US4456523A
Expired / Lapsed
US
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Processes for producing high grade asphaltic materials from low grade bituminous materials and products resulting therefrom
Assignee: Ashland LLC
•
Filing: 1981-11-12
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Granted: 1984-06-26
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Expires: 2001-11-12
Abstract
Abstract Disclosed is a process for producing high grade asphaltic materials from low grade bituminous materials and the improved products resulting therefrom. More particularly, there is disclosed a process utilizing a particular type of oxidation catalyst in preparing novel high quality paving grade asphalt cements and novel roofing grade asphalts from poor and marginal quality bituminous materials. Also, the process can be used to prepare novel superior quality asphaltic materials from good quality bituminous flux feedstocks. This process consists of catalytically oxidizing asphalt fluxes, for example, in a single or multi-stage oxidation, using the particular type of catalyst disclosed hereinafter in each stage to chemically modify the flux so that the resultant asphaltic material meets physical requirements necessary for a finished product possessing good temperature susceptibility characteristics.
Inventors
- 👤 Donald D. Carlos
- 👤 Charles R. Gannon
- 👤 Robert H. Wombles
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-08 04:50
CPC Classifications
C; C10; C10C; C10C3/00; C10C3/02; C10C3/04
Claims Analysis
Total Claims: 60
Claim 1
Independent Claim
78 words
A process for producing a high grade asphaltic material, which process comprises oxidizing a bituminous material, having a viscosity of about 30 to 400 saybolt fural seconds at 210° F., at a temperature of about 350° F. to 550° F. by passing an oxidizing gas through the bituminous material in the presence of a catalytic amount of an inorganic carbonate salt or an organic carbonate salt as an oxidation catalyst, whereby said high grade asphaltic material is produced.
Claim 2
Dependent Claim
78 words
A process for producing a high grade asphaltic material, which process comprises oxidizing a bituminous material, having a viscosity of about 30 to 400 saybolt fural seconds at 210° F., at a temperature of about 350° F. to 550° F. by passing an oxidizing gas through the bituminous material in the presence of a catalytic amount of an inorganic carbonate salt or an organic carbonate salt as an oxidation catalyst, whereby said high grade asphaltic material is produced.
Claim 3
Dependent Claim
107 words
A process for producing a high grade paving asphaltic material, which process comprises oxidizing a bituminous material, containing by weight about 10 to 20% asphaltenes, about 15 to 25% saturates and about 20 to 35% polar compounds, with the remainder being substantially aromatics, and having a viscosity of about 30 to 400 saybolt fural seconds at 210° F., at a temperature of about 350° F. to 550° F. by passing an oxidizing gas through the bituminous material in the presence of a catalytic amount of an inorganic carbonate salt or an organic carbonate salt as an oxidation catalyst, whereby said high grade paving asphaltic material is produced.
Claim 4
Dependent Claim
107 words
A process for producing a high grade paving asphaltic material, which process comprises oxidizing a bituminous material, containing by weight about 10 to 20% asphaltenes, about 15 to 25% saturates and about 20 to 35% polar compounds, with the remainder being substantially aromatics, and having a viscosity of about 30 to 400 saybolt fural seconds at 210° F., at a temperature of about 350° F. to 550° F. by passing an oxidizing gas through the bituminous material in the presence of a catalytic amount of an inorganic carbonate salt or an organic carbonate salt as an oxidation catalyst, whereby said high grade paving asphaltic material is produced.
Claim 5
Dependent Claim
116 words
A process for producing a high grade roofing, shingle saturate or shingle coating asphaltic material, which process comprises oxidizing a bituminous material, containing by weight about 5 to 15% asphaltenes, about 10 to 35% saturates and about 20 to 35% polar compounds, with the remainder being aromatics, and having a viscosity of about 30 to 400 saybolt fural seconds at 210° F., at a temperature of about 350° F. to 550° F. by passing an oxidizing gas through the bituminous material in the presence of a catalytic amount of an inorganic carbonate salt or an organic carbonate salt as an oxidation catalyst, whereby said high grade roofing, shingle saturate or shingle coating asphaltic material is produced.
