Biturox® Multigrade Bitumen - Pörner Group
Biturox® Multigrade Bitumen - Pörner Group
Biturox® Multigrade Bitumen - Pörner Group
Create successful ePaper yourself
Turn your PDF publications into a flip-book with our unique Google optimized e-Paper software.
BITUMEN BY BITUROX ®<br />
10/2008
© OMV<br />
„<strong>Bitumen</strong> is a black,<br />
sticky and, when hot,<br />
smelling material.“<br />
The world of today and tomorrow needs more and<br />
better roads...<br />
Roads have to be inexpensive both in construction and maintenance. In the same sense, they have to proof<br />
maximum durability. And finally, used road paving material should be easily and completely reprocessable<br />
and reusable.<br />
Bituminous binders of highest quality, as a component of road pavement formulations, meet all the criteria<br />
listed above. Furthermore, they perform excellently under extreme climatic conditions and thus can stand<br />
heaviest traffic loads. Under these aspects, bitumen production presents itself as an increasingly attractive<br />
and profitable sector of downstream business.<br />
<strong>Biturox®</strong> Paramo<br />
Pardubice,<br />
Czech Republic<br />
Refineries need more than only crude processing<br />
Today’s petroleum product marketers are more often confronted with the need to supply top bitumen binder<br />
qualities to the construction industry at a reasonable price level. Another business-line of interest is the chemical<br />
specialities industry. Frequently an initial bitumen business is the key-opener for new valuable business<br />
relations in the field of premium lubricants, fuels, process products etc.<br />
The main effort of any large-scale refinery in the world is to produce million of tons of fast moving products<br />
(e.g. gasoline, diesel fuel, kerosene, feedstocks for the petrochemistry etc.) at the least possible overall costs.<br />
Mainly this goal is met by selecting the proper crude mix and using sophisticated refinery technology. This<br />
approach generally has the consequence that a straight production of high quality bitumen is impracticable.<br />
The name of the tool to optimally reconcile the market-demand for top-grade bitumen with the upstream cost<br />
controlling effort is<br />
biturox ®<br />
2
<strong>Pörner</strong>: <strong>Bitumen</strong> Upgrading Specialists<br />
The world largest<br />
Biturox ® plant at<br />
Płock, Poland.<br />
The <strong>Pörner</strong> <strong>Group</strong> with a work force of 350 experts in the field of chemical and refinery engineering is specialised<br />
in bitumen technology. <strong>Pörner</strong> only and alone built the largest number of bitumen processing plants of all<br />
dimensions and all over the world. This achievement enabled <strong>Pörner</strong> <strong>Group</strong> to accumulate the most comprehensive<br />
expert knowledge in engineering, design, construction, start-up and operation of bitumen plants.<br />
Know How – Three columns of competence<br />
The Biturox ® Process represents the modern and proven solution to produce top bitumen qualities from a<br />
great variety of raw materials. The expertise of <strong>Pörner</strong> staff covers technological, economical and market<br />
related aspects. Biturox ® plants have been built according to various national quality standards (conventional<br />
or performance based - such as SHRP).<br />
• Technology<br />
The core piece of the Biturox ® Process is the unequalled loop reactor. In this perfect aeration reactor the thermo-chemical<br />
conversion of selected raw material blends by air-oxygen takes place continuously and under<br />
repeatable conditions. The process allows controlling all important process parameters (pressure, temperature,<br />
flow rates, residence time etc.) with high accuracy. Biturox ® technology proofs that the oxidation process<br />
can run both effectively and very softly: The valuable aromatic components are formed and preserved in the<br />
reaction mixture and, at the same time, the degradation of organic compounds to coke and the build-up of<br />
deposits is minimised. Deriving from the process fundamentals, the features of safe and automated operation<br />
as well as low turnaround and maintenance requirements, make the Biturox ® process to the most attractive<br />
