Creating added Value…

ALBR3CHT Supply Concepts GmbH

CSIR Convention Centre, Pretoria

Thursday, 7. November 2013

High Modulus Asphalt (HiMA) Seminar

- Bitumen Binder -

CRUDES

Yields of Crude:

- Sweet - - Sour -

~ 96 %: -Fuel - Naphtha - Gasoil - Fuel Oil ~ 4 %: - Oils, Lubes - Bitumen

~ 15 %: -Fuel ~15 %: - Oils, Lubes ~ 70 %: - Bitumen

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General Character of some Crude.

CRUDES

Crude API Gravity Sulfur Wt.% Characteristic Pour Point

Saharan Blend (Algeria) 44 0,1 Paraffinic Ver yLow

Forties Blend 41 0,3 Indermediate Low

Ekofisk 39 0,2 Indermediate Low / Medium

Statfjord 39 0,2 Indermediate Medium / High

Es Sider (Lybia) 37 0,3 Very Paraffinic High

Bonny Light 36 0,1 Naphthenic High

Minas (Indonesia) 35 0,1 Very Paraffinic Very High

Arab Light 33 1,7 Paraffinic Low

West Texas Sour 33 1,6 Indermediate Low

Kuwait 31 2,5 Paraffinic Low

Arab Medium 30 2,7 Paraffinic Low

Arab Heavy 27 3 Paraffinic Low

Alaskan North Slope 27 1 Naphthenic Very Low

Maya (Mexico) 22 3,3 Indermediate Low

California Heavy 21 1,2 Naphthenic Low

BCF-17 (Venezuela) 17 2,4 Naphthenic Very Low

Lloydminster (Canada) 15 3,4 Naphthenic Medium / High

Cold Lake Bitumen 8 5 Naphthenic Low

REFINERS & REFINERIES

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The Refiner Questions.

REFINERS

• What type of crude oil? - Heavy / Light - Sweet / Sour - Assay

• What kind of refinery configuration? - Hydroskimming - Hydrocracking - Visbreaker / Coker - Other Upgrading?

• Operating Mode? • Product Prices / Product Yields?

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Gross Product Worth (GPW).

ENGINEERING BITUMEN

• Crude Type: Dubai • Refinery Type: Straight Run (destillation only) • Operating Mode: Maximum Gas Oil • Yields (wt.%): 20% naphtha $977 pmt = $195,40 30% GO $950 pmt = $285,00 46% HFO $670 pmt =$308,20 4% fuel & loss Total GPW =$788,60 (@ 7,26 barrels pmt) GPW ($/bbl) =$108,62 Delivered Crude Cost =$111,00 Variable Processing Cost =$0,30 MARGIN =$2,68-

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Pecking Order – NWE Cracking (no Visbreaker).

REFINERS

Products Brent Arabian Heavy Boscan $ / ton

API 38,3 27,6 10,1

Gasoline 33,2% 22,7% 13,2% 1020,00

Jet 10,0% 6,0% 0,5% 1018,00

Gasoil 34,0% 16,5% -17,0% 955,00

HSFO 0,0% 70,4% 149,0% 675,00

LSFO 18,0% -21,0% -51,7% 690,00

Fuel & Loss 4,8% 5,4% 6,0%

TOTAL 100,0% 100,0% 100,0%

GPW 889,3 780,5 626,4

$ / bbl 110,0 106,00 96,00

Brent Minus 0,00 4,00 14,00

122,5 107,5 86,3

Variable Cost 0,30 0,34 0,30

MARGIN 12,20 1,17 -10,02

CHOICE 1 CHOICE 2 CHOICE 3

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Consequences on Supply.

Each change of ownership will influence the

bitumen output

Seasonality and production priorities will create temporary

overproduction and production shortfalls

The refinery landscape will continue to change

REFINERIES

Technological progress allows bitumen production ‚by choice‘

Production ‚by choice‘ increases pressure to produce profits

at expected levels with bitumen (vs. HFO or VR)

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BITUMEN

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In Consequence:

BITUMEN

Bitumen cannot be in focus of a

refinery:

- Economics

- Crude Yield

- Hardware

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Consequences for Supply.

