Bitumen_refinery

The difference between the old refining system and the new system

 

In the new refining process, in order to reduce the production cost and increase the refining speed and reduce the cost price of the final product, in the refining process, instead of using traditional bach wise methods, the continuos method is used.

 

In this process, due to the use of composite towers, all feeds available in the market such as fuel oil, vacuum baton, slabs and other feeds can be used. These production units have the ability to produce any type of bitumen and are dedicated to the production and consumption of feed. And they are not special bitumen.

 

In the new refining process, due to the design and installation of explosion-proof valves, the risk of explosion and fire will be eliminated.

 

In the old process, the bitumen firing tower needed to absorb a lot of energy to refine and raise its temperature, which was produced by spraying fuel in the central pipe of the tower with high heat and for a long time.

 This method first consumes a lot of fuel and causes a large amount of carbon dioxide, carbon monoxide and other environmental pollutants. In this method, the cost of energy consumption for production is very high, but in the new refining process to produce the heat required by the tower, this energy is not needed and it uses the heat of chemical reactions to raise the temperature and refine the bitumen.

 In the units that work in the old way, basically no bitumen is produced in the cooking tower, but only the initial feed condensation operation is done. Unfortunately, the product made from this incorrect method of bitumen production is exposed to weak UV rays of the sun. is .

 

In the old refining process, vapors and aromatic compounds from the charcoal production process due to direct heat in the tanks and its reaction with oxygen cause the production of sulfur gas and are spread in the ambient air. But in the design of the new process, this defect has been eliminated.

 

In previous processes, the aeration system of the tower, due to the lack of calculation of air pressure, did not give any data to the person in charge of bitumen firing and the person in charge is unaware of the situation inside the tower, except for the temperature inside.

 

 

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Factors affecting bitumen chemistry

Long-term studies show that the presence of oxygen, ultraviolet rays and temperature changes affect bitumen, like other organic matter.

These external factors harden the bitumen and reduce the degree of penetration, increase the softening point and typically increase the penetration index (PI).

Recent research has shown that the hardening of bitumen and consequently the asphalt mixture made from it, is effective in road construction, because as the stiffness increases, the load distribution capacity of asphalt layers increases.

 This type of hardening is known as curing and is believed to increase the life of the asphalt coating.

 

In the case of the pavement layer, due to the contact of bitumen with environmental factors, hardening of bitumen has a destructive effect on the performance of bitumen and causes cracking.

 

 

 Causes of bitumen hardening:

 

 

oxidation

 

Evaporation of volatiles

 

Steric or physical factors

 

Leaking oils

 

Oxidation changes the chemical composition of bitumen.

Like other organic materials, bitumen oxidizes slowly in the presence of oxygen in the air.

 And increases the viscosity of bitumen.

 

Calcium hydroxide prevents asphalt from aging, but the reason for this inhibition has not yet been determined.

 In addition, calcium hydroxide is used to improve the adhesion properties of bitumen.

 Sodium hydroxide also prevents bitumen aging, but often has a negative effect on bitumen adhesion.

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Bitumen product in iran

Bitumen product in iran⁦🇮🇷⁩

Mixed bitumen or liquid

Sometimes it is not possible to use solid bitumen directly in road construction operations because due to lack of access to heating equipment or cooling of heated bitumen during work or the need for safety from workers and fires and spending time requires that liquid bitumen be used. River.

 

Soluble bitumen is obtained by dissolving pure bitumen in petroleum solvents or oils.

 The type and quality of soluble bitumens depends on the quality of the original pure bitumen, the type of solvent and the amount of solvent.

The higher the amount of petroleum solvents in the bitumen solution, the greater its fluidity.

 Usually, the percentage of solvent used in Iranian soluble bitumens varies from 10 to 50%. Lack of access to bitumen heating devices at high temperatures, cooling of bitumen during operation, impossibility of its penetration into porous minerals, necessity of workers' safety, fire and time consuming cause in some cases soluble bitumen to be used.

 In order for bitumen to adhere to wet materials, the soluble bitumen used must have a suitable degree of acidity. Soluble bitumens are used in road construction for surface coatings, columns, surface asphalt, cold factory asphalt or mixtures at the place of use.

Liquid bitumen is actually a mixture of solid or soft bitumen with a suitable solvent.

These bitumens are divided into the following three categories:

- RC bitumens

Delayed bitumen or SC

Slow bit or MC

The above bitumens can be divided into more categories according to viscosity.