Claim 6
Dependent Claim
116 words
A process for producing a high grade roofing, shingle saturate or shingle coating asphaltic material, which process comprises oxidizing a bituminous material, containing by weight about 5 to 15% asphaltenes, about 10 to 35% saturates and about 20 to 35% polar compounds, with the remainder being aromatics, and having a viscosity of about 30 to 400 saybolt fural seconds at 210° F., at a temperature of about 350° F. to 550° F. by passing an oxidizing gas through the bituminous material in the presence of a catalytic amount of an inorganic carbonate salt or an organic carbonate salt as an oxidation catalyst, whereby said high grade roofing, shingle saturate or shingle coating asphaltic material is produced.
Claim 7
Dependent Claim
54 words
The process of claims 1, 2 or 3, wherein said bituminous material is selected from the group consisting of slurry oil, coal tar, coal tar pitch, petroleum pitch, cycle oils, asphalt, cylinder stock, and liquid derived from shale, coal liquefaction materials and aromatic furfural extracts from solvent refining of lube oil and mixtures thereof.
Claim 8
Dependent Claim
17 words
The process of claim 2, wherein said oxidation is carried out for about 1/2 to 6 hours.
Claim 9
Dependent Claim
17 words
The process of claim 3, wherein said oxidation is carried out for about 2 to 35 hours.
Claim 10
Dependent Claim
30 words
A process according to claim 1, wherein said asphaltic material has a penetration of from about 12 to 300 and a softening point of about 110° F. to 250° F.
Claim 11
Dependent Claim
29 words
A process according to claim 2, wherein said asphaltic material has a penetration ranging from about 40 to 300 and a softening point of about 110° to 140° F.
Claim 12
Dependent Claim
82 words
A process according to claim 3, wherein said asphaltic material is (1) asphalt for built-up roofing having penetration of from about 12 to 60 and a softening point of from about 130° to 230° F., (2) roofing shingle saturant having a penetration of from about 50 to 90 and a softening point of from about 110° to 140° F. or (3) roofing coating asphalt having a penetration of about 15 to 25 and a softening point of about 210° to 250° F.
Claim 13
Dependent Claim
29 words
A process according to claims 1, 2 or 3, wherein said catalyst is added in an amount ranging from about 0.1 to 2.0 weight percent of said bituminous material.
Claim 14
Dependent Claim
29 words
A process according to claims 1, 2 or 3, wherein said catalyst is added in an amount ranging from about 0.01 to 5.0 weight percent of said bituminous material.
Claim 15
Dependent Claim
29 words
A process according to claims 1, 2 or 3, wherein said catalyst is added in an amount ranging from about 0.1 to 1.0 weight percent of said bituminous material.
Claim 16
Dependent Claim
49 words
The process of claims 1, 2 or 3, wherein the reaction is conducted at a pressure of one atmosphere or above and the oxidizing gas is passed through the flux material at a rate ranging from about 15 to 35 cubic feet per hour, per ton, of flux material.
Claim 17
Dependent Claim
25 words
The process of claims 1, 2 or 3, wherein the process is carried out at a temperature of about between 480° F. and 550° F.
Claim 18
Dependent Claim
27 words
The process of claims 1, 2 or 3, wherein the oxidation process is carried out at a temperature of above the melting point of said bituminous material.
Claim 19
Dependent Claim
19 words
The process of claims 1, 2 or 3, wherein the catalyst is a mixture of sodium carbonate and bicarbonate.
Claim 20
Dependent Claim
16 words
The process of claims 1, 2 or 3, wherein said catalyst is an inorganic carbonate salt.
Claim 21
Dependent Claim
14 words
The process of claim 17, wherein said catalyst is sodium carbonate or sodium sesquicarbonate.
Claim 22
Dependent Claim
11 words
The process of claim 18, wherein said catalyst is sodium sesquicarbonate.
Claim 23
Dependent Claim
11 words
The process of claim 18, wherein said catalyst is sodium carbonate.
Claim 24
Dependent Claim
11 words
The process of claim 17, wherein said catalyst is sodium bicarbonate.
Claim 25
Dependent Claim
39 words
The process of claims 1, 2 or 3, wherein the catalyst is a carbonate or bicarbonate salt of calcium, magnesium, cerium, barium, strontium, lithium, ammonium, potassium, bismuth, lead, tetraalkylphosphonium, tetraarylphosphonium, tetraalkylammonium, trialkylammonium, dialkylammonium, transition metals or rare earth metals.
Claim 26
Dependent Claim
35 words
The process according to claims 1, 2 or 3, wherein the saturate content by weight of said asphaltic material is from about 25% to 85% of the saturates contained in said bituminous feedstock flux material.
