ASPHALT SHINGLES

TECHNICAL FIELD

[0001] Described herein are methods, systems and compositions for use in recycling asphalt shingles. In some embodiments, a composition comprising an alkane solvent, an aromatic petroleum distillate, and N, N-Dimethyl 9-Decenamide is mixed with asphalt shingles to accelerate the liquefaction of the asphalt component of the asphalt shingle and convert the asphalt component into a usable oil.

BACKGROUND

[0002] The current process for disposing of asphalt shingles and most asphalt roofing materials after they have been removed from roofs is to deposit the shingles in a landfill, or to ground them into smaller pieces and mix with road base materials. The volume of shingles and asphalt roofing materials disposed of each year is estimated to be 12 million tons and as much as 22 million tons per year. Accordingly, a need exists for improved methods of handling and processing waste asphalt shingles in order to alleviate filling landfills with roofing materials and accomplish a complete recycling of all of the components that make up an asphalt shingle.

SUMMARY

[0003] In some embodiments, a method of recycling asphalt shingles includes combining asphalt shingles with a composition comprising an alkane solvent, an aromatic petroleum distillate, and N, N-Dimethyl 9-Decenamide. This composition accelerates the liquefaction of the asphalt component from the asphalt shingle and converts the asphalt to a usable oil product. In some embodiments, the method may further employ the addition of water and cavitation in order to recruit hydrogen from the water in the creation of usable oil from the asphalt component. The fiberglass component of the asphalt shingle remaining after removal of the asphalt component can be subjected to additional washing to remove residual hydrocarbons. The mixture of water and oil removed from the fiberglass can be separated such that the oil component is sent to an oil tank and the water is reused in further fiberglass washing. The rock component of the asphalt shingle is separated during the mixing of the asphalt shingle with the composition and during the washing of the fiberglass, and separated rock will settle to the bottom of a mixing vessel where it can then be collected, washed to remove any residual oil, and dried.

[0004] The composition used in the method described above may include one or more alkanes, an aromatic petroleum distillate, and N, N-Dimethyl 9-Decenamide. In some embodiments, the aromatic petroleum distillate is Aromatic 100, Aromatic 150 or Aromatic 200. The aromatic petroleum distillate component of the composition may be in the range from about 70 to 95 vol.% of the composition. In some embodiments, the N, N-Dimethyl 9-Decenamide (commercially known as Steposol® Met-10U) is provided alone or as part of a composition including N, N-Dimethyl 9-Decenamide, such as Steposol® CITRI-MET, which includes Met-10U, surfactant emulsifiers, orange terpenes, and sodium carbonate. N, N-Dimethyl 9-Decenamide may be present in the composition in an amount in the range of from 5 to 30 vol.% of the composition. The alkanes may be xylene, toluene, heptane or any combination thereof, and are generally provided as a solvent. The alkane component of the composition may make up the balance of the composition after taking into account the amount of N, N-Dimethyl 9-Decenamide and aromatic petroleum distillate included in the composition based on the above disclosed vol.% ranges.

[0005] A system configured for carrying out the method described above and employing the composition described above may also be used.

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a flow diagram illustrating a method for recycling asphalt shingles in accordance with various embodiments described herein.

[0007] FIG. 2 is a schematic diagram of a system suitable for use in carrying out the method shown in FIG. 1 , the system configured in accordance with various embodiments described herein.

DETAILED DESCRIPTION

[0008] With reference to FIG. 1 , a method 100 for recycling asphalt shingles generally comprises a step 110 of combining asphalt shingles with a composition in a tank in order to liquefy the asphalt component of the asphalt shingle and produce a usable oil, a step 120 of removing the usable oil from the tank, a step 130 of removing fiberglass from the tank and washing the fiberglass to remove residual asphalt/oil from the fiberglass, a step 140 of removing sand from the tank and washing the sand to remove residual asphalt/oil, a step 150 of separating water from any of the usable oil removed from the tank in step 120, the residual asphalt/oil washed from the fiberglass in step 130 and the residual oil/asphalt washed from the sand in step 140, and a step 160 of recirculating separated water through the tank, optionally with the use of a cavitation pump.

[0009] Regarding step 110, asphalt shingles are combined with a composition in a tank with the aim of liquefying the asphalt component from the asphalt shingle and producing a usable oil from the asphalt component. The asphalt shingles provided in step 110 can be any type of asphalt shingle, and are typically asphalt shingles used in roofing. The asphalt shingles typically include three main components: an asphalt component, a fiberglass (or cloth) base material on which the asphalt is adhered, and a rock/sand component that is dispersed within the asphalt.