 

Bitumen Trinidad

In Trinidad, bitumen is removed from the crater of a volcano. The closed surface of the bitumen is broken, and the bitumen is removed from under it, which again lubricates the bitumen and fills the place of what was removed.

 This bitumen contains impurities (minerals and plant roots). It is melted at 160 ° C and refined, called Trinidad-epure bitumen, and contains 38.5% inorganic bodies, 5.5% in insoluble organic matter.....

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Iran bitumen

Iran bitumen

The beginning of the modern bitumen industry can be attributed to 1712 AD.

 At that time, bitumen materials were simply spread in lumps on the surface of local roads, allowing traffic to gradually erode and condense them.

This technique was quite successful, and in a short period of time progress was made in this field, including spraying and heating the material before use.

 The asphalts were then compacted and hardened by pounding and leveling with hot iron. This material is commonly known as Compressed Rock Asphalt ......

 

And in 2020

 

It is a hydrocarbon compound with dark brown-black color, in solid, semicircular or viscous forms, with adhesive properties that are of natural or refined origin, mainly containing high molecular weight hydrocarbons.

 These materials are completely soluble in carbon disulfide (CS2), trichloroethylene (C2HCl3) and xylene (C6H4 (CH3) 2). Its vapor pressure is negligible at ambient temperature and in this case is almost odorless.

 

The most abundant and widely used type of bitumen is petroleum bitumen, which is a physically homogeneous substance and a chemically heterogeneous mixture of different chemical compounds.

 This hydrocarbon mixture generally contains 90% of carbon and hydrogen atoms and residues, nitrogen, sulfur and oxygen and small amounts of nickel, iron, magnesium and .....

Bitumen is behaviorally a substance that does not behave like an elastic substance or a viscous substance at ambient temperature, but the behavior of bitumen includes a combination of these two states, ie viscoelastic.

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Bitumen product in iran

Bitumen product in Iran

Bitumen production process

It is done in the following two ways

 

 

Batch Process

In the discontinuous process, the aeration tower is filled with a certain volume of feed and after blowing air and reaching the desired specifications, the tower is emptied and the product enters the desired tanks.

The main components of a discontinuous aeration unit are:

Pre Heater

Blower or Compressor

Oxidizer Tower

A system for collecting and burning vapors

 

 

Continues Process

In the continuous process, the feed with a definite and controllable flow and a predetermined temperature continuously enters the aeration tower and after performing aeration operations under constant operating conditions, it continuously leaves the aeration tower.

This method of bitumen production, which is used in refineries, is considered because of the following advantages:

Reduction of pollutant vapors

Reduce equipment and maintenance costs

Increase efficiency and amount of production per unit time

Reduce the heat load of feed preheaters

Ease of control and process operations due to the continuous nature of the process

Reduced air consumption and shortened aeration time due to optimal use of blown air.

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Iran bitumen

iran bitumen

Black to dark brown hydrocarbon bitumen in which carbon tetrachloride dissolves completely.

 Bitumen is solid at ambient temperature. But as the temperature rises, it becomes a paste and then liquefies.

The important use of bitumen is due to the existence of two important properties of this material; Impermeability and adhesion.

 

General characteristics of bitumens

 

General characteristics of black adhesives are:

 

- Impermeability to moisture and water

 

- Electrical insulation

 

- Elasticity

 

- Medium stability against acids, bases and salts

 

- Adhesion to other materials

 

In Iran, mineral bitumen is high.

Several places in Kermanshah province (Patagh, Goshan), Pishkuh and behind Lorestan mountain (Qiran plot). It has been found near Bilesvar Moghan (Qira Darreh) and other places of Qir mine.

One of the mines that has a lot of bitumen is Behban mineral bitumen

 

Bituminous stones

 

In ancient times, crude oil leaked into limestone or sandstone, but over time its mineral oils jumped slowly, leaving bitumen in the rock, and bitumen formed.

 

Bitumen limestone is ground, rounded to make asphalt and asphalt concrete is used.

 

The sand filled with bitumen is ground and poured into boiling water, the heat of boiling water melts the bitumen shell on the sand grains, the sand settles and the bitumen stays afloat, the bituminous water is evaporated to leave the bitumen.

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Iran bitumen bag

Bitumen jumbo bags are designed and produced in different sizes and thicknesses according to the customer's request, with or without laminate.

 

In laminated bags, a laminated cover layer is used to make the bag to prevent moisture from penetrating into the bag.

Of course, some manufacturers produce polyethylene bags depending on the use of the bag and the customer's order. These bags are more resistant to the penetration of moisture and humidity.