Claim 27
Dependent Claim
34 words
The process according to claims 1, 2 or 3, wherein said asphaltic material has by weight from about 25% to about 75% of the saturates contained in non-catalyzed oxidized identical bituminous feedstock flux material.
Claim 28
Dependent Claim
34 words
The process according to claims 1, 2 or 3, wherein said asphaltic material has from about 25% to about 75% of the saturates contained in Lewis acid catalyzed oxidized identical bituminous feedstock flux material.
Claim 29
Dependent Claim
18 words
The process of claims 1, 2 or 3, wherein the process is carried out in a continuous fashion.
Claim 30
Dependent Claim
18 words
The process of claims 1, 2 or 3, wherein the process is carried out in a batch fashion.
Claim 31
Dependent Claim
33 words
The process of claims 1, 2 or 3, wherein said catalyst is admixed with water or with liquid bituminous material and then the admixture is introduced into the bituminous material to be oxidized.
Claim 32
Dependent Claim
20 words
The process of claims 1, 2 or 3, wherein said catalyst is introduced into said bituminous material in particulate form.
Claim 33
Dependent Claim
25 words
The process of claims 1 or 3, wherein prior to oxidation, a paraffin is introduced into the bituminous material to increase the saturate content thereof.
Claim 34
Dependent Claim
38 words
The process of claims 2, 5 or 8, wherein said asphaltic material consists essentially by weight of about 15 to 25% asphaltenes, about 3 to 15% saturates, about 30 to 50% polar compounds and 25 to 35% aromatics.
Claim 35
Dependent Claim
39 words
The process of claims 3, 6 or 9, wherein said asphaltic material consists essentially by weight of about 35 to 45% asphaltenes, about 5 to 30% saturates, about 30 to 40% polar compounds and about 10 to 30% aromatics.
Claim 36
Dependent Claim
87 words
A non-corrosive high grade paving asphaltic material consisting essentially of by clay gel analysis using n-pentane solvent about 15% to 25% pentane insoluble asphaltenes, about 3% to 15% pentane soluble saturates, about 30% to 50% pentane soluble polar compounds and about 25% to 35% pentane soluble aromatics, by weight, and wherein the sum of the asphaltenes and polar compounds is at least about 55% by weight and wherein the saturate content thereof is 25% to 80% by weight less than the saturate content of the starting flux.
Claim 37
Dependent Claim
87 words
A non-corrosive high grade paving asphaltic material consisting essentially of by clay gel analysis using n-pentane solvent about 15% to 25% pentane insoluble asphaltenes, about 3% to 15% pentane soluble saturates, about 30% to 50% pentane soluble polar compounds and about 25% to 35% pentane soluble aromatics, by weight, and wherein the sum of the asphaltenes and polar compounds is at least about 55% by weight and wherein the saturate content thereof is 25% to 80% by weight less than the saturate content of the starting flux.
Claim 38
Dependent Claim
92 words
A non-corrosive high grade roofing, shingle saturant or shingle coating asphaltic material consisting essentially of by clay gel analysis using n-pentane solvent about 35 to 45% pentane insoluble asphaltenes, about 5 to 30% pentane soluble saturates, about 30 to 40% pentane soluble polar compounds and about 10 to 30% pentane soluble aromatics, by weight, and wherein the sum of the asphaltenes and polar compounds is at least about 70% by weight and wherein the saturate content thereof is 25 to 85% by weight less than the saturate content of the starting flux.
Claim 39
Dependent Claim
92 words
A non-corrosive high grade roofing, shingle saturant or shingle coating asphaltic material consisting essentially of by clay gel analysis using n-pentane solvent about 35 to 45% pentane insoluble asphaltenes, about 5 to 30% pentane soluble saturates, about 30 to 40% pentane soluble polar compounds and about 10 to 30% pentane soluble aromatics, by weight, and wherein the sum of the asphaltenes and polar compounds is at least about 70% by weight and wherein the saturate content thereof is 25 to 85% by weight less than the saturate content of the starting flux.
Claim 40
Dependent Claim
27 words
The asphaltic material of claim 33 or 34, wherein the saturate content by weight is at least 75% less than the saturate content of the starting flux.
