System for utilizing recycled asphalt pavement and methods thereof

A method for utilizing recycled asphalt comprising:

• mixing input feed with at least one of an asphalt rejuvenator and virgin liquid asphalt in a pre-coater/mixer;
• allowing the at least one of the asphalt rejuvenator and the virgin liquid to soften residual asphalt in the input feed and encapsulate any fine particles;
• discharging the mixture into a spiral section;
• feeding the mixture into a rotary dryer comprising a counterflow zone and a temperature elevation zone;
• activating the drying process and directing a heated air stream at a point approaching the center of the rotary dryer, the heated air stream created by firing an industrial burner into an insulated combustion chamber located outside the rotary dryer;
• allowing a portion of the heated air to escape through the counterflow zone and into the temperature elevation zone;
• liberating surface moisture from the mixture along with a portion of the heated air via an outlet;
• feeding the mixture through an air baffle into the temperature elevation zone of the dryer;
• introducing additional additives to the mixture via a material entry collar;
• allowing the heated air stream to encounter one or more air dams adapted to increase the dwell time and interaction with the mixture as it is mixed with flights;
• introducing at least one of additional rejuvenator, liquid asphalt, or additional fillers to the mixture via one or more injection lines;
• processing the exhaust from the system by allowing the exhaust from the temperature elevation zone to proceed through a low velocity knock out block to promote the separation of any particulate matter that has become entrained in the air stream;
• and
• discharging a finished mixture.

A system for utilizing recycled asphalt comprising:

• a pre-coater for mixing an input feed with at least one of asphalt rejuvenator and virgin liquid asphalt and discharging the mixture;
• a spiral section adapted to receive the discharged mixture, the spiral section comprising a drum spiral section adapted to allow the at least one of asphalt rejuvenator and virgin liquid asphalt to soften any residual asphalt in the discharged mixture and encapsulate any fine particles;
• a rotary dryer comprising a counterflow zone for liberating surface moisture from the mixture and a temperature elevation zone comprising one or more air dams adapted to allow for dwell time;
• a burner for creating a heated air stream within the rotary dryer;
• a material entry collar for introducing additional additives into the mixture;
• one or more injection lines for introducing one or more of additional rejuvenator, liquid asphalt, or additional fillers to the mixture;
• a low velocity knock out block for promoting the separation of any particulate matter in the air stream;
• and
• a discharge for discharging the finished mixture.