Patent Publication Number: US-10323149-B2

Title: System, method, apparatus, means, and computer program product for recycling asphalt shingles

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a Divisional of U.S. patent application Ser. No. 14/826,458, filed Aug. 14, 2015 (now issued as U.S. Pat. No. 9,951,224), which claims priority from U.S. Provisional Patent Application No. 62/039,149, which was filed on Aug. 19, 2014. The disclosure of each of the referenced applications is hereby incorporated herein in its entirety by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates to recycling asphalt shingles. More particularly, the present disclosure relates to systems, methods, apparatuses, means, and computer program products for recycling asphalt shingles. The resultant asphalt mix output may be suitable for use as asphalt pavement or other asphalt based products. 
     BACKGROUND 
     Certain embodiments of shingles are formed from asphalt. Asphalt shingles may be removed during the replacement of a roof. The removed asphalt shingles may be discarded. More preferably the asphalt shingles may be recycled. For example, the recycled asphalt shingles may be recycled to form asphalt pavement. However, certain existing embodiments of methods for recycling asphalt shingles may insufficiently process the asphalt shingles such that chunks of the asphalt shingles undesirably remain in the resultant asphalt pavement. Accordingly, it would be desirable to more completely process asphalt shingles during recycling thereof to produce an asphalt mix output more suitable for usage as asphalt pavement. 
     SUMMARY OF THE DISCLOSURE 
     Embodiments of the present disclosure relate to recycling asphalt shingles for usage in asphalt pavement. The asphalt shingles may be melted and mixed with a fluid asphalt input in a preliminary mixing unit. This molten asphalt may then be directed to a primary mixing unit, at which the molten asphalt is mixed with an aggregate material and/or a recycled pavement material to form an asphalt mix output that is relatively low in, or substantially free of, solid chunks of asphalt shingles and suitable for usage as asphalt pavement. 
     In one aspect a method for producing asphalt mix is provided. The method may include mixing and heating a fluid asphalt input and an asphalt shingle input in a preliminary mixing unit to melt the asphalt shingle input and produce a molten asphalt. Additionally, the method may include directing the molten asphalt and a particulate input into a primary mixing unit. The method may further include mixing the molten asphalt with the particulate input to produce an asphalt mix output. 
     In some embodiments the method may additionally include directing a recycled asphalt input into the primary mixing unit. Further, the method may include mixing the recycled asphalt input with the molten asphalt and the particulate input to produce the asphalt mix output. The method may also include directing the molten asphalt through a strainer prior to directing the molten asphalt into the primary mixing unit. 
     In some embodiments the method may further include directing the molten asphalt to an intermediate tank before directing the molten asphalt into the primary mixing unit. Additionally, the method may include directing the fluid asphalt input to a bottom of the preliminary mixing unit. Further, the method may include grinding a plurality of asphalt shingles to produce the asphalt shingle input. The method may additionally include recirculating the molten asphalt at the preliminary mixing unit. 
     In an additional aspect a preliminary mixing unit for asphalt is provided. The preliminary mixing unit may include a tank. Further, the preliminary mixing unit may include a first inlet port connected to the tank and configured to receive an asphalt shingle input. The preliminary mixing unit may additionally include a second inlet port connected to the tank and configured to receive a fluid asphalt input. The preliminary mixing unit may further include a heater configured to heat the asphalt shingle input and the fluid asphalt input in the tank. The preliminary mixing unit may additionally include a mixer configured to mix the asphalt shingle input and the fluid asphalt input in the tank and melt the asphalt shingle input to produce a molten asphalt. The preliminary mixing unit may further include an outlet port configured to output the molten asphalt. 
     In some embodiments the preliminary mixing unit may further comprise a recirculation loop configured to recirculate the molten asphalt received from the outlet port. Additionally, the preliminary mixing unit may include a valve configured to selectively direct the molten asphalt through the recirculation loop. The preliminary mixing unit may further include a strainer positioned downstream of the outlet port. The second inlet port may be positioned proximate a bottom of the tank. 
     In an additional aspect a system for producing asphalt mix is provided. The system may include a preliminary mixing unit configured to receive an asphalt shingle input and a fluid asphalt input and output a molten asphalt. Further, the system may include a primary mixing unit configured to mix the molten asphalt with a particulate input to produce an asphalt mix output. 
     In some embodiments the primary mixing unit may be further configured to receive a recycled asphalt input and mix the recycled asphalt input with the molten asphalt and the particulate input to produce the asphalt mix output. The system may further include a strainer positioned downstream of the preliminary mixing unit and upstream of the primary mixing unit and configured to filter the molten asphalt. The system may additionally include an intermediate tank positioned downstream of the preliminary mixing unit and upstream of the primary mixing unit and configured to store the molten asphalt. 
     In some embodiments the system may also include a grinder configured to grind a plurality of asphalt shingles to produce the asphalt shingle input. The system may further include a recirculation loop configured to recirculate the molten asphalt at the preliminary mixing unit. The preliminary mixing unit may include a tank and a first inlet port configured to discharge the asphalt shingle input proximate a top of the tank. The preliminary mixing unit may further include a second inlet port configured to direct the fluid asphalt input to a nozzle positioned proximate a bottom of the tank. 
