise the entire heating requirement in the overall asphalt surface recycling process. Thus, while it is contemplated that the present process may be used in conjunction with many of the prior art processes described above, it may also be utilized with a greatly simplified remixer which is devoid of heaters. This is believed to be a significant advance in the art.

While the choice of remixer is not particularly restricted, a preferred remixer is depicted in Figure 3. In Figure 3, the remixer is shown in a top schematic view in Figure 3A and side elevation in Figure 3B. Thus, a remixer is illustrated generally at 10. The leading portion of remixer 10 comprises a dump truck 20 connected to a hopper 30 which is attached to a grinder/mixer shown generally at 40. Grinder/mixer 40 comprises a pair of leading grinders 50 and a trailing grinder 60 such that the overall effect of grinders 50 and 60 is to traverse the asphalt surface to be recycled. Trailing grinder 60 is connected to a pugmill 70 which, in turn, is connected to a conveyor 80. Below conveyer 80, there is disposed a repave screed 90. The trailing portion of grinder/mixer 40 is connected to a paver 100. Paver 100 serves to propel itself and grinder/mixer 40 in unison with dump truck 20. The trailing portion of paver 100 comprises a screed 110.

In use, dump truck 20 would be loaded with fresh asphalt and/or asphalt rejuvenant and, in unison with grinder/mixer 40 and paver 100, would be propelled behind the heater or heaters used in the present process. The fresh asphalt/asphalt rejuvenant is dispensed from dump truck 20 via hopper to the heated asphalt surface. It will be appreciated that the fresh asphalt/asphalt rejuvenant may be optionally preheated prior to application to the heated asphalt surface. The heated asphalt surface, with the fresh asphalt/asphalt rejuvenant lying thereon, is then ground in place by grinders 50 and 60, and thereafter is thoroughly mixed in pugmill 70. Thereafter, the thoroughly mixed product exiting pugmill 70 is lifted off the unruptured surface via conveyor 80 while repave screed 90 serves to level the unruptured

surface. The mixed product is reapplied to the unruptured asphalt surface and pressed into place by screed 110 on the trailing portion of paver 100.

It will be apparent to those of skill in the art that many variations may be made to this embodiment of the invention while maintaining the advantages associated therewith. For example, it may be possible to added the fresh asphalt at a more downstream point rather than prior to operation of grinder/mixer 40. Further, in certain applications, it may be possible to omit dump truck 20 and its contents in favour of a 100% recycle process. Alternatively, in other applications, sufficient recycling may be obtaining simply by adding oil, optionally preheated, before or during the operation of grinder/mixer 40.

A particularly preferred application of the present process is that it may be used in conjunction with a modified form of the process and apparatus described in published International (PCT) patent application No. WO 93/17185, the contents of which are incorporated herein by reference. In this published International patent application, a process is described which comprises, inter alia, heating and mixing a ruptured asphalt surface without the need to remove the ruptured surface or use complicated windrowing techniques to achieve uniform heating thereof. The present inventors have now discovered that it is possible to use the present process with the process described in the published International patent application. M o r e beneficially, the present inventors have discovered that the present process may be used with a more simplified version of the process described in published International patent application No. WO 93/17185. Specifically, it is contemplated that the requirement for cyclical heating and mixing as described in the published International application is not required due to ability of the present process to heat an unruptured asphalt surface in an efficient manner to a desired temperature and depth without overheating thereof . This allows for modifying the process in the published International patent application to do without the heaters interposed between the mixers. Thus, the present process, in a preferred embodiment, comprises the further steps of:

(vi) rupturing the heated asphalt surface to a depth of at least about 1.5 inches to provide a ruptured upper surface and an unruptured surface therebelow;

(vii) mixing the ruptured upper surface while it is on the unruptured surface to produce a ruptured upper surface which is substantially free of moisture; and

(viii) pressing the heated, ruptured upper surface to provide a recycled asphalt surface.

Further, the present process, in another preferred embodiment, comprises the further steps of:

(vi) rupturing the heated asphalt surface to a desired depth, the ruptured surface overlying a remaining unruptured portion of the asphalt surface;

(vii) mixing at least some of the ruptured surface on the unruptured portion asphalt surface; and

(viii) pressing the ruptured surface to form a recycled asphalt surface.

The rupturing, mixing and pressing described in Steps (vi), (vii) and

(viii), respectively, in both of the foregoing embodiments may be conducted using the techniques and equipment described in published International patent application No. WO 93/17185, the contents of which are incorporated herein by reference.

Depending on the nature of the overall recycling process (e.g. condition of asphalt surface, speed at which the equipment will be passing over the asphalt surface, the temperature at which the heaters are operated, the number of heaters, etc.), supplementary heaters may be used after rupturing in Step (vi) in either of the foregoing preferred embodiments.

Another preferred aspect of the present process comprises the step of dispensing an aggregate on the asphalt surface prior to heating thereof.

Preferably, the aggregate is dispensed in the form of a windrow. The process is then carried out as described above such that both the asphalt surface and the windrow of aggregate are heated.

This embodiment of the present process is illustrated in Figure 4. Figure 4 is comprised of Figures 4A (a top schematic view) and 4B (a side view of the process) which are aligned to depict the same process.

Thus, there is illustrated a dump truck 200 leading a hopper 210. Trailing hopper 210 is a leading asphalt surface heater 220 which comprises three banks of infrared heaters 221, 222 and 223. Trailing asphalt surface heater 220 is an intermediate asphalt surface heater 230 which similarly comprises three banks of infrared heaters 231, 232 and 233. After asphalt surface heater 230 is a trailing asphalt surface heater 240 which comprises three banks of infrared heaters 241 , 242 and 243. After asphalt surface heater 240 there is a grinder/mixer 250 connected to a paver 260. Grinder/mixer 250 and paver 260 are similar to the grinder/mixer (40) and paver (100) described hereinabove with reference to Figure 4.

In use, dump truck 200 would be loaded with a suitably sized aggregate and propelled, in unison, with hopper 210. As dump truck 200 and hopper 210 are propelled, aggregate is dispensed from dump truck 200 to hopper 210 and is formed into a windrow 270 on the (unheated) asphalt surface. Thereafter, leading asphalt surface heater 220 is passed over the asphalt surface/aggregate windrow in a reciprocating manner as depicted by arrows 280. Next, intermediate asphalt surface heater 230 passes over the asphalt surface/aggregate windrow in a reciprocating manner as illustrated by arrows 290. Further, as shown, trailing bank of heaters 231, there is a cylindrical broom 300 which serves to shift the aggregate windrow sideways by approximately one windrow width. Preferably, cylindrical broom 300 is lowered when intermediate asphalt surface heater 230 is moved in a forward direction (i.e. toward dump truck 200) and raised when it is moved in a rearward direction (i.e. toward paver 260). Thereafter, trailing asphalt surface heater 240 passes over the asphalt surface/aggregate windrow in a reciprocating manner as depicted by arrows 310. Trailing bank of heaters 242 is a cylindrical broom 320 which operates similarly to cylindrical broom 300 but serves to shift aggregate windrow 270 to the opposite side of the asphalt surface. Finally, the recycling process is completed by grinder/mixer 250 and

paver 260 in a manner similar to that described above with reference to Figure 4.

As will be appreciated, many variations of the disclosed process are possible without deviating from the spirit and substance thereof. Accordingly, while this invention has been described with reference to illustrative embodiments, this description is not intended to be construed in a limiting sense. Various modifications of the illustrative embodiment as well as other embodiments of the invention will be apparent to persons skilled in the art upon reference to this disclosure. It is therefor contemplated that the dependant claims with cover any such modifications or embodiments.