 

Jumbo bag with open entrance

 

The jumbo bag with fully open entrance has holes and ropes in the entrance part which, after filling, are used to collect the entrance opening.

 

Jumbo bag with full lid

 

In this type of jumbo bag, there is a lid at the entrance, which is installed to protect the bitumen inside the bag against various factors. Of course, through this lid, the materials and contents inside the bag can be easily accessed.

 

Big bag with leaf at the entrance

 

In this type of jumbo bag, in the entrance part, in order to further protect the contents of the bag, a funnel is usually made of fabric, which allows access to the materials inside the jumbo bag through this funnel. When the bag is full, the inlet of this type of bag It is gathered by straps around the hopper to protect the cargo.

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Bitumen product in iran

Types of bitumen modifiers and additives

 In order to modify some properties of bitumen additives or bitumen modifiers

Is used.

These compounds

They include a wide range of minerals, organic, natural and industrial.

Modified bitumens by type

Additives or bitumen modifiers are divided into the following three main groups:

1- Modified polymer bitumens

2- Bitumen modified with rubber

3- Bitumens modified with chemicals

 

Modified polymer bitumens

Construction of asphalt concrete pavements has been developed using pure bitumen modified with suitable polymers.

 Since the tests do not show the performance characteristics of polymer-modified bitumens, therefore, the appropriate polymer is selected based on the physical properties of the polymers and the desired performance characteristics.

 Polymers are divided into two categories based on their physical properties: plastomers and elastomers.

When the polymer is stretched, if the load is pulled in the same position, the residue remains

It remains a plastomer and if it returns to its original shape, it is an elastomer.

 

 Rubber modified bitumen

These bitumens are made by mixing recycled rubber powder

And if necessary, mineral additives or other fiber materials are prepared with pure bitumen.

Consumable powder should be mixed with hot bitumen so that the particles

The tires are sufficiently swollen and expanded before using bitumen.

Bitumens that are modified in this way

They are divided into three groups in terms of viscosity, which are high to low concentrations, respectively.

 

Chemical modified bitumen

Chemical-modified bitumens are made by adding stabilizing chemicals to pure bitumens

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Iran high quality bitumen

iran high quality bitumen

Petroleum bitumen is produced by refining crude oil at high temperatures and in a short time.

It is liquid at high temperatures and becomes viscous, pasty, and hard as the heat decreases. Excessive heating of the bitumen causes excessive evaporation of its mineral oils and reduces the adhesion of the bitumen.

 

 

Waxed bitumen is not suitable for making black surface because wax reduces the elasticity of bitumen and causes black surface to lose its springy state and become brittle.

The black surface shrinks in the cold and tensile stress is found in it. When this stress is greater than the tolerance of the frozen asphalt surface, the surface cracks.

The less petroleum paraffin, the closer it is to mineral bitumen and the more suitable it is for making the surface.

 In addition to paraffin, asphaltene, oxygen and mineral oils also affect the quality of bitumen. The heavier the crude oil, the more asphalt is extracted from it.

 Basically, light crude oil is less used for bitumen production due to the production of high-distillation materials, although bitumen production is related to various other parameters, which generally include refining knowledge and technology issues and economic issues.

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Iran high quality bitumen

Bitumen quality control tests

The bitumen used should be homogeneous and should not foam when heated to 176 degrees Celsius.

Oil or steam pipes or electrical appliances should be used to heat the bitumen. The monitoring device is obliged to prevent the evacuation of bitumen of tankers that use direct flame for heating, and the contractor must also refrain from evacuating the bitumen of such separate tanks.

The temperature of bitumen in tanks and pipes and when mixing with aggregates in the asphalt plant mixer should not exceed 175 degrees Celsius for pure bitumen.

Bitumen transport tanks as well as workshop bitumen tanks must be equipped with a thermometer. One thermometer is installed at the bottom of the tanker and another at the top. In the asphalt factory, a thermometer for bitumen must be installed so that the temperature of the bitumen can be controlled at any time.

Bitumen is stored in metal tanks and concrete pools in the workshop.

If the pool is used, the floor and walls should be concrete and the roof should be covered so that the bitumen is completely protected from dust, rain and other contaminants. Bitumen heating equipment should be provided on the pool floor.

 

 The bitumen required for each stage of asphalt production should not last more than 15 seconds after the start of the bitumen discharge process.

Bitumen measuring instruments must measure the required bitumen that is emptied at each stage to the nearest 1 kg.

 To quickly identify the basic properties of bitumen, some penetration-based grading tests are used. Stain testing is also used for this purpose.

 

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