     These and other features, aspects, and advantages of the disclosure will be apparent from a reading of the following detailed description together with the accompanying drawings, which are briefly described below. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order to assist the understanding of embodiments of the disclosure, reference will now be made to the appended drawings, which are not necessarily drawn to scale. The drawings are exemplary only, and should not be construed as limiting the disclosure. 
         FIG. 1  schematically illustrates a system for producing asphalt mix including a mixing unit according to a first example embodiment of the present disclosure; 
         FIG. 2  schematically illustrates a system for producing asphalt mix including a preliminary mixing unit and a primary mixing unit according to an additional example embodiment of the present disclosure; 
         FIG. 3  schematically illustrates the system of  FIG. 2  including additional components according to an example embodiment of the present disclosure; 
         FIG. 4  schematically illustrates the system of  FIG. 2  further including an intermediate tank according to an example embodiment of the present disclosure; 
         FIG. 5  illustrates the preliminary mixing unit of the system of  FIGS. 2-4  according to an example embodiment of the present disclosure; 
         FIG. 6  illustrates a side view of a feed hopper of the system of  FIGS. 2-4  according to an example embodiment of the present disclosure; 
         FIG. 7  illustrates a partial top view of the feed hopper of  FIG. 6  according to an example embodiment of the present disclosure; 
         FIG. 8  illustrates a side view of a storage tank for a fluid asphalt input of the system of  FIGS. 2-4  according to an example embodiment of the present disclosure; 
         FIG. 9  illustrates an internal view of a tank of the preliminary mixing unit of the system of  FIGS. 2-4  according to an example embodiment of the present disclosure; 
         FIG. 10  illustrates an alternative internal view of the tank of  FIG. 9  according to an example embodiment of the present disclosure; 
         FIG. 11  illustrates a side view of the intermediate tank of  FIG. 4  according to an example embodiment of the present disclosure; 
         FIG. 12  illustrates an alternative side view of the intermediate tank of  FIG. 4  according to an example embodiment of the present disclosure; 
         FIG. 13  schematically illustrates a method for producing an asphalt mix according to an example embodiment of the present disclosure; and 
         FIG. 14  schematically illustrates a controller of the system of  FIGS. 2-4  according to an example embodiment of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The present disclosure now will be described more fully hereinafter with reference to the accompanying drawings. The disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. As used in this specification and the claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise. 
     As described herein, embodiments of the disclosure relate to producing an asphalt mix from recycled asphalt shingles. In this regard,  FIG. 1  illustrates a first embodiment of a system  100  for producing an asphalt mix output. The system  100  may be controlled by a controller  102  configured to control some or all of the operations described below. In some embodiments the controller  102  may comprise a programmable logic controller. Note that although the controller  102  is illustrated as a single, unitary device, in some embodiments the controller may be distributed across multiple separate devices that may separately or jointly control operation of various portions of the system  100 . 
     As illustrated, the system  100  may further include a mixing unit  104  (e.g. a drum mixer). The mixing unit  104  may include a mixer configured to mix a plurality of inputs. In some embodiments the primary mixing unit  204  may be employed in traditional asphalt mix production by combing a fluid asphalt input with the particulate input. Note that although use of a plurality of inputs are described below, fewer inputs or a greater number of inputs of the same or differing types may be employed in other embodiments. Further, the mixing unit  104  may be configured to heat the inputs. Thus, the mixing unit  104  may include a heater  106  that heats and dries the various inputs directed into the mixing unit. In this regard, production of asphalt ideally minimizes the water content therein to the greatest extent possible. 
     The mixing unit  104  may be configured to receive a particulate input  108 . The particulate input  108  may include a degree of moisture (e.g., due to being stored outdoors), which may be lessened by the heater  106 . The particulate input  108  may comprise sand, gravel, crushed stone, slag, recycled concrete, aggregates (geosynthetic aggregates), and/or any other particulate materials. 
     Further, the mixing unit  104  may be configured to receive a fluid asphalt input  110 . The fluid asphalt input  110 , also referred to as bitumen, is a black and highly viscous fluid form of petroleum. Thereby, the mixing unit  104  may mix the particulate input  108  with the fluid asphalt input  110  to form an asphalt mix output  112 , which may be delivered to a desired location and laid as asphalt pavement. 
     Use of recycled materials in the production of asphalt may be desirable in some embodiments. In this regard, certain asphalt-containing materials may be recycled to produce asphalt. Thus, for example, in some embodiments a recycled asphalt input  114  may be directed into the mixing unit  104 . The recycled asphalt input  114  may comprise recycled asphalt pavement. 
     Further, some embodiments of shingles are formed from asphalt. Accordingly, the mixing unit  104  may be additionally or alternatively configured to receive an asphalt shingle input  116 . The asphalt shingle input  116  may be provided as a plurality solids, rather than in a liquid form. The asphalt shingle input  116  may comprise used asphalt shingles or scraps or rejects from asphalt shingle production, or any other embodiment of asphalt shingles. Note also that although the present systems are particularly described herein as being configured to produce an asphalt mix output from asphalt shingles, various other asphalt-containing materials may be additionally or alternatively employed to form the asphalt mix output in accordance with embodiments of the present disclosure. The asphalt shingles and scrapes may be ground in a grinder or otherwise processed to produce pieces of asphalt shingles defining a relatively smaller size, which are employed as the asphalt shingle input  116 . Further, nails and other debris may be removed from the asphalt shingles during processing to produce the asphalt shingle input  116 . 
