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System and method for manufacturing asphalt products with recycled asphalt shingles

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System and method for manufacturing asphalt products with recycled asphalt shingles

A method for manufacturing a processed asphalt suspension is provided. The method includes dry grinding shingle waste material to a particle size of less than 1 cm, forming ground recycled shingle material, introducing virgin asphalt into a heated slurry tank and mixing the ground recycled shingle material with the virgin asphalt in the heated slurry tank, forming a mixed asphalt slurry, introducing the mixed asphalt slurry into a wet grinding machine, and recovering a processed asphalt suspension comprising particles having a size no greater than about 200 microns. Roofing and paving products manufactured from the processed asphalt suspension are also provided.
Related Terms: Shingle Shingles

Owens Corning Intellectual Capital, LLC - Browse recent Corning patents - Toledo, OH, US
USPTO Applicaton #: #20140014000 - Class: 1062731 (USPTO) -

Inventors: Michael R. Franzen, David Charles Trumbore, Laurand H. Lewandowski, Herb Wissel, James E. Burkett, Barry Garriett Hornbacher, Christian Peregrine, Anthony Kriech

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The Patent Description & Claims data below is from USPTO Patent Application 20140014000, System and method for manufacturing asphalt products with recycled asphalt shingles.

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This non-provisional utility patent application claims priority to and the benefits of U.S. Provisional Patent Application Ser. No. 61/671,742 filed on Jul. 15, 2012 and to U.S. Provisional Application No. 61/728,891, filed on Nov. 21, 2012, each entitled System and Method for Manufacturing Roofing Products with Recycled Asphalt Shingles. Each application is incorporated herein by reference in its entirety.


The present invention relates generally to asphalt products, including processed asphalt compositions, that include recycled shingle material. More particularly the present invention relates to methods and apparatuses for forming processed asphalt suspensions, including mixing systems and process methods for creating performance enhanced asphalt compositions used in asphalt products.

Asphalt roofing shingles make up over two-thirds of the residential roofing market for both new homes and roof replacements. However, the high volume production of asphalt shingles leads to the production of significant waste, not only during the manufacture of the shingles, but also through removal (“tear-off”) of used shingles. In fact, it is estimated that 11 million tons of shingle waste is produced each year and approximately 10 million of these tons end up buried in landfills. The waste generated from the asphalt roofing products is concerning, since the shingles themselves do not degrade and stay permanently in the landfill. This and the fact that there is considerable raw material value in the shingles has resulted in significant efforts in recycling all types of roofing materials for a variety of purposes.

U.S. Pat. No. 5,848,755 to Zickell et al. discloses an asphalt roofing material recycling system used to recycle asphalt materials, such as asphalt shingles and tar paper that include granules, fibers or other particles. The asphalt material is simultaneously heated and milled in a heated milling apparatus, such as a heated ball mill, to reduce the size of the asphalt material granules in suspension in liquid asphalt.

U.S. Pat. No. 6,290,152 B1 to Zickell discloses that asphalt material is simultaneously heated and milled in a heated milling apparatus such as a heated ball mill. Excess moisture is removed from the asphalt material by continuously venting the heated ball mill apparatus.

U.S. Patent Application Publication No. 2010/0129667 to Kalkanoglu et al. discloses roofing products that are made from recycled roofing materials. The recycled roofing materials can be processed in an attritor or other media mixer to reduce the size of roofing granules and fibers.



The general inventive concepts are directed to a method for manufacturing roofing products using a processed asphalt suspension. The method includes pre-processing shingle waste material by grinding the material to a first minimum size, forming ground recycled shingle material. The preferred process for preparing the shingles is to dry grind the waste shingles using horizontal or vertical shaft impactors or hammer mills. This minimizes moisture in the ground shingles and allows removal of metallic particles. This ground recycled shingle from either of these processes produces a particle less than 1 cm. The ground recycled shingles are stored in a dry condition until further processing to make a processed asphalt suspension. According to some exemplary embodiments, the ground shingles are processed in a vibratory screen deck or trommel screen to remove the granules and metallic material before being used to make the processed asphalt suspension.

The process of making the processed asphalt suspension may begin with a heated slurry tank. The tank may be partially filled with virgin asphalt with a preferred temperature between 150-260° C. The virgin asphalt is manufactured to produce a processed asphalt suspension with rheological properties appropriate to the end use application. An antifoam agent is optionally added to the top of the mixed virgin asphalt to prevent excessive foaming of the ground shingles from trapped moisture. The ground recycled shingle material may then be added to the slurry tank, forming a mixed asphalt slurry. The ground recycled shingles are added slowly to the slurry tank to control moisture released as steam. The mixer is powerful enough to keep the asphalt material in suspension as any residual trace amounts of water trapped in the ground recycled shingle is released as steam in the vented tank and until the slurry is pumped to the next step in the process. The tank may also be heated to bring the mixed asphalt slurry to the proper temperature of 150-260° C. before pumping to the attritor or ball mill. This embodiment of producing a completely dry processed asphalt prevents foaming of the slurry in the attritor or ball mill from even low (<0.5% moisture) levels of water trapped in the shingles.

The mixed asphalt slurry may then be fed into a wet grinding mill, such as an attritor or stirred vertical or horizontal ball mill. This device reduces the size of mineral matter and agglomerates, including granules or fiberglass, until 90% of the mineral matter or agglomerates is less than about 150 micron in size and 50% is less than about 50 micron in size. This sizing minimizes settlement in transport and storage.

A wide range of virgin asphalts, including un-oxidized, air rectified, and oxidized asphalts as well as asphalt oxidized in the presence of catalyst or asphalts modified by waxes, oils or other additives may be used and are discussed in more detail below. The mixture should spend enough time in the wet grinding machine to not only reduce the size of the mineral particles, but also to fully incorporate the asphalt from the recycled ground shingle material into the virgin asphalt, thereby getting full use of the recycled asphalt as a processed asphalt suspension

The foregoing and other objects, features, and advantages of the general inventive concepts will become more readily apparent from a consideration of the detailed description that follows.


The present invention will be described with reference to the attached drawings which are given as non-limiting examples.

FIG. 1 is a schematic diagram of the processes of producing the ground recycled shingle material and the processed asphalt suspension according to one embodiment of the present invention.

FIG. 2 is a schematic diagram of an exemplary attritor or ball mill.

FIG. 3 illustrates a graphical regression analysis that depicts the softening point of the exemplary roofing products made with the processed asphalt suspensions compositions listed in Table 1.

FIG. 4 illustrates the unexpected beam fatigue properties for the processed asphalt suspension in an asphalt concrete beam after 100,000 cycles loading compared to a control pavement without the processed asphalt suspension.

FIG. 5 illustrates the improved dynamic modulus (E*) for an exemplary asphalt concrete mixture containing the processed asphalt suspension in comparison to a straight virgin asphalt mixture.

FIG. 6 illustrates the viscosity of exemplary calcite asphalt mixes.

FIG. 7 illustrates the viscosity of exemplary talc asphalt mixes.

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