dan weidman bp- bitumen bu december 7, 2006
TRANSCRIPT
3
how a refinery makes good quality bitumen
Overview
• Process– how a refinery makes bitumen– how are the different bitumen products made
• Quality– how a refinery makes good quality bitumen
4
Oil products – global consumption
Total = 75 Million barrels/day in 2000
Source: BP
LPG (6.5) Propylene (0.5)
Gasoline (19.7)Naphtha (4.2)
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)
(80 Million barrels/day in 2004)
5
3 - 45 - 10
12 - 18
18 - 2424 - 40
24 - ~300~40 - ~300
Carbonnumber
Boilingpoint (°C)
-10 - 1515 - 150
150 - 260
230 - 370370 - 525
370 -525 -
Product properties
LPGGasoline
Kerosene
Diesel
Lubricating oils
Heavy fuel oil
Bitumen
6
Complex refinery process flow diagramRefinery GasLPG
EthylenePropylene
Benzene
o-Xylene
p-Xylene
Solvents
Aviation Fuel
Diesel / Light heating oilGasoline
Methanol
Ammonia
Sulphur
Bitumen
Petroleum coke
Petroleum coke
Heavy fuel oil
Gases
Naphtha
Middle distillates
Gasoil
Residue
Crude Oil Cru
de o
il di
stilla
tion
VacuumUnit
Reformer
Calciner
Gas Plant
AromaticsUnits
OlefinUnits
Dealkyl.Hydrofiner
HT/FCC
Hydro-cracker
Vis-breaker
Coker
CHD
Bitumen
H2S-GasRefinery
MethanolSynthesis
PartialOxidation Ammonia
Synthesis
Claus
Isomerisation
Alkylation
Separations Conversion Treatments
7
Atmospheric residue
GasGasoline
125 °C150 °C
165 °C
250°C300 °C
280 °C
Pre-heatedcrude oil
Watercondenser
Atmospheric distillation
Kerosine
Gas oil
8
Vacuumdistillates
Vacuum residue(bitumen feedstock)
46 °C
110 °C
185 °C
260°C340 °C
Pre-heatedatmosphericresidue
Watercondenser
385 °C
Vacuum
350 °C(525 °C)
Vacuum distillation
9
Simplest production route for bitumen
Heavycrudes
VacuumDistillation
AtmosphericDistillation
Hard
Soft
Blended grades
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Higher boiling point = harder bitumen
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500 600 700 800 900 1000
True Boiling Point, °C
Res
idue
yie
ld, %
wt
Atmosphericdistillation
Vacuumdistillation
200 pen 42 pen
Distillation curve for Arab Heavy
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Essential properties of refined bitumen
• Specific consistency at key temperatures• Durability = resistance to ageing• Adhesion• Cohesion• Low fuming tendency
12
Bituminous products
Bitumenbase
NormalPaving
PolymerModified
+ polymer
Emulsion+ water& soap
Oxidised+ flux &blowing
Cut Back+ kerosene
13
Bitumen quality depends mainly on choice of crude
0.6
0.65
0.7
0.75
0.8
0.85
0.9
0.95
1
0.001 0.01 0.1 1 10
Sulphur in crude, %wt
Cru
de d
ensi
ty, k
g/l
Heavy
Sweet
Sweet
Sour
SourHeavy Heavy
Light Light
SourSweet
Light
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Refinery activities that influence bitumen
Planning
Scheduling
Processing
Blending Loading
Months Weeks Days Hours
15
Summary of Feedstock Selection Criteria
Available processequipment
Composition Impact onother products
BitumenYield
EconomicQuality
16
Product yield varies from crude to crude
0%
20%
40%
60%
80%
100%
Sahara
n Blend
West T
exas
Inter
mediat
eBren
t Blen
dAmen
amWali
o Export
Isthmus
Terra N
ovaArab
Med
iumDubai
Export
Alaska
North
SlopeBcf-1
7
Demand in 20
00
Volu
me
dist
illed LPG
NaphthaKeroseneGas OilVacuum Residue
API gravity
Sulphur, %wt
45.2 39.8 37.9 37.8 36.3 32.8 31.8 30.8 30.4 27.9 16.2
0.09 0.39 0.44 0.16 0.56 1.36 0.56 2.40 2.05 1.11 2.33
Source: BP
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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
18
Distillation curves
0
10
20
30
40
50
60
70
80
90
100
0 100 200 300 400 500 600 700 800 900 1000
True Boiling Point, °C
Res
idue
yie
ld, %
wt
Atmosphericdistillation
Vacuumdistillation
Cerro Negro
Isla
AH
Kuwait
Iran Light
UralsCossack
19
Heavy crudes are best for bitumen
FortiesCPC Blend
BCF17
WTI Brent
ANS
Arab Light
Dubai Export
UralsMaya
LLK
Souedie
Mars
Kirkuk
WTS
Known bitumen crude
Other crude
0.6
0.65
0.7
0.75
0.8
0.85
0.9
0.95
1
0.001 0.01 0.1 1 10
Sulphur in crude, %wt
Cru
de d
ensi
ty, k
g/l