     However, production of the asphalt mix output  112  may not sufficiently process the asphalt shingle input  116  to a desired extent. In this regard, despite grinding the asphalt shingles prior to introduction into the mixing unit  104 , the asphalt shingles may not melt sufficiently to fully liquefy therein. In this regard, the asphalt included in asphalt shingles is typically much more stiff than asphalt binders included in the fluid asphalt input  110  typically employed to form asphalt pavement, and hence much more difficult to melt as a result. Accordingly, the asphalt mix output  112  may undesirably include solid chunks of asphalt shingles therein. The inclusion of solid asphalt pieces may cause the asphalt mix output  112  to fail to meet specifications required or desired for usage as asphalt pavement. In this regard, the solid asphalt pieces may cause the paving process to suffer from challenges in terms of forming a smooth surface and/or the pavement may suffer from premature wear and failure as a result of the asphalt shingle pieces loosening over time and/or failing to bind with the surrounding asphalt and aggregate. 
     Accordingly,  FIG. 2  illustrates a second embodiment of a system  200  for producing an asphalt mix output. The system  200  may be controlled by a controller  202  configured to control some or all of the operations described below. In some embodiments the controller  202  may comprise a programmable logic controller (PLC). Note that although the controller  202  is illustrated as a single, unitary device, in some embodiments the controller may be distributed across multiple separate devices that may separately or jointly control operation of various portions of the system  200 . 
     As illustrated, the system  200  may include a mixing unit  204  (e.g. a drum mixer), which may also be referred to as a primary mixing unit. The primary mixing unit  204  may include a mixer configured to mix a plurality of inputs. Note that although use of a plurality of inputs are described below, fewer inputs or a greater number of inputs of the same or differing types may be employed in other embodiments. Further, the primary mixing unit  204  may be configured to heat the inputs. Thus, the primary mixing unit  204  may include a heater  206  (e.g., an electric coil, a burner, a boiler, circulating hot fluid (e.g., oil or steam) that surrounds the tank, or any other embodiment of heat producer) that heats and dries the various inputs directed into the primary mixing unit  204 . In this regard, production of asphalt ideally minimizes the water content therein to the greatest extent possible. 
     The primary mixing unit  204  may be configured to receive a particulate input  208 . The particulate input  208  may include a degree of moisture (e.g., due to being stored outdoors), which may be lessened by the heater  206 . The particulate input  208  may comprise sand, gravel, crushed stone, slag, recycled concrete, aggregates (e.g., geosynthetic aggregates), and/or any other particulate materials. 
     Use of recycled materials in the production of asphalt may be desirable in some embodiments. In this regard, certain asphalt-containing materials may be recycled to produce asphalt. Thus, for example, in some embodiments a recycled asphalt input  214  may be directed into the primary mixing unit  204 . The recycled asphalt input  214  may comprise recycled asphalt pavement. 
     Further, the primary mixing unit  204  may be configured to receive a fluid asphalt input  210 . The fluid asphalt input  210 , also referred to as bitumen or a fluid asphalt binder, is black and highly viscous fluid form of petroleum. Further, the primary mixing unit  204  may be configured to receive an asphalt shingle input  216 . The asphalt shingle input  216  may comprise used asphalt shingles or scraps or rejects from asphalt shingle production, or any other embodiment of asphalt shingles. Note also that although the present systems are particularly described herein as being configured to produce an asphalt mix output from asphalt shingles, various other asphalt-containing materials may be additionally or alternatively employed to form the asphalt mix output in accordance with embodiments of the present disclosure. The asphalt shingles and scrapes may be ground in a grinder or otherwise processed to produce pieces of asphalt shingles defining a relatively smaller size, which are employed as the asphalt shingle input  216 . Further, nails and other debris may be removed from the asphalt shingles during processing to produce the asphalt shingle input  216 . 
     In the embodiment of a system  100  described above with reference to  FIG. 1 , fluid asphalt and asphalt shingle inputs are directly inputted to the mixing unit. However, as noted above, this configuration may result in the asphalt mix output undesirably including solid chunks of shingles or other solid recycled asphalt-containing materials. Accordingly, the system  200  illustrated in  FIG. 2  is configured to minimize the existence of any solid chunks of shingles or other solid recycled asphalt-containing materials in the asphalt mix output. 
     In this regard, the system  200  may further include a preliminary mixing unit  218  including a mixer. The preliminary mixing unit  218  may be configured to receive and mix a fluid asphalt input  210  and an asphalt shingle input  216 , which may be substantially similar to the fluid asphalt input  110  and the asphalt shingle input  116  described above. Accordingly, heat from the fluid asphalt input  210  and the mixing action from the preliminary mixing unit  218  may substantially entirely melt the asphalt shingle input  216 . Thereby, the preliminary mixing unit  218  may output a molten asphalt  220  to a primary mixing unit  204 . Accordingly, rather than directing the asphalt shingle input  216  directly to the primary mixing unit  204 , the asphalt shingle input may be melted through mixing with the hot fluid asphalt input  210  in the preliminary mixing unit  218 . Further, the system  200  may be configured to retain the molten asphalt  220  in fluid form during transport and introduction into the primary mixing unit  204  such that issues with respect to the asphalt from the shingles resolidifying and hampering mixing at the primary mixing unit may be avoided. 
