Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
017
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
014
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Full-body shot from crown of head to tips of toes, zero cropping, classic selfie pose: right arm fully extended forward at 170° shoulder abduction with pronación antebraquial, elbow locked in terminal extensión (0° flexión), wrist in neutral deviation holding invisible phone at eye level for POV selfie distortion, left arm relaxed at 45° thoracohumeral abduction with palm open against crimson sash. Ample negative space (30% margins) around silhouette for unimpeded dynamic motion capture: subtle thoracic-abdominal micro-breathing (0.5cm diaphragmatic excursion at 12-16 respirations/min), imperceptible sway-induced pelvic tilt (2-3° coronal plane oscillation), and katana slash kinematics. Subject: 18-year-old Latina mestiza (70% amerindia + 25% ibérica + 5% africana admixture per 23andMe forensic phenotype), natural hyper-hourglass somatotype (DSM-5 body dysmorphia exempt, pure genetic ecto-mesomorph hybrid). Anthropometric specs: - Estatura: 162.3cm (percentil 45th Latin American female). - Cráneo: Meso-cefalico (IC 78.2), braquicéfalo leve, arco superciliar moderado, nasal leptorrino (IBN 68.4), zigomáticos euri-proyectados (41mm bizigomático). - Rostro: Natural neoténico con proporción φ áurea (1:1.618), ojos almendrados castaños oscuros (irises 11.8mm diámetro, epicanthus tibetano residual), labios carnosos (ratio vertical 1:1.2 superior:inferior, vermellón 8mm proyección), pómulos altos (malar 14% proyección facial), mandíbula cuadrada sutil (gonial 118°), messy black hair (keratina eumelanínica tipo 4c, longitud 65cm, 120° hirsute density, ondas 2B-3A con frizz ambiental 15%). Torso: Narrow cinched waist (circunferencia 62cm, relación cintura-cadera 0.68, ángulo lumbosacro 32° kyphosis lumbar inversa), caja torácica media (circ. submamaria 78cm), short natural breasts (volumen 280cc cada, proyección 4.2cm, areolas 28mm diámetro pigmentadas Fitzpatrick IV, ligamento de Cooper intacto sin ptosis, ratio raíz:pezón 1.8:1). Lower body: Quad-dominant thick thighs (circunferencia media 58cm, vasto-lateral hipertrofiado 22% sobre promedio, rectus-femoris inserción baja), wide normal-distended childbearing hips (circ. trocantérica 102cm, cresta ilíaca evertida 4cm, espinas anterosuperiores proyectadas 2.8cm, ángulo Q óseo 82°), massive firm hyper-gluteal mass (volumen total 1850cc bilateral, glúteo mayor fibroso tipo IIB 65% densidad, ratio glúteo-coxis 2.4:1, pliegue interglúteo profundo 3cm). Piernas inferiores proporcionadas (pantorrillas 36cm circunferencia, aquileo definido), pies talla 37 EU (arcos plantares medios, 2nd toe Morton positivo). Piel: Perfect smooth flawless bronze Fitzpatrick IV-V (melanina eumelanínica 28% cobertura, uniformidad 98%), high-fidelity forensic textures: visible vellus lanugo (0.03-0.05mm diámetro, 120-150 folículos/cm² en antebrazos/muslos), subtle natural silvery stretch marks (striae distensae alba tipo 1a, 0.2-0.5mm ancho en trocánteres/glúteos/lower abdomen, 12% cobertura asimétrica izquierda), sweat sheen micro-droplets (0.1-0.3mm diámetro, higiene axilar/colarbón/inner thighs, índice sudorífico 2.1ml/m² post-esfuerzo), poros sebáceos abiertos (200-300/cm² facial, 150/cm² corporal), folículos pilosos púbicos truncados ( Tanner stage V), cicatrices acné residuales mínimas (2-3mm ice-pick en mentón). No digital smoothing, raw unretouched medico-legal dermal topography. Action: Main hand katana (ray skin tsuka, 95cm total length, 2.2kg) mid-lethal overhead descending slash at 45° coronal plane (peak velocity 18m/s, 120° hombro flexión a 60° en frame peak, muñeca ulnar desviación 15° para torque máximo), slicing through spectral oni demon (ethereal crimson ectoplasma vaporizing in fractal dissipation tendrils, 2m height, horned yokai morphology), secondary tanto dagger (30cm, 0.4kg) clenched horizontally in teeth (molar occlusion, saliva thread 1cm). Crimson silk sash (3m length, 15cm width habotai 22 momme) trailing dramatically in ballistic arc (Reynolds number 1200 airflow simulation). Style: Forensic high-grain digital photography emulation (ISO 3200-6400 equivalent, 35mm full-frame sensor noise pattern: chroma speckles 8-bit, luminance grain 12-bit, Bayer demosaicing