[0010] In some embodiments, the asphalt shingles provided in step 110 are first separated into individual shingles or smaller agglomerates of shingles prior to being introduced into the tank and combined with the composition in order to increase the surface area and access to asphalt material by the composition. Such steps may be useful where the asphalt shingles to be processed are in larger agglomerates due to the manner in which waste shingles are typically stored (e.g., dumped in piles and left in the sun, leading to the shingles becoming sticky and sticking together). Any manner of separating the shingles can be used, such as the use of blades that are inserted into the agglomerates to separate shingles. In some embodiments, such separation can take place in a hopper used to store and feed shingles into the tank where the shingles and composition are combined. In such embodiments, blade-like inserts can be inserted from the sides of the hopper into the pile of shingles deposited into the hopper. Rollers can then be used to propel the shingles and shingle pieces to a conveyor that drops whole shingles and shingle pieces into the tank.

[0011] The tank in which step 110 takes place can be any type of tank suitable for holding the shingles and the composition and allowing for the composition to interact with the asphalt component of the shingles in order to liquefy and react with the asphalt to produce a usable oil. The size of the tank is generally not limited and may be selected based on the volume of material that is desired to be processed within a period of time. Further details on the tank will be provided in the discussion of FIG. 2 provided below.

[0012] The composition provided in step 110 and which is combined with the asphalt shingles generally includes three primary components, though other components may be provided as desired or needed. The three primary components of the composition are one or more alkanes, an aromatic petroleum distillate, and N, N-Dimethyl 9-Decenamide.

[0013] Regarding the aromatic petroleum distillate component of the composition, the aromatic petroleum distillate component is generally provided to liquefy the asphalt, bond with the asphalt and make multiple benzene compounds. In some embodiments, the aromatic petroleum distillate is Aromatic 100, Aromatic 150 or Aromatic 200. The aromatic petroleum distillate component of the composition may be in the range from about 70 to 95 vol.% of the composition.

[0014] Regarding, the N, N-Dimethyl 9-Decenamide, N, N-Dimethyl 9-Decenamide (commercially known as Steposol® Met-10U) is generally provided to increase the efficiency of the conversion of the asphalt into oil. The N, N-Dimethyl 9-Decenamide may present in the composition alone or as part of a composition including N, N-Dimethyl 9- Decenamide, such as Steposol® CITRI-MET, which includes Met-10U, surfactant emulsifiers, orange terpenes, and sodium carbonate. N, N-Dimethyl 9-Decenamide may be present in the composition in an amount in the range of from 5 to 30 vol.% of the composition.

[0015] Regarding the alkanes, alkanes are generally provided to help accelerate the liquefaction of the asphalt. The alkanes used in the composition may be xylene, toluene, heptane or any combination thereof. The alkane component of the composition may make up the balance of the composition after taking into account the amount of N, N-Dimethyl 9-Decenamide and aromatic petroleum distillate included in the composition based on the above disclosed vol.% ranges.

[0016] Non-limiting examples of specific compositions suitable for use in step 110 include the following: [0017] Example 1 : 70 to 95 vol.% Aromatic 100, 5 to 25 vol.% N, N-Dimethyl 9- Decenamide, and balance of xylene. Additional toluene or heptane may also be added as part of the alkane component of the composition.

[0018] Example 2: 70 to 95 vol.% Aromatic 150, 5 to 25 vol.% N, N-Dimethyl 9- Decenamide, and any combination of xylene, heptane and toluene making up the balance.

[0019] Example 3: 70 to 95 vol.% Aromatic 200, 5 to 25 vol.% N, N-Dimethyl 9- Decenamide, and any combination of xylene, heptane and toluene making up the balance.

[0020] In an alternate embodiment, the composition does not include an aromatic petroleum distillate. In such embodiments, the composition will include more alkane to compensate for the absence of the aromatic petroleum distillate. In one embodiment, the composition includes from 70 to 95 vol% alkane, such as heptane, and 5 to 30 vol.% N, N-Dimethyl 9-Decenamide. If a composition such as Citri-Met is used for the N, N- Dimethyl 9-Decenamide, then the composition may include 20 vol.% or more of Citri-Met.

[0021] Step 110 generally comprises combining the asphalt shingles and the composition in order to liquefy the asphalt component of the shingles. Any manner of combining the composition and the shingles can be used. In some embodiments, combining the shingles and composition is an agitation-free method. For example, shingles may simply be deposited into a tank containing the composition, with no additional stirring or mixing required. Agitation is generally not required because the composition used will actively liquefy the asphalt without need for mixing or the like.