solution for a modern bitumen producer.<br />
Biturox ® Pilot Plant in<br />
Schwechat, Austria.<br />
• Design, Research and Pilot Testing<br />
A satisfying bitumen quality depends on the harmonised balance of its chemical components: saturates, aromatics,<br />
naphthenes, resins, asphaltenes. In more than 30 years and supported by several Hundred of research<br />
laboratory and pilot tests on almost any crude type, <strong>Pörner</strong>, together with its partner OMV, developed methods<br />
how to formulate and to process bitumen: All findings were filed in a comprehensive database of know-how.<br />
Thus <strong>Pörner</strong> is able to recommend for almost any feed stock-product combination the most efficient and least<br />
costly way to make top-bitumen quality.<br />
• Experience<br />
<strong>Pörner</strong> knows much about bitumen: A visco-elastic, complex mixture of chemical compounds, difficult to<br />
handle. Based on <strong>Pörner</strong>‘s engineering expertise the most perfect bitumen plants have been realised. Applying<br />
all principles of efficiency to blending, heating, cooling of bitumen, to optimise instrumentation and automation,<br />
to minimise by-products and emissions, to save and recover energy, to keep maintenance and downtimes<br />
low. Selecting, the ideally suited equipment, minimising delivery times and making construction fast<br />
and easy and to taking care of personnel training, commissioning and start-up.<br />
<strong>Pörner</strong> designs and realises <strong>Bitumen</strong> Plants including all infrastructures out of one hand:<br />
production units of high availability, easy to operate and designed for a long lifetime.<br />
3 3
Modern world of bitumen<br />
Roads are connecting people. <strong>Bitumen</strong> is the most versatile and qualified material for fast construction of<br />
long-life and inexpensive roads. The process product industry is another consumer of extra bitumen qualities<br />
for roofing felts, construction coating, bitumen emulsions etc.<br />
Biturox ® bitumen products contribute to have a „world-wide growing network of perfect roads“ and to have<br />
„tight roofs everywhere“.<br />
Changes - Challenges - Chances<br />
Almost every day crude prices, qualities and availability undergo radical changes. The number of bitumen<br />
producers fall off, as smaller, non-profitable producers have to close their books anywhere. New performance<br />
oriented bitumen standards (e.g. SHRP) show up frequently. Flexibility and rapid response to new demands<br />
are a must in the petroleum industry‘s every day fight for market shares.<br />
The modern refineries generally need to improve the bitumen processing technology, which should fit into<br />
their completely automated manufacturing pattern and contribute to the plant’s economic efficiency by higher<br />
production flexibility combined with an almost complete independence of the crude type available.<br />
The Biturox ® Process offers the solution to produce both multigrade road construction bitumen and high PEN<br />
Index bitumen using a continuous, fully automated operation and achieving nearly full independence from<br />
feedstock quality and price.<br />
Highlight<br />
The Biturox ® Process guarantees the user almost complete independence from crude types, simultaneously<br />
allowing to make the best qualities of bitumen.<br />
The name is the Biturox ® paradoxon: Better quality from cheaper feedstock components.<br />
Biturox ® : High Quality – Efficient – Large Quantities<br />
High PI <strong>Bitumen</strong><br />
Low PI <strong>Bitumen</strong><br />
<strong>Multigrade</strong>:<br />
combined and improved<br />
product characterists<br />
at high as well<br />
as low temperatures.<br />
Stiffness<br />
low temperature limit<br />
for performance<br />
high temperature limit<br />
for performance<br />
Low PI<br />
High PI<br />
temperature range<br />
for compaction<br />
(High PI)<br />
maximum viscosity for<br />
satisfactory compaction<br />
Viscosity<br />
minimum viscosity for<br />
satisfactory compaction<br />
temperature range<br />
for compaction<br />
(Low PI)<br />
4<br />
-50 0 50 100 150<br />
TEMPERATURE ° C<br />
Biturox ® <strong>Multigrade</strong> <strong>Bitumen</strong><br />
© <strong>Pörner</strong> Ingenieurgesellschaft m.b.H.