     The primary mixing unit  204  may receive the molten asphalt  220  and combine it with a particulate input  208  and/or a recycled asphalt input  214 , which may be substantially similar to the particulate input  108  and the recycled asphalt input  214  described above, and which may be heated and mixed therein to form an asphalt mix output  212  suitable for use as an asphalt pavement. A controller  202 , which may be substantially similar to the controller  102 , may be employed to control the operations of the various components of the system  200 . 
     As a result of the solid chunks of shingles being substantially removed by mixing and melting the asphalt shingle input  216  with the fluid asphalt input  210 , the asphalt mix output  212  may also be substantially free of chunks of asphalt shingles. Thereby, the preliminary step of melting the asphalt shingle input  216  in the preliminary mixing unit  218  may reduce or remove issues with respect to the asphalt mix output  212  including solid chunks of shingles. Accordingly, the asphalt mix output  212  may define a quality substantially equal to that of asphalt mix which does not include asphalt shingles, whereas asphalt mix produced without the preliminary melting step may define a relatively inferior quality, as described above. Thus, issues with respect to employing recycled asphalt shingles in asphalt mix may be substantially avoided, while allowing for production of a relatively cheaper (e.g., due to the relatively inexpensive price of used shingles) and more environmentally conscious asphalt mix output. 
       FIG. 3  illustrates an embodiment of a system  200 ′ that is substantially similar to the system  200  illustrated in  FIG. 2 . However,  FIG. 3  illustrates additional details and components that may be included in the system. Note that the description of the system  200 ′ in some instances below includes alternate terminology that may more particularly describe the components and operation of the system  200 ′. 
     As variously described above with respect to  FIG. 2 , the present disclosure provides a system, method, means, computer program product, and apparatus to wet process the asphalt shingle input  216  with the fluid asphalt input  210  of various grades. The wet process refers to wetting the asphalt shingle input  216  materials with the hot fluid asphalt input  210 , in a separate process, prior to entering the primary mixing unit  204 . This process provides a stream of materials, integrated with existing asphalt plant mix components by means of the controller  202 . The molten asphalt  220  produced from the fluid asphalt input  210  and the asphalt shingle input  216  can be well regulated and metered (e.g., due to the fluid state thereof) and provides a better means of activating the residual asphalt binder contained in the asphalt shingle input for use in asphalt pavement construction. 
     As noted above, the residual asphalt contained in the asphalt shingle input  216  is often much harder/stiffer than typical paving grades of asphalt binders. This makes the residual asphalt, which generally has a range of about 15-22% in each of the shingles, much more difficult to activate or melt and make usable for mixing in a primary mixing unit. Accordingly, as described above, directing solid pieces of the asphalt shingle input  216  directly into a mixing unit (e.g., as described above with respect to the system  100  illustrated in  FIG. 1 ) may not fully melt the asphalt shingle input, resulting in chunks of the asphalt shingles remaining in the resultant asphalt mix output. However, as additionally described above, wetting and mixing the asphalt shingle input  216  in a separate process with the hot fluid asphalt input  210  prior to entering the primary mixing unit  204  significantly aides in the activation, melting and dispersion of the residual asphalt in the asphalt shingle input for use in asphalt pavement mixtures. 
     The asphalt shingle input  216  may be produced by a grinder  217  that performs a crushing or grinding process on asphalt shingles as needed based on production and availability to a desired particle size (e.g., to maximum dimensions from about ⅛″ to about 1″, and preferably to maximum dimensions from about ¼″ to about ⅜″), cleaned of nails and other debris, and stockpiled to meet agency specifications. The processed asphalt shingle input  216  is generally stored in a stockpile  221  at the mix plant site, on a well-drained area and/or covered to minimize the moisture content. The stockpile  221  of the asphalt shingle input  216  may be tested prior to use in mix production for residual asphalt content, aggregate gradation, and moisture content. The asphalt shingle input  216  may be fed by a loader  222  or other piece of equipment to a feed system  224 . The feed system  224  (and any of the other apparatuses described herein) may be interlocked with other plant components and controlled by the controller  202 . The feed system  224  may include a feed hopper  226 , which may be equipped with a variable frequency drive (VFD) motor  228 , a strainer  230  (e.g., comprising one or more screens), and one or more conveyors  232  (e.g., comprising an auger). The feed system  224  may be calibrated to regulate flow of the asphalt shingle input  216  to the preliminary mixing unit  218 , as controlled by the controller  202 , and may account for moisture content, residual asphalt content, mixture production rates, and the percentage of the total asphalt mixture to be defined by the asphalt shingle input. 
