Patent Grant
10494172
The present invention relates generally to storage systems, and more particularly, to portable asphalt emulsion storage facilities capable of storing asphalt emulsions at sub-zero temperatures.
Asphalt emulsions have many uses. One typical use is in road repair. In one such example, a water-based asphalt emulsion is mixed with aggregate to perform spray injection patching of potholes in roadways. To perform spray injection patching, a truck towable trailer is provided, which includes a heated tank containing the emulsion. The emulsion is pumped from the tank to a spraying wand where the emulsion is mixed with the aggregate as the emulsion is applied to the target area of the roadway.
The tank for the truck towable trailer can only hold a limited amount of emulsion (e.g. 300 gallons) because the tank must be able to be safely transported on public roadways with typical towing vehicles owned by most cities and states. Thus, the tank must be refilled with some frequency. This requires the tank to be towed to a refill facility, which is often in an inconvenient location. Refilling stations are often inconvenient (i.e. a considerable distance from the roadway repair work being performed) because they are in fixed locations not typically near the roadway work being performed. Therefore, the truck driver must take the time to drive to and from the work site when refilling the towed tank.
Providing a conveniently located storage tank is not often possible because the emulsion must be maintained at an elevated temperature (e.g. 125-175 degrees F.) in order to keep the emulsion in its flowable state. Thus, in cold weather, and particularly sub-freezing temperature weather, the emulsion must be kept heated. Conventional storage systems are, therefore, not suitable for being exposed to cold weather. And it is not financially feasible to move a permanent storage facility or to erect many new permanent facilities.
Therefore, there is a need to provide a portable storage system for asphalt and other like material that is required to be maintained at a particular constant heated temperature even in sub-zero ambient temperatures.
The disclosure includes a portable storage system for asphalt and other like material that is required to be maintained at a particular constant heated temperature even in sub-zero ambient temperatures. The system may include an exterior covering over a frame to define an enclosure. The frame defines an interior space where an insulated tank resides. The tank is heated. The interior of the enclosure may be heated. Rails provided along a vertical surface of the enclosure and extending above the roof of the enclosure allow the entire system to be loaded as a roll-off load on a truck. A plurality of lugs with apertures therethrough extend beyond the exterior surface of the enclosure to enable the enclosure to be lifted by cranes and tied down during transport.
One or more access doors or hatches can be provided to the enclosure to permit access to the interior of the enclosure.
Additional heater components can be provided to heat the interior of the enclosure outside of the tank.
The disclosure also includes a method of portably storing flowable material in environments with sub-freezing temperatures. The method includes providing an enclosure having an interior. A storage tank is provided within the enclosure. The storage tank includes a heat exchanger disposed within the tank to heat any contents of the tank. A heating system is provided to heat the interior of the enclosure. The enclosure is rotated from a vertical orientation to a horizontal orientation such that a pair of rails protrudes below the enclosure. The enclosure is loaded onto a transport vehicle in the horizontal orientation. The enclosure is offloaded from the transport vehicle and rotated back to the vertical orientation. The enclosure further can be lifted via one or more lugs protruding from the enclosure.
Additional features of certain embodiments will be described throughout this application.
The above summary is not intended to limit the scope of the invention, or describe each embodiment, aspect, implementation, feature or advantage of the invention. The detailed technology and preferred embodiments for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the present invention.
While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.
In the following descriptions, the present invention will be explained with reference to various exemplary embodiments. Nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention.
Referring specifically to
The frame 104 comprises a plurality of vertically spaced apart horizontal frame members 106 spanning between vertical corner members 107. The frame 104 defines an interior space where an insulated tank 108 resides. The exterior covering 102 panels are secured to the frame members 106, 107. The top horizontal frame members 106a can be angled upward from the horizontal to define a pitch to the roof panels 103 of the exterior covering 102.
In one example embodiment, a heating system 110 is disposed inside the tank 108, which is disposed inside of the enclosure 105. The heating system 110 is sized to heat the tank contents by circulating heated liquid though heating pipes in communication with the tank 108.
