Warm mix asphalt production system and method

A method of providing warm mix asphalt, the method comprising the steps of:

• providing a rotating drum configured to receive at an aggregate receiving end aggregate material, and further configured to create hot mix asphalt with drum exit temperatures in excess of 275 degrees Fahrenheit;
• providing an asphalt expander configured to receive heated asphalt cement and mix in water at a rate of between 1% to 4% water weight to A/C weight, and thereby form an asphalt foam without contacting any moving parts within said asphalt expander;
• the asphalt foam being of a consistency to coat aggregate material at a lower aggregate material temperature;
• and
• distributing said asphalt foam within said rotating drum and contacting heated aggregate moving therethrough and thereby creating warm mix asphalt with a rotating drum exit temperature of between approximately 220 degrees to 275 degrees Fahrenheit;
• wherein said water is substantially clean water, being free from material which would substantially affect production of asphalt foam upon mixture of said water with said A/C.

A method of creating warm mix asphalt, the method comprising the steps of:

• providing a rotating drum configured to receive at an aggregate receiving end aggregate material;
• providing an asphalt expander configured to receive heated A/C, mix therein clean water at a rate of between 1% to 4% water weight to A/C weight, and thereby form an asphalt foam without contacting any moving parts within said asphalt expander;
• and
• distributing said asphalt foam within said rotating drum and contacting heated aggregate moving therethrough and thereby creating warm mix asphalt with a drum exit temperature of between 220 and 275 degrees Fahrenheit further comprising the steps of:
• providing a controlled amount of water to said asphalt expander and forming a curtain of flowing water inside said asphalt expander.

An asphalt production method comprising the steps of:

• providing a counter-flow asphalt plant rotating drum;
• providing an asphalt expander configured to accept asphalt cement (A/C) and generate an expanded asphalt foam;
• providing measured and controlled amounts of water to said asphalt expander;
• selectively providing measured amounts of A/C to a plurality of internal drum A/C delivery pipes;
• wherein said plurality of internal A/C delivery pipes comprises a asphalt cement internal drum delivery pipe and a expanded asphalt injection pipe assembly;
• providing an asphalt cement check valve between said asphalt expander and said means for selectively providing measured amounts of asphalt cement;
• wherein said asphalt expander is free of any moving internal parts therein and comprises:
• an asphalt expander material input top end;
• asphalt expander material output bottom end;
• a longitudinal asphalt expander axis extending from a central location at said asphalt expander material input top end to a central location at said asphalt expander material output bottom end;
• a double side wall pipe extending from the top end to the bottom end, disposed coaxially about said longitudinal asphalt expander axis;
• asphalt expander interior central support shaft disposed along said longitudinal asphalt expander axis;
• an omni-directional flow diverter disposed on top of said support shaft and inside said material input top end;
• said omni-directional flow diverter configured to divert incoming A/C to only a plurality of peripheral locations inside said double sidewall pipe;
• providing a fluid injection ring disposed circumferentially around said longitudinal asphalt expander axis and configured to provide a ring of flowing fluid to contact the A/C at said plurality of peripheral locations;
• providing a plurality of expansion flow diverters disposed below said fluid injection ring configured to mix a flow of foam created as the ring of flowing fluid contacts the A/C being pumped into said asphalt expander;
• and
• said asphalt expander further having a plurality of ports for aiding in the flow of oil through a cylindrical void located coaxially about said longitudinal asphalt expander axis in said double side wall pipe.