行業(yè)資訊
濟(jì)南瀝青生產(chǎn)廠家：瀝青生產(chǎn)的精密之旅
來源：http://www.81tyre.com/ 日期：2025-05-27
在道路建設(shè)領(lǐng)域，瀝青作為路面鋪裝的核心材料，其生產(chǎn)過程猶如一場精密的化學(xué)交響樂。從深埋地下的原油到黝黑發(fā)亮的道路建材，每一滴瀝青都經(jīng)歷著復(fù)雜的物理化學(xué)轉(zhuǎn)變。本文將深度解析瀝青生產(chǎn)的全流程工藝，揭示這種常見建材背后的科技奧秘。
In the field of road construction, asphalt, as the core material for pavement, is produced like a precise chemical symphony. From deeply buried crude oil to dark and shiny road building materials, every drop of asphalt undergoes complex physical and chemical transformations. This article will deeply analyze the entire process of asphalt production and reveal the technological secrets behind this common building material.
一、原料預(yù)處理：基礎(chǔ)材料的精制藝術(shù)
1、 Raw material pretreatment: the refined art of basic materials
瀝青生產(chǎn)的原料體系包含三重保障：以減壓渣油為主的基質(zhì)原料，占總量70%-85%；作為改性劑的催化油漿，提供關(guān)鍵的膠體結(jié)構(gòu)；以及專用的添加劑包，包含穩(wěn)定劑、抗氧化劑等組分。原料進(jìn)入生產(chǎn)系統(tǒng)前，需經(jīng)三級過濾凈化，首先通過80目振動篩去除機(jī)械雜質(zhì)，再經(jīng)電脫水器脫除95%以上的游離水，最后進(jìn)入真空干燥塔，在150℃、-0.09MPa條件下將含水量降至0.1%以下。
The raw material system for asphalt production includes three guarantees: matrix raw materials mainly composed of vacuum residue, accounting for 70% -85% of the total; As a modifier, catalytic slurry provides key colloidal structures; And a dedicated additive package, including stabilizers, antioxidants, and other components. Before entering the production system, the raw materials need to undergo three-stage filtration and purification. Firstly, mechanical impurities are removed through an 80 mesh vibrating screen. Then, more than 95% of free water is removed through an electric dehydrator. Finally, it enters a vacuum drying tower and the water content is reduced to below 0.1% at 150 ℃ and -0.09MPa.
預(yù)處理環(huán)節(jié)的核心設(shè)備是減壓蒸餾塔，其塔盤間距經(jīng)過流體力學(xué)優(yōu)化，確保渣油在塔內(nèi)形成穩(wěn)定的逆流接觸。通過精確控制塔頂壓力（2-5kPa）和塔底溫度（360-380℃），實(shí)現(xiàn)渣油中輕質(zhì)組分與重質(zhì)組分的精準(zhǔn)分離。某煉化企業(yè)實(shí)測數(shù)據(jù)顯示，該工藝可使渣油軟化點(diǎn)波動范圍控制在±1.5℃以內(nèi)。
The core equipment of the preprocessing stage is the vacuum distillation tower, whose tray spacing is optimized by fluid mechanics to ensure stable countercurrent contact of residual oil inside the tower. By precisely controlling the top pressure (2-5kPa) and bottom temperature (360-380 ℃), precise separation of light and heavy components in residual oil can be achieved. The actual test data of a certain refining enterprise shows that this process can control the fluctuation range of residual oil softening point within ± 1.5 ℃.
二、氧化工藝：核心性能的鍛造工坊
2、 Oxidation process: forging workshop for core performance
氧化反應(yīng)是瀝青品質(zhì)成型的關(guān)鍵階段。連續(xù)式氧化生產(chǎn)系統(tǒng)由氧化塔、換熱網(wǎng)絡(luò)、尾氣處理單元構(gòu)成。原料在氧化塔內(nèi)經(jīng)歷三個溫度區(qū)間：預(yù)熱段（200-230℃）、反應(yīng)段（250-280℃）、熟化段（230-250℃）。在反應(yīng)段，壓縮空氣以0.8-1.2m?/kg的配比注入，引發(fā)深度氧化縮合反應(yīng)。
Oxidation reaction is a critical stage in the formation of asphalt quality. The continuous oxidation production system consists of an oxidation tower, a heat exchange network, and a tail gas treatment unit. The raw materials undergo three temperature ranges in the oxidation tower: preheating section (200-230 ℃), reaction section (250-280 ℃), and maturation section (230-250 ℃). In the reaction section, compressed air is injected at a ratio of 0.8-1.2m/kg to initiate a deep oxidation condensation reaction.
該過程的核心控制參數(shù)是反應(yīng)溫度和空氣流量。采用模糊PID控制算法，建立溫度-粘度-針入度的三維關(guān)聯(lián)模型，實(shí)現(xiàn)工藝參數(shù)的動態(tài)優(yōu)化。某瀝青生產(chǎn)企業(yè)的中試數(shù)據(jù)顯示，當(dāng)反應(yīng)溫度波動±2℃時，成品瀝青的60℃動力粘度變化率可達(dá)8%，凸顯了精準(zhǔn)控制的重要性。
The core control parameters of this process are reaction temperature and air flow rate. Adopting the fuzzy PID control algorithm, a three-dimensional correlation model of temperature viscosity penetration is established to achieve dynamic optimization of process parameters. The pilot data of a certain asphalt production enterprise shows that when the reaction temperature fluctuates by ± 2 ℃, the 60 ℃ dynamic viscosity change rate of the finished asphalt can reach 8%, highlighting the importance of precise control.