     The fluid asphalt input  210  may be stored in a heated tank  234 , which may be positioned adjacent the preliminary mixing unit  218 . The temperature in the heated tank  234  may be regulated (e.g., by the controller  202 ) to maintain a desired temperature generally between 200-450 degrees Fahrenheit depending on the type and grade of the fluid asphalt input  210  being used. A pump  236 , which may be equipped with a VFD motor, may be controlled and interlocked to other plant components by means of the controller  202 . The pump  236  may be configured to supply the fluid asphalt input  210  to the preliminary mixing unit  218 . The fluid asphalt input  210  may be metered to the preliminary mixing unit  218  by the pump  236 , as controlled by the controller  202  and metered by an flow meter  238 , and regulated based on aggregate moisture content, production rates, residual asphalt content, and the percentage of the total asphalt mixture to be defined by the asphalt shingle input  216 . One or more heated injection lines  240  (e.g., one or more conduits) and valves may be used and the fluid asphalt input  210  can be recirculated through a heated recirculation loop  242  in order to allow for even heating and mixing of the fluid asphalt. 
     The preliminary mixing unit  218  may be separate and positioned upstream of the primary mixing unit  204 . The preliminary mixing unit  218  may comprise a tank  244 , which may be sized to match the plant production and heated and insulated. A heater  245  (e.g., an electric coil, a burner, circulating hot oil or steam that surrounds the tank, or any other embodiment of heat producer) may heat the tank  244  and the materials received therein. Further, the preliminary mixing unit  218  may include a nozzle  246  (e.g., one or more asphalt spray nozzles), a mixer  248  which may comprise one or more blades, a heated recirculation loop  250  (which may be configured to evenly heat and mix the asphalt shingle input  216  with the fluid asphalt input  210  by recirculating the molten asphalt  220  received from the nozzle  246  to ensure that the asphalt shingle input completely melts), a valve  251  configured to selectively direct the molten asphalt through the recirculation loop, an asphalt shingle input inlet port  252  (e.g., a first inlet port) configured to receive the asphalt shingle input from the conveyor  232 , a fluid asphalt inlet port  254  (e.g., a second inlet port) configured to receive the fluid asphalt input from the heated injection line  240 , a strainer  255  positioned downstream of the outlet port  257  and configured to receive the molten asphalt  220  and remove particulates larger than a predetermined size, a pump  256  (e.g., a VFD direct drive pump) configured to receive the molten asphalt after it flows through the strainer, a flow meter  259  (which may be included in, or separate from, the pump  256 ), a fluid additive/anti-strip inlet  258 , and associated temperature gauges, level sensors, and valves. The strainer  255  may be positioned upstream of the pump  256  and configured to protect the pump by filtering out large particulate (e.g., stones) which may otherwise damage the pump, and which may commonly appear in the asphalt shingle input  216  as a result of it comprising recycled materials which may be produced under relatively less controlled conditions as compared to virgin inputs. Further, the tank  244  may be covered (e.g., by a lid) so as to prevent water entry therein. 
     As noted above, the preliminary mixing unit  218  may include the inlet port  254 , which is in communication with the heated injection line  240 . The fluid asphalt input  210  may thus be received through the inlet port  254  from the heated injection line  240  and injected through the nozzle  246  in the tank  244 . If applicable, a fluid additive (e.g., an anti-strip agent)  260  may be blended with the fluid asphalt input  210  by means of a pump  261  (e.g., a VFD pump), which may be controlled by the controller  202 . Further, the asphalt shingle input  216  may be introduced to the top of the preliminary mixing unit  218  by the conveyor  232  through the inlet port  252 . The asphalt shingle input  216  may be wetted with hot fluid asphalt input  210  sprayed thereon and/or pooled at the bottom of the tank  244  as it falls into the tank. The hot fluid asphalt input  210  may begin to remove moisture from the asphalt shingle input  216 , thereby creating a slight foaming action, while also beginning to activate/melt the residual binder in the asphalt shingle input. The mixture of the asphalt shingle input  216  and the fluid asphalt input  210  has a dwell time in the preliminary mixing unit  218 , where it is continuously agitated by the mixer  248 , to thereby remove moisture from the asphalt shingle input, activate the residual asphalt, and prevent precipitation of solids after the asphalt shingle input is melted. 
     The molten asphalt  220  comprising the asphalt shingle input  216  and the fluid asphalt input  210  in proper proportion is then pumped to the primary mixing unit  204  through a heated injection line  262  and a nozzle  264  (e.g., a spray nozzle), where it may be mixed with the particulate input  208  and/or the recycled asphalt input  214 . In this regard, the recycled asphalt input  214  may be supplied by a feed system  266  and the particulate input  208  may be supplied by a feed system  268 . Belt scales  270  may be employed to dispense the desired quantity of the recycled asphalt input  214  and the particulate input  208  into the primary mixing unit  204 . These systems may be interlocked and controlled by the controller  202  to account for total moisture content, recycled asphalt content, recycled asphalt aggregate gradation, recycled shingle content, recycled shingle aggregate gradation, particulate aggregate gradation, and the percentages of the total asphalt mixture to be defined by the molten asphalt  220 , the recycled asphalt input  214 , and the particulate input  208 . The preliminary mixing unit  218  provides wetting and agitation in an interlocked and continual process scaled to match plant production separate from and upstream of the primary mixing unit  204 , to provide the asphalt shingle input  216  time to activate and be more properly dispersed for use in producing the asphalt mix output  212 . 
     Example embodiments of methods for starting up and shutting down the systems  200 ,  200 ′ of  FIGS. 2 and 3  are provided below. As may be understood, some or all of these operations may be directed or controlled by the controller  202 . 