Claim 41
Dependent Claim
27 words
The asphaltic material of claim 33 or 34, wherein the saturate content by weight is at least 80% less than the saturate content of the starting flux.
Claim 42
Dependent Claim
25 words
The asphaltic material of claim 33 having a penetration ranging from about 40 to 300 and a softening point of about 110° to 140° F.
Claim 43
Dependent Claim
31 words
The asphalt material of claim 34 as an asphalt for built-up roofing having a penetration of about 12 to 60 and a softening point of about 130° F. to 230° F.
Claim 44
Dependent Claim
30 words
The asphalt material of claim 34 as a roofing shingle saturant having a penetration of about 50 to 90 and a softening point of about 110° F. to 140° F.
Claim 45
Dependent Claim
30 words
The asphalt material of claim 34 as a roofing coating asphalt having a penetration of about 15 to 25 and a softening point of about 210° F. to 250° F.
Claim 46
Dependent Claim
27 words
The asphaltic material of claim 23 containing up to about 30,000 ppm sodium introduced by said asphaltic material having been prepared using a catalyst comprising sodium carbonate.
Claim 47
Dependent Claim
27 words
The asphaltic material of claim 34 containing up to about 30,000 ppm sodium introduced by said asphaltic material having been prepared using a catalyst comprising sodium carbonate.
Claim 48
Dependent Claim
96 words
A non-corrosive high grade paving asphaltic material made by the process of claim 2, said asphaltic material consisting essentially of by clay gel analysis using n-pentane solvent about 15% to 25% pentane insoluble asphaltenes, about 3% to 15% pentane soluble saturates, about 30% to 50% pentane soluble polar compounds and about 25% to 35% pentane soluble aromatics by weight and wherein the sum of the asphaltenes and polar compounds is at least about 55% by weight and wherein the saturate content is 25% to 85% by weight less than the saturate content of the starting flux.
Claim 49
Dependent Claim
100 words
A non-corrosive high grade roofing, shingle saturant or shingle coating asphaltic material made by the process of claim 3, and consisting essentially of by clay gel analysis using n-pentane solvent of about 35 to 45% pentane insoluble asphaltenes, about 5 to 30% pentane soluble saturates, about 30 to 40% pentane soluble polar compounds and about 10 to 30% pentane soluble aromatics by weight and wherein the sum of the asphaltenes and polar compounds is at least about 70% by weight and wherein the saturate content is 25 to 85% by weight less than the saturate content of the starting flux.
Claim 50
Dependent Claim
27 words
The asphaltic material of claim 43 or 44, wherein the saturate content by weight is at least 75% less than the saturate content of the starting flux.
Claim 51
Dependent Claim
27 words
The asphaltic material of claim 43 or 44 wherein the saturate content by weight is at least 80% less than the saturate content of the starting flux.
Claim 52
Dependent Claim
31 words
The asphaltic material of claim 43, as a paving grade asphalt cement having a penetration of about 40 to 300 and a softening point of about 110° F. to 140° F.
Claim 53
Dependent Claim
31 words
The asphaltic material of claim 44, as an asphalt for built-up roofing having a penetration of about 12 to 60 and a softening point of about 130° F. to 230° F.
Claim 54
Dependent Claim
30 words
The asphaltic material of claim 44, as a roofing shingle saturate having a penetration of about 50 to 90 and a softening point of about 110° F. to 140° F.
Claim 55
Dependent Claim
30 words
The asphaltic material of claim 44, as a roofing coating asphalt having a penetration of about 15 to 25 and a softening point of about 210° F. to 250° F.
Claim 56
Dependent Claim
18 words
The asphaltic material of any of claims 43, 44, 45 or 46, wherein the catalyst comprises sodium carbonate.
Claim 57
Dependent Claim
13 words
The asphaltic material of claim 51 containing up to about 30,000 ppm sodium.
Claim 58
Dependent Claim
14 words
The process of claim 30 wherein said paraffin is a wax or a petrolatum.
Claim 59
Dependent Claim
13 words
The process of claim 53 wherein said paraffin is a branched chain paraffin.
Claim 60
Dependent Claim
10 words
The process of claim 54 wherein said paraffin is petrolatum.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1987-06-26 | 1987-12-26 | 1988-06-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1991-06-26 | 1991-12-26 | 1992-06-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1995-06-26 | 1995-12-26 | 1996-06-26 | $7700.00 | Window Closed / Lapsed |