[0022] It is envisioned that the entire system will be built to accommodate having the shingles immersed in the solvent for approximately 20 minutes. Experiments have shown that the predominant volume of asphalt has dissipated into the solvent/oil mixture within approximately 16 minutes. The immersion tank does not have to be deep or long, the critical factor for recycling the asphalt of the shingle is the time it is exposed to the moving solvent mixture.

[0023] In some embodiments, the shingles are transported through the tank via a conveyor belt extending from one end of the tank to the other. In such embodiments, the conveyor can be immersed in the composition to allow for interaction between the shingles and the composition. In some embodiments, the tank is fitted with nozzles to keep the composition moving over the shingles with a high level of pressure.

[0024] In some embodiments, the composition is introduced into the tank along with a water content. Any suitable amount of water can be added into the tank along with the composition. In some embodiments, the water is added at an amount of 10 to 20% of the volume of the entire tank used in step 110. The water can be added to the tank separately from the composition, or can be mixed with the composition before or as it is introduced into the tank. In some embodiments, the mixture of water and composition is introduced into the tank with the use of a pump designed to cavitate the water and chemical composition. The energy released at the edge of the cavitating blades of the pump will allow a percentage of hydrogen from the water to be bonded to the oil component, which will result in the manufacture of lighter oil. Combining the shingles with the composition, along with the use of cavitation will enhance the molecular bonding of certain elements and increase the volume of usable benzenes produced. As described in greater detail below, the mixture of water and composition introduced into the tank may also include some asphalt or oil, such as when some amount of recirculation of recovered asphalt/oil is used as part of the process.

[0025] As discussed previously, the composition used in step 110 will rapidly liquefy the asphalt component of the shingles. The interaction between the composition and the shingles may also produce volatile organic compounds. In such embodiments, the tank may further be equipped with a system for capturing any VOCs produced in step 110. Any such VOCs captured can be cooled and collected for further use, including incorporation back into the method described herein.

[0026] In some embodiments, step 110 results in the mass balance of the composition to asphalt becoming overburdened with liquid asphaltenes, which results in a thickening of the mixture of asphalt/usable oil and the composition. In such embodiments, a thinning amount of the composition can be added to the mixture during step 110 to maintain a higher API number in the oil

[0027] With respect to step 120, usable oil is removed from the tank after combining the shingles and the composition and liquefying the asphalt component. In some embodiments, the tank includes a draining system to collect and remove from the tank the asphalt that has been liquified and converted to usable oil. Generally speaking, the draining system will collect and remove from the tank a combination of the usable oil and the composition used to liquefy the asphalt component of the shingles. Water may also be present in the material collected by the draining system in embodiments where water is introduced into the tank along with the composition as described previously.

[0028] As discussed in greater detail below with respect to FIG. 2, the usable oil removed from the tank may be used in one or more different ways. In some embodiments, the removed usable oil or a portion thereof, is recirculated back into the tank, such as via use of the cavitation pump. In such embodiments, the usable oil may also include a water content and/or may be supplemented with additional water as part of recirculating the usable oil back into the tank. Recirculating the usable oil back into the tank can assist with further liquefaction of asphalt from subsequent shingles introduced into the tank. In other embodiments, the usable oil or a portion thereof is sent to an oil/water separator to separate any water content present in the usable oil removed from the tank. Any suitable technique for separating the oil and water components of the usable oil removed from the tank can be used. In some embodiments, oil and water separation is accomplished by pumping the oil and water mixture through an oil/water separator. In another option, the oil and water is pumped into a gunbarrel tank where it will separate. Separated oil can then be treated as a final product of the method described herein, while separated water can be recycled back into the method, such as being introduced into the tank with the composition and shingles. Product oil may be held in an oil sell tank. Separated water can be held in a holding tank prior to being reintroduced into the tank where composition and shingles are combined in step 110. Separated water can also be used in subsequent washing steps discussed in greater detail below.