     Start-up of the mix system  200 ,  200 ′ may involve the following: Run the preliminary mixing unit  218 , the conveyor  232 , and the pump  236  for the fluid asphalt input  210  in the heated recirculation loop  242 . The loader  222  feeds the asphalt shingle input  216  from the stockpile  221  to the feed system  224 . Start up the other system components including, for example, the primary mixing unit  204  and the feed systems  266 ,  268  for the recycled asphalt input  214  and the particulate input  208 . 
     Close the heated recirculation loop  242 , and begin pumping the hot fluid asphalt input  210  through the asphalt flow meter  238  and heated injection line  240  to the nozzle  246  at the preliminary mixing unit  218 , properly timed and interlocked with other system components. Start the motor  228  for the feed system  224  for the asphalt shingle input  216  such that the strainer  230  removes oversized particles. The conveyor  232  begins feeding the asphalt shingle input  216  to the preliminary mixing unit  218 . 
     The asphalt shingle input  216  is wetted by the hot fluid asphalt input  210  from the nozzle  246  and is mixed by the mixer  248 . The pump  256  is started at proper sequence time, and pumps the molten asphalt  220  through the heated recirculation loop  250 . At the proper sequence time the heated recirculation loop  250  is closed and the heated injection line  262  is opened such that the molten asphalt  220  is pumped and metered to the nozzle  264  in the primary mixing unit  204 . The controller  202  controls mix plant production and properly proportions materials to compensate for: particulate input gradation, particulate input moisture content, recycled asphalt input gradation, recycled asphalt input residual asphalt content, recycled asphalt input moisture content, asphalt shingle input gradation, asphalt shingle input residual asphalt content, asphalt shingle input moisture content, desired mixture blend content of the inputs, total fluid asphalt content desired, and the production rate. 
     Shut-down of the mix system  200 ,  200 ′ may involve the following: Shut off the feed system  224 . Continue running the feed system conveyor  232  to clean it out. The asphalt pump  236  speeds up to account for loss of residual asphalt from the asphalt shingle input  216 . The hot fluid asphalt input  210  continues to spray into the preliminary mixing unit  218  through the heated injection line  240  and the nozzle  246  to flush the remaining asphalt shingle input  216  through the system and the pump  256  continues to pump/meter material to the primary mixing unit  204 . The other plant components are shut down in the proper timed sequence. Additionally, the preliminary mixing unit  218  is emptied. The pumps  236 ,  256  are run in reverse to clean out any remaining asphalt from the heated injection lines  240 ,  262 . 
       FIG. 4  schematically illustrates an additional embodiment of the system  200 ″ that is substantially similar to the system  200  illustrated in  FIG. 2  and which may include any of the additional components of the system  200 ′ of  FIG. 3 . However, as illustrated, the system  200 ″ may further comprise an intermediate tank  272 . The intermediate tank  272  may be positioned downstream of the preliminary mixing unit  218  and upstream of the primary mixing unit  204 . The intermediate tank  272  may be configured to store the molten asphalt  220  prior to directing the molten asphalt to the primary mixing unit  204 . 
     In this regard, the quantity of the molten asphalt  220  produced in the preliminary mixing unit  218  may be less than the amount needed or desired for usage of the primary mixing unit  204 . Accordingly, the intermediate tank  272  may be configured to receive and store the molten asphalt  220  until a sufficient quantity thereof is received from the preliminary mixing unit  218  and/or until the primary mixing unit  204  is ready for receipt of the molten asphalt  220 . In some embodiments the intermediate tank  272  may include a mixer  274 , which may agitate the molten asphalt  220  to prevent precipitation of solids out of the molten asphalt. Thus, in some embodiments the intermediate tank  272  may be referred to as an intermediate mixing unit. 
     Further, in some embodiments the intermediate tank  272  may include a heater  276  (e.g., an electric coil, a burner, circulating hot oil or steam that surrounds the tank, or any other embodiment of heat producer). The heater  276  may apply heat to the molten asphalt  220  to retain the fluidity thereof. Further, the intermediate tank  272  may include a screen  278 , which may remove any remaining particulates, a pump  280  to discharge the molten asphalt  220  from the intermediate tank  272 , a recirculation loop  282  configured to recirculate the molten asphalt  220 , and a valve  284  configured to selectively direct the molten asphalt to the recirculation loop and/or through a heated injection line  286  to the primary mixing unit  204 . 
       FIGS. 5-12  illustrate example embodiments and configurations of certain components of the systems  200 ,  200 ′,  200 ″ described above. As may be understood, such components are illustrated by way of example only, and such components may be configured in various manners in other embodiments. However, by way of example,  FIG. 5  illustrates the preliminary mixing unit  218 .  FIG. 5  further illustrates the feed hopper  226  and the conveyor  232  (e.g., an auger) leading to the asphalt shingle input inlet port  252 . A side view of the feed hopper  226  is provided in  FIG. 6 . An internal view of the top of the feed hopper  226  is illustrated in  FIG. 7 . As illustrated therein, the conveyor  232  may comprise a rotating auger that transports the asphalt shingle input  216  (see, e.g.,  FIG. 3 ) generally to the left in terms of the orientation illustrated in  FIG. 7 . 