Biturox ® - <strong>Multigrade</strong> <strong>Bitumen</strong><br />
The designation <strong>Multigrade</strong> used in this leaflet has the same meaning as in the lubricating oil terminology.<br />
<strong>Multigrade</strong> oils are characterised by a reduced dependence of viscosity with temperature. They are able<br />
to do their services over a wider temperature range and are characterised by a high viscosity index. The<br />
same system fits to bitumen products: <strong>Multigrade</strong> can be used in the above sense, viscosity index should be<br />
replaced by penetration index - PI.<br />
• The Feedstock<br />
High molecular weight components of all chemical configuration types, present in most crude oils are suited<br />
as feedstock for the Biturox ® Process. The only exception is, when in the starting material for bitumen the<br />
paraffinic hydrocarbons predominate. In this case the Paratox ® process, a two-step Biturox ® Process, has to<br />
be used. The following products of refining activities are on the list of bitumen raw material:<br />
• Vacuum residue (short residue) VR<br />
• Pitch from bright stock de-asphalting PDA-P<br />
• Aromatic extracts from lubricating oil processing EXT<br />
• Atmospheric residue (long residue)<br />
• Heavy vacuum gas oil HVGO<br />
• Heavy cycle oils from cracking, visbreaking, coking<br />
• The Method<br />
High quality bitumen must show a harmonic distribution of saturates, aromatics, resins and asphaltenes.<br />
Biturox ® multigrade bitumen is made by the method of composition control.<br />
Several raw material components of different chemical nature are selected and combined to an adequate<br />
feed composition. This composition is forwarded to the Biturox ® Process where it is integrated by air oxidation<br />
under clearly defined and absolutely controlled processing conditions.<br />
• Biturox ® -controlled operation<br />
The Biturox ® reactor is the perfect tool for such operation:<br />
efficient, controllable and safe. The feed composition is processed<br />
very gently under elevated pressure and the polarity of<br />
the aromatic components is increased minimising the risks of<br />
local overheating and coke build-up. Internal reactor cooling<br />
allows exact temperature control. The process runs continuously<br />
resulting in a consistent and homogenous finished product<br />
quality.<br />
ANALYSIS OF<br />
FEED COMPONENTS<br />
BY SCANNING<br />
VR<br />
PDA-P<br />
EXT<br />
HVGO<br />
OPTIMIZED FEED<br />
COMPOSITION BY<br />
PILOT TESTING<br />
<strong>Biturox®</strong> Process Scheme<br />
PROCESSING UNDER<br />
SPECIFIC PRESSURE<br />
AND TEMPERATURE<br />
OPTIMIZED FINAL<br />
PRODUCT MEETING<br />
TARGET SPECIFICATION<br />
(MULTIGRADE)<br />
© <strong>Pörner</strong> Ingenieurgesellschaft m.b.H.<br />
Conclusion<br />
<strong>Bitumen</strong> as the residue of crude is chemically very complex. Taking advantage from its research database<br />
and many hundreds of pilot tests carried out on crudes from all over the world, <strong>Pörner</strong> has gained the experience<br />
to optimise feedstock compositions and to design the process most adequate to make a quality product -<br />
even from cheaper feed components.<br />
The Biturox ® Process creates and preserves the valuable medium molecular weight aromatics<br />
in bitumen improving the elastic properties as well as adhesion on the aggregate. The<br />
result is a product with tailored chemical structure and optimum quality characteristics:<br />
Biturox ® <strong>Multigrade</strong> <strong>Bitumen</strong>.<br />
5 5
The Biturox ® pla<br />
Product Storage<br />
and Loading<br />
Product storage designed to keep<br />
the product homogeneous.<br />
Feedstock Section<br />
Circulation in the tanks to establish<br />
an uniform temperature profile.<br />
“BituFil” stations for automated<br />
loading of product to rail wagon or<br />
tank trucks.<br />
Utilities<br />
Plant and instrument<br />
air.<br />
Electrical power, steam,<br />
water<br />
Product Section<br />
6<br />
Product blending for tailor-made<br />
products (optional).<br />
Heat recovery for pre-heating.