A pair of rails 112 are secured to the frame along the rear side of the frame. The rails 112 extend from a base of the enclosure upward vertically and protrude above the top of the roof 103 of the enclosure.
The rails 112 are rigid beams (e.g. steel) and are laterally spaced apart by a distance to allow the entire portable asphalt emulsion storage system 100 to be transported flat by truck like a roll-off dumpster or on a flat train car in a horizontal orientation.
As can be seen in
A plurality of flanges or lugs 114 with apertures defined therethrough can be secured at various points along the frame members to enable the system 100 to be lifted by a crane. The lugs 114 protrude beyond the exterior covering 102. The lugs 114 are also useful for tying the enclosure down during transport. The lugs 114 can be located in any suitable position such as vertically spaced along a front vertical side and horizontally spaced apart at the top of the frame (at the highest point of the roof). The lugs 114 can also be positioned elsewhere, or additional (or fewer) lugs can be provided in addition to those positions shown in the figures. The lugs 114 can alternatively be attached directly to the tank 108.
A bottom access door 116 is provided to the enclosure to allow an operator to access the heating system or other equipment that may reside under the tank 108 or at the base of the tank. In addition, or alternatively, a removable panel 120 (shown in
An exterior control panel 118 can be provided to the exterior of the enclosure for a user to interact with the system. The control panel 118 can include a graphical user interface, physical control knobs and switches, or both, or other suitable means for operating and interacting with the system. The controls for the heating system can be included as part of the control panel or can be housed in a separate control panel. The control panel 118 can be housed inside of a lockable hatch to prevent unauthorized access.
A dispensing/filling port is provided inside of a secured enclosure or panel 119 in the exterior of the enclosure. The port is in fluidic communication with the contents of the tank 108. The dispensing/filling port allows the user to access the tank contents to refill his or her towed application unit. The port can also be used in a reverse direction to fill the tank 108. Alternatively, separate dispensing and filling ports can be provided.
The entire system 100 can be electrically powered. For example, 208V single phase power or 240V three-phase power can be supplied to power the heater, pump, electrical systems, agitator, etc. Alternatively, a fuel-powered power generator (e.g. gas, diesel, propane, natural gas, etc.) can be coupled to the system 100. The heating system can be fuel-powered. Batteries and solar cells can also be used to supply the power necessary for one of more aspects of the system. A hybrid combination of any of the preceding can also be utilized. Multiple redundant power systems can also be provided from a combination of the foregoing.
The system 100 is configured to allow for the outdoor storage of asphalt emulsion or any other liquid that needs to be kept at an elevated temperature (e.g. over 100° F.) while being stored in an environment that might experience sub-freezing (and even sub-zero ° F.) temperatures.
In an example embodiment, the heating system 110 can be configured as a radiant glycol-based heating system that provides passive heat to the tank's contents. Such heating system can be located entirely within the enclosure and includes a 37 kW circulation heater that is placed external to the tank in a horizontal position. Glycol is pumped through a heating element using a glycol circulation pump to heat the contents of the tank.
In another example of the heating system, a boiler is provided to heat a liquid that is pumped through a heat exchanger tube 111 located inside of the tank 108. This arrangement is shown in
In a further alternative illustrated in
A pumping system is also disposed adjacent to the tank 108. The pumping system includes a 2 inch electrically driven pump that is configured for asphalt emulsion as is known in the art. The pump system can also be a 3 inch, 4 inch or other size without departing from the scope of the invention. The pump has the capability to run in either direction to allow for loading or unloading of material to/from the tank. The pump includes jacketed heads that allow the heated glycol to be pumped through the main areas of the pump to keep it hot for cold weather use.
The system 100 can include a means to measure the level of material in the tank. In one example embodiment the level is monitored via a Pulse Burst Radar Level Transmitter that is designed to be used in high temperature applications. The level monitor can be remotely monitored from any location, including via an exterior control panel and wirelessly via a central computer remote from the storage system's location when coupled to the level transmitter.
In another embodiment, a manual float tank level gauge can be used to provide a level measurement for the material in the tank. Multiple level monitoring means can be provided simultaneously as well.