     The heated injection line  240  that directs the fluid asphalt input  210  (see, e.g.,  FIG. 3 ) to the fluid asphalt inlet port  254  is further illustrated in  FIG. 5 .  FIG. 8  illustrates the heated tank  234  from which the fluid asphalt input  210  is received. As illustrated, in some embodiments the fluid asphalt input  210  leaving the heated tank  234  may be directed through a valve  290  (e.g., a three-way valve) before entering the heated injection line  240  that leads to the preliminary mixing unit  218  (see, e.g.,  FIG. 3 ). The valve  290  may also connect to a heated injection line  292  that leads to a traditional asphalt mixing unit for production of asphalt mix without usage of the asphalt shingle input, when desired. For example, the heated injection line  292  may lead substantially directly to the primary mixing unit  204  (see, e.g.,  FIG. 3 ), such that the primary mixing unit may optionally be used without the asphalt shingle input in some embodiments. In other words, the primary mixing unit  204  may mix the fluid asphalt input  210  with the particulate input  268 , and optionally the recycled asphalt input  214  when the valve  290  directs the fluid asphalt input directly to the primary mixing unit. Accordingly, the system may be provided with the ability to produce asphalt including or excluding the asphalt shingle input. 
     As further illustrated in  FIG. 5 , the preliminary mixing unit  218  may further comprise one or more load cells  288 . The load cells  288  may be employed to determine the mass of the fluid asphalt input  210  and/or the mass of the asphalt shingle input  216  directed into the tank  244 . Thereby, a proper mixture thereof may be achieved. 
       FIG. 9  illustrates the inside of the tank  244  of the preliminary mixing unit  218 . As illustrated, the fluid asphalt inlet port  254  is configured to direct the fluid asphalt input  210  (see, e.g.,  FIG. 3 ) to the nozzle  246 , which may be positioned proximate a bottom  244 A of the tank  244 . Thereby, issues with respect to the fluid asphalt input  210  splattering out of the tank  244  or sticking to the top of the sides of the tank without reaching the bottom  244 A of the tank may be avoided. In contrast, as illustrated in  FIG. 5 , the asphalt shingle input inlet port  252  may be configured to discharge the asphalt shingle input  216  proximate a top  244 B of the tank  244 . In this regard, the asphalt shingle input  216  (see, e.g.,  FIG. 3 ) may comprise solids, which may not splatter like a fluid. 
     As illustrated in  FIG. 10 , the mixer  248  may include a plurality of blades  294 . The blades  294  may agitate and mix the asphalt shingle input  216  with the fluid asphalt input  210  as the asphalt shingles melt. Once the asphalt shingle input  216  is fully melted, continued heating and agitation in the preliminary mixing unit  218  and optionally the intermediate tank  272  may prevent precipitation of solids from the molten asphalt  220 . In this regard, such precipitates may reduce the quality of any resultant asphalt product in the same manner as solids that are never fully melted would. 
     After the molten asphalt  220  (see, e.g.,  FIG. 3 ) is formed, the molten asphalt may be directed through the strainer  255 , the pump  256 , and the heated injection line  262 , or as illustrated in  FIG. 11 , the intermediate tank  272  may receive the molten asphalt  220  through a heated injection line  285 . As further illustrated in  FIG. 11 , the intermediate tank  272  may include a level gauge  296  indicating the amount of the molten asphalt  220  received therein. 
     As illustrated in  FIG. 12 , the molten asphalt  220  may be directed through the strainer  278  and into one or both of the recirculation loop  282  and the heated injection line  286 , depending on the position of the valve  284 . Recirculation may be conducted until a desired quantity of the molten asphalt  220  is received in the intermediate tank  272 , at which time the valve  284  may direct the molten asphalt through the heated injection line  286  to the primary mixing unit  204  (see, e.g.,  FIG. 4 ). 
     Each of the conduits and other components handling fluid substances described herein may be heated. For example, a heated fluid (e.g., oil or steam) may be circulated amongst the components to maintain the fluidity of the asphalt materials. By way of example, each of the conduits transporting the fluid asphalt materials may include an outer conduit that surround an inner conduit. The inner conduit may transport the asphalt materials (e.g., the molten asphalt  220 ), and the outer conduit may transport the heated fluid (e.g., oil or steam) so as to heat the asphalt materials received in the inner conduit to maintain the fluidity thereof. 
     A method for producing asphalt mix is also provided. As illustrated in  FIG. 13 , the method may include mixing and heating a fluid asphalt input and an asphalt shingle input in a preliminary mixing unit to melt the asphalt shingle input and produce a molten asphalt at operation  302 . Further, the method may include directing the molten asphalt and a particulate input into a primary mixing unit at operation  304 . The method may additionally include mixing the molten asphalt with the particulate input to produce an asphalt mix output at operation  306 . 
     In some embodiments the method may further comprise directing a recycled asphalt input into the primary mixing unit. Additionally, the method may include mixing the recycled asphalt input with the molten asphalt and the particulate input to produce the asphalt mix output. Further, the method may include directing the molten asphalt through a strainer prior to directing the molten asphalt into the primary mixing unit at operation  304 . 