The producer will make use of the specs: e.g. 70/100

The crude diet will change constantly: „what-

makes-the-dollar-today“ attitude

Less grades will be available

BITUMEN

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Observations.

vs. need for constant prices

vs. longterm security of supply

vs. performance related

production needs

BITUMEN

- Prices fluctuate heavily

- On/off bitumen production

by choice

- Less products / wider

specs

BITUMEN BINDER FOR HIMA

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Bitumen Binder for HiMA.

Small Specification windows: 10/20, 15/25, 20/30

Chemical composition and colloidal structure are strongly

dependent on the manufacturing process

Rheological & ageing properties can vary widely

In High Modulus Asphalt application the binder performance is

crucial

REFINERIES

Balance of properties: optimised modulus, thermal susceptibility

and ageing resistance

Only achievable through special processes and formulations,

hence the need for engineering bitumen

Hence the need for SARA analysis and Gaestel-Index correlation

THE TECHNOLOGY: ENGINEERING BITUMEN

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Crude oil.

ENGINEERING BITUMEN

•There are approximitely 1.500 different crude oils in existence •The natural bitumen yield ranges from ca. 60% to practically 0% •Bitumen ain‘t bitumen as crude oil ain‘t crude oil

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Bitumen Chemistry.

ENGINEERING BITUMEN

•As soon as you start to immerse a bit more into bitumen chemistry you should make yourself realise that bitumen as such is not in existence. You should start to envision it as a pretty wild mixture of different substance groups which are in short described by the acronym SARA:

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SARA.

ENGINEERING BITUMEN

•Saturates or in other words saturated hydrocarbons or alkanes or paraffins are present with 5 – 15 weight-%. Examples: Ethane, Butane, Propane •Aromates or aromatic hydrocarbons (PAH) are present with up to 30 – 45%. Example: Benzene and multipe combinations hereof

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SARA.

ENGINEERING BITUMEN

•Resin or hydrocarbon resins as they are used in varnishes and adhesives are present with 30 – 45% and function as stabiliser for the asphaltenes. Examples: Polyurethane und other resins •Asphaltenes Asphaltenes again are a very complex moleculare structure by itself of Carbon, hydrogen, nitrogen, oxygen, sulphur, vanadium and nickel. Through their structural network they serve as a kind of reinforcement and strongly influence the viscosity. They are present with 5 – 20%.

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It is fundamentally insufficient to define the

quality of a bitumen by its physical properties only.

SEITE 23 ENGINEERING BITUMEN

You have a good quality bitumen, if the

substance groups (SARA) are present in the right

balance to each other.

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The Technology.

ENGINEERING BITUMEN

•Through the controlled chemical processes in a multigrade plant under addition of pressure, heat and air respectively oxygen it is possible to re-arrange chemical structures, respectively to create Asphaltenes. •In a loop reactor these processes are continuosly initiated. •The gentle process and the highly efficient exothermic dehydration reaction reserves the highly polar Aromates/resins fraction and minimizes the coke built up.

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Cornerstones.

ENGINEERING BITUMEN

•Asphaltenes are created. •High polar aromatics /resins are preserved. •The overall bitumen composition improves. •The most economical grade (e. g. 70/100, 160/220 or VR) serves as a feedstock. •All other specs will be produced made to measure. •Bitumen quality shortcomings can be specifically addressed. •Addititves: Polymers (SBS, EVA, Waxes), PPA, Adhesion Promoters etc.

MULTIGRADE BITUMEN

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Multigrade.

MULTIGRADE

•Is a bitumen with a positive penetration index. •Higher modulus at elevated temperatures , less brittle in the cold. •Can be produced in a Multigrade Plant under addition of polyphosphoric acid (PPA). •In many cases performs like a PmB - at significantly lower cost (no expensive polymers), but subsequently no elastic recovery. •Is used e.g. in Australia, France and Poland. •Example: Multifalt from Shell.

And now let‘s talk some Bitumen…