為提升氧化效率，現(xiàn)代生產(chǎn)線引入微納米氣泡技術(shù)。通過特殊設(shè)計(jì)的文丘里管，將空氣分散為直徑50-100μm的微氣泡，使氣液接觸面積提升3倍，氧化反應(yīng)速率提高25%。該技術(shù)使氧化時間縮短至傳統(tǒng)工藝的60%，同時降低能耗18%。
To improve oxidation efficiency, modern production lines introduce micro nano bubble technology. By using a specially designed Venturi tube, the air is dispersed into microbubbles with a diameter of 50-100 μ m, increasing the gas-liquid contact area by three times and increasing the oxidation reaction rate by 25%. This technology shortens the oxidation time to 60% of traditional processes, while reducing energy consumption by 18%.
三、改性工藝：性能升級的創(chuàng)新引擎
3、 Modified technology: an innovative engine for performance upgrade
針對不同應(yīng)用場景，瀝青需進(jìn)行深度改性處理。SBS改性工藝采用高速剪切機(jī)，在180-190℃條件下將苯乙烯-丁二烯-苯乙烯嵌段共聚物（SBS）與基質(zhì)瀝青混合。剪切頭轉(zhuǎn)速達(dá)5000rpm，產(chǎn)生的高剪切力使SBS顆粒細(xì)化至5μm以下，形成穩(wěn)定的海島結(jié)構(gòu)。某高速公路項(xiàng)目應(yīng)用表明，該工藝使瀝青高溫穩(wěn)定性提升3倍，低溫抗裂性改善40%。
Asphalt needs to be deeply modified for different application scenarios. The SBS modification process uses a high-speed shearing machine to mix styrene butadiene styrene block copolymer (SBS) with matrix asphalt at 180-190 ℃. The shear head rotates at 5000rpm, generating high shear force that refines SBS particles to below 5 μ m, forming a stable island structure. The application of a certain highway project shows that this process increases the high-temperature stability of asphalt by three times and improves the low-temperature crack resistance by 40%.
對于特種需求，采用復(fù)合改性技術(shù)。將納米蒙脫土、石墨烯等功能材料與SBS協(xié)同作用，通過溶液共混法實(shí)現(xiàn)納米級分散。透射電鏡觀察顯示，復(fù)合改性劑在瀝青中形成三維網(wǎng)狀結(jié)構(gòu)，使瀝青的抗車轍能力提升50%，疲勞壽命延長3倍。
For special requirements, composite modification technology is adopted. By synergistically combining functional materials such as nano montmorillonite and graphene with SBS, nanoscale dispersion can be achieved through solution blending. Transmission electron microscopy observation shows that the composite modifier forms a three-dimensional network structure in asphalt, which increases the anti rutting ability of asphalt by 50% and prolongs the fatigue life by three times.
四、成品精制：品質(zhì)保障的最后防線
4、 Finished product refinement: the last line of defense for quality assurance
成品瀝青需經(jīng)三級精制：首先通過高速離心機(jī)脫除機(jī)械雜質(zhì)，再經(jīng)薄膜蒸發(fā)器脫除輕組分，最后進(jìn)入成品罐進(jìn)行陳化。陳化過程采用智能溫控系統(tǒng)，在150-160℃條件下保持72小時，使瀝青組分充分締合，消除內(nèi)應(yīng)力。
The finished asphalt needs to be refined in three stages: first, mechanical impurities are removed by a high-speed centrifuge, then light components are removed by a thin film evaporator, and finally it enters the finished product tank for aging. The aging process adopts an intelligent temperature control system, which maintains a temperature of 150-160 ℃ for 72 hours to fully combine the asphalt components and eliminate internal stress.
質(zhì)量控制體系包含23項(xiàng)檢測指標(biāo)，涵蓋物理性能（針入度、軟化點(diǎn)、延度）、化學(xué)組成（飽和分、芳香分、膠質(zhì)、瀝青質(zhì)）、路用性能（動穩(wěn)定度、彎曲應(yīng)變）三大維度。采用近紅外光譜技術(shù)建立快速檢測模型，可在2分鐘內(nèi)完成主要指標(biāo)的篩查，檢測結(jié)果與傳統(tǒng)方法偏差小于3%。
The quality control system includes 23 testing indicators, covering three dimensions: physical properties (penetration, softening point, ductility), chemical composition (saturation fraction, aromatic fraction, resin, asphalt), and road performance (dynamic stability, bending strain). Using near-infrared spectroscopy technology to establish a rapid detection model, the screening of main indicators can be completed within 2 minutes, and the deviation between the detection results and traditional methods is less than 3%.
瀝青生產(chǎn)工藝的進(jìn)化，是材料科學(xué)與過程工程深度融合的典范。從原料精選到深度改性，從氧化縮合到智能精制，每個環(huán)節(jié)都凝聚著工程技術(shù)的智慧。這種精密制造不僅賦予瀝青優(yōu)異的路用性能，更推動著道路建設(shè)向綠色化、智能化方向發(fā)展。當(dāng)一輛輛汽車平穩(wěn)駛過黑色路面時，背后正是這場跨越物理化學(xué)界限的品質(zhì)鍛造之旅。
The evolution of asphalt production technology is a model of deep integration between materials science and process engineering. From raw material selection to deep modification, from oxidation and condensation to intelligent refining, every step embodies the wisdom of engineering technology. This precision manufacturing not only endows asphalt with excellent road performance, but also promotes the development of road construction towards green and intelligent direction. As cars smoothly cross the black road surface, behind them lies a journey of forging quality that transcends physical and chemical boundaries.
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