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
SEITE 5
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
SEITE 7
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?
SEITE 8
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-
SEITE 9
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
SEITE 10
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)
SEITE 11
BITUMEN
SEITE 12 SEITE 12
In Consequence:
BITUMEN
Bitumen cannot be in focus of a
refinery:
- Economics
- Crude Yield
- Hardware
SEITE 13
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
SEITE 14 SEITE 14
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
SEITE 16
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
SEITE 18
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
SEITE 19
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:
SEITE 20
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
SEITE 21
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%.
SEITE 22 ENGINEERING BITUMEN
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.
SEITE 24
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.
SEITE 25
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
SEITE 27
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…