nt<br />
Reactor<br />
Inner loop type reactor<br />
design warrants optimised<br />
but also very gentle treatment<br />
of the medium.<br />
Operation is very safe due to<br />
total utilisation of air oxygen.<br />
Pre-heating<br />
Pre-heating of feedstock<br />
blend to processing temperature.<br />
© <strong>Pörner</strong> Ingenieurgesellschaft<br />
7 7
Research and Piloting<br />
Biturox ® Research Facilities<br />
For more than 30 years the Biturox ® Research Centre is an excellently performing service provider to the<br />
whole industry, making or using bitumen. Up to date laboratory and semi-technical research and development<br />
facilities, analytical methods of newest standard and the backup of the nearby OMV refinery enabled and<br />
promoted <strong>Pörner</strong>‘s efforts to stock-up the most comprehensive expertise on bitumen making world-wide.<br />
Two Biturox ® pilot plants are available for practical testing of feedstock or composition of several components<br />
in batch or continuous operating mode. The results of pilot tests are used as design basis for Biturox ® plants<br />
(i.e. reactor rating). Reference samples can be produced from defined feed compositions ready for further<br />
applied testing by the client.<br />
All results of basic and applied research work, the experience gathered during design, construction, start-up<br />
and routine operation of the numerous Biturox ® plants, the information feedback from the Biturox ® licensees,<br />
the newest findings of the Biturox ® Enhancement Technique (chemical upgrading of bitumen) and, obviously,<br />
the performance reports on application of Biturox ® bitumen have been collected in a most comprehensive<br />
database.<br />
Target<br />
Many bitumen research institutes over-emphasise the significance of crude oil provenance and compositional<br />
classification, simultaneously neglecting to notice and to review the chances, which lie in the thermo-chemical<br />
modification of an almost unlimited palette of crude oil derived feedstock.<br />
The main objective of the Biturox ® Research Facilities is therefore, to find methods how to optimise the chemical<br />
composition of bitumen, namely reaction conditions, which promote the synthesis of polar, aromatic compounds<br />
and suppress the decomposition of asphaltenes to coke.<br />
But finally the goals of the said efforts have to be to satisfy the market demand for bitumen qualities with<br />
outstanding and superior application characteristics at a reasonable low price.<br />
Desired characteristics<br />
Fatique resistance<br />
Ability for emulsion<br />
Stiffness<br />
Good short- and long-term aging properties<br />
Compatibility with polymers<br />
Problems to solve<br />
Chemical composition<br />
Life time<br />
Cracking at low temperatures<br />
Rutting at high temperatures<br />
Optimise adhesive properties<br />
Stability<br />
Result<br />
The Biturox ® technology is a representative example how applied and scientific research can be conducted<br />
effectively, rewarding and to the benefit of many people, driving on good roads, living in comfortable accommodations<br />
and both under cost-saving conditions.<br />
Biturox ® MBW<br />
Mitteldeutsches <strong>Bitumen</strong>werk<br />
Granschütz, Germany<br />
8
Project realization<br />
The <strong>Pörner</strong> <strong>Group</strong> is, as documented in this brochure, the most experienced bitumen plant designer and constructor<br />
worldwide. The volume of data in the electronic files is the basis for an expedient and cost-saving<br />
project realisation in every single step. The table below gives a general overview of the scope and steps of the<br />
realisation of a “turn-key grass-root” project:<br />
• Preliminary studies, information & data collection<br />
• Feasibility study<br />
• Evaluation of raw material, laboratory & pilot-plant testing<br />
• Evaluation of the technical, commercial, legal and<br />
ecological conditions<br />
• Presentation of the recommendations to and<br />
acknowledgement by the client<br />
• Action planning, scheduling, project cost assessment<br />
• Chemical, mechanical, civil basic and detail<br />
engineering<br />
• Approval of the final project documents by the<br />
client and by the supervising authorities<br />