     The method may additionally include directing the molten asphalt to an intermediate tank before directing the molten asphalt into the primary mixing unit at operation  304 . The method may also include directing the fluid asphalt input to a bottom of the preliminary mixing unit. Further, the method may include grinding a plurality of asphalt shingles to produce the asphalt shingle input. Additionally, the method may include recirculating the molten asphalt at the preliminary mixing unit. 
       FIG. 14  schematically illustrates an embodiment of the controller  202 . The controller  202  may be configured to execute computer code for performing the operations described herein. In this regard, as illustrated in  FIG. 4 , the controller  202  may comprise a processor  402  that may be a microprocessor or a controller for controlling the overall operation thereof. In one embodiment the processor  402  may be particularly configured to execute program code instructions related to the functions described herein, including the operations for forming the molten asphalt  220  from the asphalt shingle input  216  and the fluid asphalt input  210  and ultimately producing the asphalt mix output  212  (see,  FIGS. 2, 3, and 4 ). The controller  202  may also include a memory device  404 . The memory device  404  may include non-transitory and tangible memory that may be, for example, volatile and/or non-volatile memory. The memory device  404  may be configured to store information, data, files, applications, instructions or the like. For example, the memory device  404  could be configured to buffer input data for processing by the processor  402 . Additionally or alternatively, the memory device  404  may be configured to store instructions for execution by the processor  402 . 
     The controller  202  may also include a user interface  406  that allows a user to interact therewith. For example, the user interface  406  can take a variety of forms, such as a button, keypad, dial, touch screen, audio input interface, visual/image capture input interface, input in the form of sensor data, etc. Still further, the user interface  406  may be configured to output information to the user through a display, speaker, or other output device. A communication interface  408  may provide for transmitting and receiving data through, for example, a wired or wireless network  410  such as a local area network (LAN), a metropolitan area network (MAN), and/or a wide area network (WAN), for example, the Internet. The communication interface  408  may enable the controller  202  to communicate with one or more further computing devices, either directly, or via the network  410 . In this regard, the communication interface  408  may include one or more interface mechanisms for enabling communication with other devices and/or networks. The communication interface  408  may accordingly include one or more interface mechanisms, such as an antenna (or multiple antennas) and supporting hardware and/or software for enabling communications via wireless communication technology (e.g., a cellular technology, communication technology, Wi-Fi and/or other IEEE 802.11 technology, Bluetooth, Zigbee, wireless USB, NFC, RF-ID, WiMAX and/or other IEEE 802.16 technology, and/or other wireless communication technology) and/or a communication modem or other hardware/software for supporting communication via cable, digital subscriber line (DSL), USB, FireWire, Ethernet, one or more optical transmission technologies, and/or other wireline networking methods. Further, the controller  202  may include a mixing module  412 . The mixing module  412  may be configured to, in conjunction with the processor  402 , direct operations for forming the molten asphalt  220  from the asphalt shingle input  216  and the fluid asphalt input  210  and/or ultimately producing the asphalt mix output  212  (see, e.g.,  FIGS. 2 and 3 ) as described herein. 
     The various aspects, embodiments, implementations or features of the described embodiments can be used separately or in any combination. Various aspects of the described embodiments can be implemented by software, hardware or a combination of hardware and software. The described embodiments can also be embodied as computer readable code on a computer readable medium for controlling the above-described operations. In particular, computer readable code may be configured to perform each of the operations of the methods described herein and embodied as computer readable code on a computer readable medium for controlling the above-described operations. In this regard, a computer readable storage medium, as used herein, refers to a non-transitory, physical storage medium (e.g., a volatile or non-volatile memory device, which can be read by a computer system. Examples of the computer readable medium include read-only memory, random-access memory, CD-ROMs, DVDs, magnetic tape, and optical data storage devices. The computer readable medium can also be distributed over network-coupled computer systems so that the computer readable code is stored and executed in a distributed fashion. 
     As noted above, the controller  202  may be configured to execute computer code for performing the above-described mixing operations. In this regard, an embodiment of a non-transitory computer readable medium for storing computer instructions executed by a processor in a controller (e.g. controller  202 ) configured to form the molten asphalt  220  from the asphalt shingle input  216  and the fluid asphalt input  210  and/or ultimately produce the asphalt mix output  212  (see, e.g.,  FIGS. 2, 3, and 4 ) is provided. The non-transitory computer readable medium may thus include program code instructions for performing the operations disclosed herein. 
     Note that although the apparatuses, systems, and methods provided herein are generally described as being used in the production of asphalt pavement, such apparatuses, systems, and methods may be employed to produce other asphalt-based products. For example, the apparatuses, systems, and methods of the present disclosure may be employed to produce asphalt shingles. In this regard, the apparatuses, systems, and methods of the present disclosure are configured to recycle any asphalt-based products into a form usable as an input for the production of any asphalt-based product. Accordingly, the description regarding usage of asphalt shingles as the recycled input and description regarding usage of the output for the production of asphalt pavement is provided for example purposes only. 
     Many modifications and other embodiments of the disclosure will come to mind to one skilled in the art to which this disclosure pertains having the benefit of the teachings presented in the foregoing description; and it will be apparent to those skilled in the art that variations and modifications of the present disclosure can be made without departing from the scope or spirit of the disclosure. Therefore, it is to be understood that the disclosure is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.