The control panel 118 is mounted on the outside of the enclosure. The control panel can be painted steel and have a NEMA 4 rating. The panel includes a high level alarm and low flow alarm that protects the heating system.
The tank controls for loading and unloading can be push button controls mounted on a 30 foot retractable cable reel. Both the controls and the cable reel can be NEMA 4 rated.
The fill hose is mounted on a steel reel that is rated for use with a variety of hot oil products. The hose can be heated to help maintain temperature of the dispensed product during the dispensing operation. The heating can be by means of electric resistance wires or by circulating a heated liquid through a jacketed hose.
All external piping within the building can be heated by means of a heat trace cable and can be insulated.
The tank comprises ¼ inch steel that is rolled and welded at the seams. It has a conical bottom design to allow for 100% tank drainage and to avoid any residue build-up in the tank. The tank 108 can be insulated. In one embodiment, the tank 108 includes at least 2 inches of high density closed cell spray foam insulation which has an R-value of at least 12.
The tank can be mounted on legs 122 or a frame as shown in
The outer frame members 106 and 107 around the tank can be fabricated from ¼ inch steel angle that is welded in place around the tank.
The exterior or outer covering or panels 102 over the frame can be insulated with 2 inch board foam insulation having an R-rating of at least 7.5. The outer-facing exterior panels can be 22 gauge ribbed steel siding that is attached to the skeletal frame work with self-sealing steel screws. All of the seams are chalked with an adhesive sealant prior to assembly to ensure a watertight structure.
Referring to
The heating coils disclosed herein can be formed of 2 inch schedule 40 carbon steel pipe that is welded or formed into the shapes indicated herein.
A bottom plate 126 can be provided to enclose the bottom end of the enclosure 102. A bottom plate is illustrated in
When the system 100 is placed in the upright position for use, it will look like any other outbuilding. The exterior panels of the enclosure can be painted or manufactured in any color or pattern to match existing structures.
The pump controls can be mounted on a retractable cable reel that allows for one person to safely load and unload the tank. The tank fill hose can also be mounted on a retractable reel when not in use. The hose can be stored inside of the enclosure out of the elements.
The pulse burst radar level gauge ensures accurate measurement and provides remote level monitoring capability from any location.
All of the main components are housed under the tank 108 in a heated environment. An access hatch 120 in the enclosure's side panels can be removed for easy access to all components for any needed repairs or maintenance (shown in
The tank 108 and enclosure 102 can be formed in many different sizes and include heaters with many different power ratings. The inner tank can be manufactured out of different materials to allow for the storage of many types of products.
In certain embodiments, the tank can range from 2000 to 6000 gallons, however, larger and smaller tanks can be provided without departing from the scope of the invention. Additionally, the material storage inside of the enclosure can be configured as multiple individual smaller tanks. Each smaller tank can hold the same material, or the separate tanks can be configured to store different materials. If different materials, then separate pump and load/unload fluid paths can be provided within the enclosure.
The operator controls can include security access features and usage monitoring means such as a card reader system that will allow for self-serve customer use. A weight scale can be coupled to the control system to allow users to fill their tanks to specified weights as well.
A timer operated agitation System can be provided to the tank.
Certain embodiments of the present invention can provide certain features and benefits, including one or more of the following:
self-contained design allows for placement of tank at desired location with little containment issues and transportation is convenient since the tank itself is on a roll off frame for easy transportation from one location to the next;
below zero temperature storage of material;
self-contained heating unit prevents pumps from freezing;
pumping system easily accessible and self-contained;
unique loading/unloading procedure, including remote operation;
exterior panels of enclosure can be matched to fit design/style of buildings in tank location area;
no burners are used to heat tanks. Burners can cause damage to sensitive emulsion or other material sensitive to extreme temperature changes;
the tank is protected from the elements by the enclosure;
long term storage can be provided, especially in cold weather locations; and
convenient placement of the system near work sites.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. Moreover, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention.
This application claims the benefit of U.S. Provisional Application Ser. No. 62/144,292, filed on Apr. 7, 2015, which is hereby incorporated herein by reference in its entirety.
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