Asphalt Binder Production
Dan Weidman BP- Bitumen BU December 7, 2006
1 HowHow isis bitumenbitumen made?made?
2 Overview
• Process – how a refinery makes bitumen – how are the different bitumen products made •Quality – howhow aa refineryrefinery makesmakes goodgood qualityquality bitumenbitumen
3 Oil products – global consumption
Total = 75 Million barrels/day in 2000
(80 Million barrels/day in 2004) LPG (6.5) Propylene (0.5)
Naphtha (4.2) Gasoline (19.7) Aromatics (0.9)
Jet and Kerosene (6)
Diesel & Heating oil (20) Lubricants (0.7)
Inland Fuel Oil (8.7)
Refinery Fuel (3.3) Marine FO (2.1) Bitumen (1.5) Coke (0.9) Source: BP 4 Product properties
Carbon Boiling number point (°C)
3 - 4 LPG -10 - 15 5 - 10 Gasoline 15 - 150 12 - 18 Kerosene 150 - 260
18 - 24 Diesel 230 - 370 24 - 40 Lubricating oils 370 - 525 24 - ~300 Heavy fuel oil 370 -
~40 - ~300 Bitumen 525 -
5 Complex refinery process flow diagram
Gases Gas Plant Refinery Gas LPG
Ethylene Isomerisation Olefin Units Propylene
Naphtha Aromatics Hydrofiner Reformer Dealkyl. Benzene Units
Middle distillates CHD o-Xylene p-Xylene Alkylation Solvents Gasoil Aviation Fuel HT/FCC
Vacuum Hydro- Unit Diesel / Light heating oil Crude Oil Crude oil distillation cracker Gasoline Vis- Methanol breaker Synthesis Methanol Partial Residue Ammonia Oxidation Ammonia Synthesis Coker H2S-Gas Refinery Claus Sulphur
Bitumen Bitumen Petroleum coke Calciner Petroleum coke
Heavy fuel oil
Separations Conversion Treatments 6 Atmospheric distillation
Water condenser
125 °C Gas 150 °C Gasoline
165 °C Kerosine
250°C Gas oil Pre-heated 300 °C crude oil
280 °C
Atmospheric residue
7 Vacuum distillation
Water 46 °C condenser Vacuum 110 °C
185 °C Vacuum distillates 260°C 340 °C
Pre-heated atmospheric 385 °C residue 350 °C (525 °C) Vacuum residue (bitumen feedstock) 8 Simplest production route for bitumen
Atmospheric Distillation
Vacuum Distillation Heavy crudes Soft
Blended grades
Hard
9 Higher boiling point = harder bitumen
100
90 Distillation curve for Arab Heavy
80
70
60 200 pen 42 pen 50 Atmospheric 40 distillation
Residue yield, %wt Residue yield, %wt 30
20 Vacuum distillation 10
0 0 100 200 300 400 500 600 700 800 900 1000 True Boiling Point, °C
10 Essential properties of refined bitumen
• Specific consistency at key temperatures • Durability = resistance to ageing • Adhesion • Cohesion • Low fuming tendency
11 Bituminous products
Normal Paving
+ polymer Polymer Modified
Bitumen + water Emulsion base & soap
+ flux & Oxidised blowing
+ kerosene Cut Back
12 Bitumen quality depends mainly on choice of crude
Heavy 1
0.95
0.9 HeavySweet Heavy Sour
0.85
0.8
0.75 Crude density, kg/l Crude density, 0.7 Light Sweet Light Sour 0.65
Light 0.6 0.001 0.01 0.1 1 10 Sweet Sulphur in crude, %wt Sour 13 Refinery activities that influence bitumen
Months Weeks Days Hours
Planning Processing Blending Loading
Scheduling
14 Summary of Feedstock Selection Criteria
Composition Impact on other products Quality Economic
Available process Bitumen equipment Yield
15 Product yield varies from crude to crude
API gravity 45.2 39.8 37.9 37.8 36.3 32.8 31.8 30.8 30.4 27.9 16.2 Sulphur, %wt 0.09 0.39 0.44 0.16 0.56 1.36 0.56 2.40 2.05 1.11 2.33
100%
80%
LPG 60% Naphtha Kerosene 40% Gas Oil Vacuum Residue Volume distilled 20%
0%
t t e 0 m r a m r 7 0 nd a o o p -1 0 le n p iu p f e x hmus d c 2 Blend B E t Nov Ex B n t m Is a in n A io rr Me ai d re l e b b n B T ra a Wa A Du m Sahara ka North Slo e s D Ala
West Texas Intermediate Source: BP 16 To make good quality bitumen
• Bitumen that meets specs & is fit for purpose – specific refinery components – with the right physical properties – determined by composition • determined by choice of raw materials • and processing –and know-how
17 Distillation curves
100 Vacuum 90 distillation 80 Cerro Negro 70
60 Isla 50 Atmospheric 40 distillation AH
Residue yield, %wt Residue yield, %wt 30 Kuwait 20 Iran Light 10 Urals 0 Cossack 0 100 200 300 400 500 600 700 800 900 1000 True Boiling Point, °C
18 Heavy crudes are best for bitumen
1 BCF17 Maya ANS Urals Known bitumen crude Mars LLK 0.95 Other crude
0.9 Souedie
0.85 Dubai Export Kirkuk
Arab Light 0.8 WTS
0.75
CPC Blend Crude density, kg/l Crude density, Forties 0.7 WTI Brent
0.65
0.6 0.001 0.01 0.1 1 10 Sulphur in crude, %wt 19 20 Canadian crude to US
21 Summary
• Adhesive, durable, waterproof, thermoplastic • Many applications • Not all residues suitable • Complex chemistry • Processing /modifiers can alter properties • Heavy oil production growing
22