[0029] With respect to step 130, fiberglass material having some or all asphalt removed therefrom is removed from the tank and subjected to washing in order to remove any residual asphalt and/or oil from the fiberglass. In some embodiments, the fiberglass continues to move along the conveyor provided to move the shingle through the tank, until the fiberglass reaches a far end of the tank and is removed from the tank. Once removed from the tank, the fiberglass is subjected to washing to remove residual asphalt and/or oil not removed from the fiberglass during step 110. In some embodiments, the fiberglass is conveyed under a set of spray nozzles that will spray high pressure water over the fiberglass to remove the remaining hydrocarbons. Oil and water washed from the fiberglass can be captured as it runs off of the fiberglass and conveyor. In some embodiments, the captured oil and water mixture is transported to an oil/water separator, such as oil/water separators described previously. Separated water can be reused to wash subsequent fiberglass removed from the tank, or for any other process carried out in the method disclosed herein that requires water. Separated oil can be sent to an oil tank for storage until the oil is sold. Washed fiberglass can then be dried and either bailed or shredded, at which point the material can be sold or reused and repurposed.

[0030] With respect to step 140, sand and/or rock that has been separated from the shingles can be collected, removed from the tank, and washed of residual asphalt and/or oil. In some embodiments, the sand/rock component of the shingle is removed from the shingle as part of the asphalt being removed from the shingle. The rock/sand then falls away from the asphalt and may collect at the bottom of the tank. In some embodiments, the rock/sand is pushed out of the tank via, e.g., an auger. This process carries oil and water with the rock/sand, such that when the rock is removed from the tank, it may initially be transported to a holding tank for draining oil and water from the rock. The rock may then be subjected to washing, such as by conveying the rock under high pressure nozzles that will spray water at the rock and remove any remaining oil. The cleaned rock may then be subjected to drying, such as by dropping the rock down a tall shaft. After drying, the rock may be stored for later sale or reuse. Oil and water washed from the rock may be transported to an oil/water separator as previously described with respect to the oil/water mixture washed from the fiberglass in step 130 or obtained from combining the shingles and the composition in step 110.

[0031] With reference to step 150, oil and water mixtures obtained from any of the usable oil removed from the tank in step 120, the washing of fiberglass in step 130 and/or washing rock in step 140 are subjected to separation processes in order to separate water from oil. As described in greater detail above, this separation can take place using any suitable equipment, such as oil/water separators. In some embodiments, all oil and water mixtures obtain from the process 100 are sent to the same oil/separator, while in other embodiments, individual oil/water separators are provided for each oil/water mixture produced. [0032] As described previously, separated water obtained from step 150 is recirculated to the tank in step 160, such as being mixed with the composition introduced into the tank in step 110 or being separately introduced into the tank in step 110. As also described in greater detail previously, in some embodiments, the recirculated water is introduced into the tank via a cavitation pump.

[0033] With reference to FIG. 2, a system 200 suitable for carrying out embodiments od the method 100 described previously is shown. The system 200 can generally include any of the equipment, including piping, valves, pumps, etc., required for carrying out the steps of method 100 and for transporting materials in the manner described previously. In some embodiments, the system 200 will generally include a tank 210 in which shingles, the composition and water are introduced in order to remove asphalt from shingles and produce a usable oil. As shown in FIG. 2, the tank is generally in fluid communication with a source of shingles and with a source of the composition, which may also include a water content. As also shown in FIG. 2, the tank 210 may be equipped with a hood 211 for capturing VOCs produced as a result of step 110 and the overall process described herein. As described previously, tank 210 generally includes a draining system for removing usable oil produced from the asphalt separated from the shingles. In some embodiments, this usable oil, which may include a water component, is either recirculated to tank 210 via cavitation pump 220, or send to an oil water separator 230.

[0034] With continued reference to FIG. 2, conveyors may be used to transport fiberglass and rock from the tank 210 to respective washing tanks. Washing tank 240 may be used to wash residual oil from fiberglass, while washing tank 250 may be used to wash residual oil from rock. As shown in FIG. 2, separated water produced from oil/water separator 230 may be used as the wash water for either of fiberglass wash tank 240 or rock wash tank 250. While washed fiberglass and rock will be removed from the wash tanks 240, 250 and stored for future use, processing or sale, the oil and water mixture washed from the fiberglass and rock will be sent to oil/water separator 230 for separation of these components. While the separated water may be reused in the system 200 in one or more ways as previously described (e.g., recirculated to tank 210, used as wash water in washing tanks 240, 250), separated oil is generally treated as a product of the overall system and is transported to a holding tank 260 for subsequent sale. [0035] While not shown in FIG. 2, the system may further include a programmable logic computer (PLC) design to automate the entire method with little to no human intervention required in order to provide continuous treatment of the shingles feed into the system.

[0036] From the foregoing, it will be appreciated that specific embodiments of the invention have been described herein for purposes of illustration, but that various modifications may be made without deviating from the scope of the invention. Accordingly, the invention is not limited except as by the appended claims.