• Procurement & logistics of equipment and material<br />
• Engagement and supervision of contractors<br />
• General on-site supervision of the construction work<br />
• Project progress reporting and documentation<br />
• Commission of the completed plant<br />
• Presentation of the plant and operation manuals to the client<br />
• Test run & staff training<br />
• Project post-completion auditing and services<br />
Biturox ® ESHA,<br />
Amsterdam, Netherlands<br />
From Lab Tests to<br />
Turn Key Realization<br />
<strong>Pörner</strong> has learned a lot about bitumen<br />
in more than 35 years.<br />
Make advantage not to repeat any mistake from which <strong>Pörner</strong> has learned in three decades of plant construction!<br />
With <strong>Pörner</strong> the world of<br />
Biturox ® bitumen is yours.<br />
9 9
The Proof: Bitur<br />
Project Client Operator Location Country Year<br />
Biturox ® Wörth Mobil Oil Wörth Mobil Oil Wörth Wörth Germany 1978<br />
Biturox ® Esfahan NIOC NIOC Esfahan Iran 1988<br />
Biturox ® Kaoshiung CPC CPC Kaohsiung Taiwan 1990<br />
Biturox ® Bandar Abbas NIOC NIOC Bandar Abbas Iran 1991<br />
Biturox ® Adelaide Mobil Oil Australia Mobil Adelaide Australia 1992<br />
Biturox ® Plock PKN Orlen Orlen Asfalt Plock Poland 1994<br />
Biturox ® Madras CPCL CPCL Refinery Chennai India 1994<br />
Biturox ® OMV<br />
Schwechat, Austria<br />
Bitukomb Lisichansk Lisichanskij NPZ Lisichanskij NPZ Lisichansk Ukraine 1995<br />
Biturox ® Mangalore Toyo Engineering MRPL Mangalore India 1995<br />
Biturox ® Baku<br />
Azerneftyag<br />
Azerneftyag<br />
Refinery<br />
Baku Azerbaidjan 1995<br />
Biturox ® Krasnovodsk NEKRA NEKRA Turkmenbashi Turkmenistan 1995<br />
Configuration<br />
Capacity<br />
Image<br />
Fact Sheet<br />
1 Reactor, Feedstock heating/cooling<br />
through direct<br />
heat exchange, Scrubber,<br />
Offgas-Incinerator<br />
1,080 tons/day<br />
Configuration<br />
Capacity<br />
Image<br />
Configuration<br />
Capacity<br />
Image<br />
Fact Sheet<br />
1 Reactor, Feedstock<br />
heating/Product cooling<br />
through direct heat<br />
exchange, Knock Out Drum,<br />
Offgas-Incinerator, Pipeline,<br />
truck-, drum- and bag filling<br />
400 tons/day<br />
Fact Sheet<br />
1 Reactor, Feedstock heating/Product<br />
cooling through<br />
spiral heat exchanger and<br />
hot oil<br />
circulation, Scrubber and<br />
Offgas-Incinerator<br />
192 tons/day<br />
10
ox ® References<br />
Project Client Operator Location Country Year<br />
Biturox ® Rayong LGEN IPRC PCL Rayong Thailand 1996<br />
Biturox ® Visakh HPCL Visakh Refinery Visakhapatnam India 1998<br />
Biturox ® Amsterdam ESHA ESHA Amsterdam Netherlands 1998<br />
Biturox ® Myanmar Fritz Werner MPE Yangon Myanmar 1999<br />
Biturox ® Chelyabinsk Dept. Car Roads Dept. Car Roads Chelyabinsk Russia 2000<br />
Biturox ® Bharat BPCL Mumbai Refinery Mumbai India 2000<br />
Biturox ® Jarbit Jarbit Jarbit Jaroslavl Russia 2002<br />
Biturox ® Taiwan Simosa Oil Corp. Simosa Oil Corp. Mailiao Taiwan 2002<br />
Biturox ® Gujarat IOCL Gujarat Refinery Vadodara India 2002<br />
Biturox ® plant<br />
Jaroslavl, Russia<br />
Biturox ® Lavéra Innovene Innovene Lavéra France 2004<br />
Biturox ® Gdansk Grupa Lotos Lotos Asfalt Gdansk Poland 2005<br />
Biturox ® Schwechat OMV OMV Schwechat Austria 2006<br />
Biturox ® Nizhnekamsk TAIF-NK TAIF-NK Nizhnekamsk Russia 2007<br />
Biturox ® Cochin BPCL Kochi Refinery Cochin India 2008<br />
Scope of<br />
services<br />
Capacity<br />
Image<br />
Fact Sheet<br />
Basic design for the process<br />
and off-plot units, detailed<br />
engineering, procurement<br />
and supply of the plant<br />
equipment and material, site<br />
supervision, start-up, training<br />
and documentation (general<br />
contracting)<br />
480 tons/day<br />
Scope of<br />
services<br />
Capacity<br />
Image<br />
Fact Sheet<br />
Basic design, detailed<br />
engineering, procurement<br />
and supply of the process<br />
unit, site su pervision,<br />
start-up assistance, training<br />
and documentation<br />
1,032 tons/day<br />
11 11
WWW.BITUROX.COM<br />
<strong>Pörner</strong> Ingenieurgesellschaft mbH<br />
Hamburgerstraße 9<br />
A-1050 Vienna<br />
Austria<br />
Tel.: +43 (1) 589 90-0<br />
Fax: +43 (1) 589 90-99<br />
Email: vienna@poerner.at<br />
Web: www.poerner.at<br />
www.biturox.com