Bitumen Production Processes
Bitumen, known for its valuable properties such as adhesion and excellent water impermeability, is produced through specific processes. The primary method of bitumen production involves the distillation of crude oil. In this article, we will explore the processes involved in bitumen production to provide you with a comprehensive understanding.
- Distillation of Crude Oil: Crude oil is subjected to distillation at ambient pressure and temperatures ranging from 300 to 350 degrees Celsius. This distillation process separates the lighter components of crude oil, including gasoline and kerosene. These components are extracted at various temperatures.
- Separation of Heavy Components: The heavy components of crude oil, such as bitumen and lubricating oils, contain high-molecular-weight hydrocarbons. These heavy components are discharged from the lower part of the distillation tower. To separate them, temperatures exceeding 400 degrees Celsius are utilized. The elevated temperature breaks the molecular structure of the heavy components, leading to their thermal degradation. To prevent this, the pressure within the tower needs to be reduced.
- Vacuum Distillation: The residue remaining from the atmospheric distillation tower is further heated in a furnace, typically from 400 to 350 degrees Celsius. It is then directed into a vacuum distillation tower. During this process, water vapor is introduced, facilitating the separation and purification of light volatile substances in fractional columns. At the end of the column, the non-volatile materials, primarily bitumen, are extracted.
These processes allow for the production of bitumen from crude oil, enabling the utilization of its unique properties in various industries. If you have any further questions, feel free to ask.
Bitumen production processes
After the oil and fuel materials are separated under vacuum conditions in the bitumen production process, the vacuum tower residue first enters the oil making unit and then enters the Visbraker unit to produce oil, fuel oil, etc. Finally, these materials enter the bitumen unit.
In the bituminous unit, aeration and oxidation are done inside the reactor by Conventional and Biturox methods, based on temperature changes and aeration rate, they become different grades of bitumen.
In general, two main processes are used to produce bitumen, which we will examine below:
- Discontinuous or discontinuous process
In the discontinuous process, the distillation tower must first be filled with bitumen to the desired level. Preheating will then be achieved by circulating the bitumen between the furnace and the tower. Direct heating by the fire tube in the tower can affect and reduce the quality of the product.
When the bitumen temperature reaches 190-240 degrees, complete aeration should begin. At this time, the heat from the reaction can raise the temperature of bitumen to 260 degrees. Also, the duration of blowing can vary from 3 to 24 hours. In the same way that at the beginning of the process, to prevent the phenomenon of foaming, one should refrain from splashing water into the container, while cooling, when the temperature drops below 200 degrees, water should not be injected into the container.
The continuous aeration unit consists of various components, which are:
Oxidizer Tower
Pre-heater furnace
A system for collecting and burning vapors
Blower or Compressor
- Continuous process
Continuous process is something like discontinuous process; With the difference that whenever the specification of blown bitumen reaches the desired value, fresh feed is continuously and continuously introduced and blown into the product with flow control. Finally, it will be removed by the height controller.
Of course, it is important to mention that the fresh feed is brought in at a lower temperature than the operation temperature and is heated due to the heat caused by the reaction of bitumen blowing inside the tower. Temperature control is done by preheating the incoming feed in a furnace or heat exchanger, using methods such as water injection.
Among the most important advantages of the continuous process in bitumen production can be summarized as follows:
It is easier to produce bitumen
Reducing equipment and maintenance costs
Significant reduction in the amount of polluting vapors
Increase in efficiency and amount of production per unit of time
Reducing the thermal load of edible preheaters
Reducing aeration time and reducing air consumption
And…
Process variables and possible problems
Bitumen production process can be affected by various variables and factors, the most important of which can be mentioned as follows:
Bitumen height
Temperatures
feed composition
Aeration intensity
Aeration time
And…
Of course, at this time, problems may arise:
The final return
The appearance of fleas
Explosion of gases and vapors
Cooling the pipeline and blocking it
And…
Finally, each of the mentioned problems can cause other problems; As:
Further softening of bitumen
increasing its permeability
Dilution of volatile substances
Trapped oils
And…
Effective factors in bitumen production
In general, each bitumen production method can have several advantages and disadvantages; However, today, the continuous process is getting more attention compared to the discontinuous process due to the advantages it offers. Among the most important factors that can be effective in the bitumen production process, can be summarized as follows:
Thermal reaction control, by Cold Recycle
Injecting Snuffing Steam into the tower to prevent fire
The direct effect of the bitumen stop time inside the tower on its softness
Reduction or increase of the reaction rate under the influence of the amount of injected air and temperature
Starting operation at a temperature of 420 degrees Fahrenheit and increasing with increasing temperature up to 550 degrees
Better performance of oxidation and reduction reaction if the difference between temperature (Point 1) and temperature (Base) is high.
Increasing the aeration ratio in conditions where the ratio of temperature changes is constant causes an increase in temperature and decreasing it also causes a decrease in temperature.
Not reducing the stop time if the liquid level is low; Because the contact of hot liquid and excess air released from the liquid molecules leads to fire.
the final conclusion
Bitumen is a practical material that is used in many industries today. The process of bitumen production from crude oil can be done in different ways and in two different processes, including continuous and discontinuous process, and each of these processes can have its own advantages. Various factors such as temperature, aeration time, feed composition, aeration intensity, bitumen height, etc. can be effective in the bitumen production process and the quality of the final product.
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At ATDM CO, we prioritize product quality, reliability, and customer satisfaction. Our bitumen 60/70 is manufactured to meet international standards, ensuring optimal performance and durability in various applications. Currently, we have supplies in three countries of the United Arab Emirates (Dubai), Panama and Singapore are available. We take pride in delivering exceptional products that meet the diverse needs of our valued customers, both domestically and internationally.