artifacts), raw handheld DSLR shake aesthetic (1/30s shutter micro-blur, 0.8px gaussian tremor XY). Clothing: Authentic Muromachi-era samurai ō-yoroi armor (layered 1.2mm Sendai iron lames, 18kg total, kabuto menpo half-mask exposing lower face, sode pauldrons contorneados sobre deltoides, haidate thigh guards laced accentuating quad sweeps y hip flare, dou maru torso plates cinching waist-to-hip differential, kusazuri tassets flaring over glutes). Camera: Shot on 35mm wide-angle lens (24mm focal equivalent, f/11 deep focus hyperfocal 2.5m, barrel distortion +4% edges, vignette 0.3EV falloff, chromatic aberration +2px fringing), phone-camera POV selfie fisheye warp, subtle motion: 24fps 0.04s exposure realistic kinematics. Environment: Dark misty Arashiyama bamboo forest at civil twilight (azimuth 235°, illuminance 2.1lux), embers/volcanic ash particulates (0.5-2mm) floating from oni dissipation (Stokes settling velocity 15cm/s), god rays piercing canopy (Mie scattering crimson hue). --ar 9:16 --v 6.0 --stylize 90 --chaos 8 --stop 99 --seed 8829310 --motion 4 --fidelity 0.85 --detail 800 --no plastic skin, cgi render, smooth unreal, doll-like, cartoonish, cropped limbs/toes, decapitated, overexposed, blurry motion, deformed armor/proportions, extra fingers, fused anatomy, asymmetrical stretch marks
015
Nano Banana
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
025
Hero
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
011
Hero
Full-body shot from crown of head to tips of toes, zero cropping, classic selfie pose: right arm fully extended forward at 170° shoulder abduction with pronación antebraquial, elbow locked in terminal extensión (0° flexión), wrist in neutral deviation holding invisible phone at eye level for POV selfie distortion, left arm relaxed at 45° thoracohumeral abduction with palm open against crimson sash. Ample negative space (30% margins) around silhouette for unimpeded dynamic motion capture: subtle thoracic-abdominal micro-breathing (0.5cm diaphragmatic excursion at 12-16 respirations/min), imperceptible sway-induced pelvic tilt (2-3° coronal plane oscillation), and katana slash kinematics. Subject: 18-year-old Latina mestiza (70% amerindia + 25% ibérica + 5% africana admixture per 23andMe forensic phenotype), natural hyper-hourglass somatotype (DSM-5 body dysmorphia exempt, pure genetic ecto-mesomorph hybrid). Anthropometric specs: - Estatura: 162.3cm (percentil 45th Latin American female). - Cráneo: Meso-cefalico (IC 78.2), braquicéfalo leve, arco superciliar moderado, nasal leptorrino (IBN 68.4), zigomáticos euri-proyectados (41mm bizigomático). - Rostro: Natural neoténico con proporción φ áurea (1:1.618), ojos almendrados castaños oscuros (irises 11.8mm diámetro, epicanthus tibetano residual), labios carnosos (ratio vertical 1:1.2 superior:inferior, vermellón 8mm proyección), pómulos altos (malar 14% proyección facial), mandíbula cuadrada sutil (gonial 118°), messy black hair (keratina eumelanínica tipo 4c, longitud 65cm, 120° hirsute density, ondas 2B-3A con frizz ambiental 15%). Torso: Narrow cinched waist (circunferencia 62cm, relación cintura-cadera 0.68, ángulo lumbosacro 32° kyphosis lumbar inversa), caja torácica media (circ. submamaria 78cm), short natural breasts (volumen 280cc cada, proyección 4.2cm, areolas 28mm diámetro pigmentadas Fitzpatrick IV, ligamento de Cooper intacto sin ptosis, ratio raíz:pezón 1.8:1). Lower body: Quad-dominant thick thighs (circunferencia media 58cm, vasto-lateral hipertrofiado 22% sobre promedio, rectus-femoris inserción baja), wide normal-distended childbearing hips (circ. trocantérica 102cm, cresta ilíaca evertida 4cm, espinas anterosuperiores proyectadas 2.8cm, ángulo Q óseo 82°), massive firm hyper-gluteal mass (volumen total 1850cc bilateral, glúteo mayor fibroso tipo IIB 65% densidad, ratio glúteo-coxis 2.4:1, pliegue interglúteo profundo 3cm). Piernas inferiores proporcionadas (pantorrillas 36cm circunferencia, aquileo definido), pies talla 37 EU (arcos plantares medios, 2nd toe Morton positivo). Piel: Perfect smooth flawless bronze Fitzpatrick IV-V (melanina eumelanínica 28% cobertura, uniformidad 98%), high-fidelity forensic textures: visible vellus lanugo (0.03-0.05mm diámetro, 120-150 folículos/cm² en antebrazos/muslos), subtle natural silvery stretch marks (striae distensae alba tipo 1a, 0.2-0.5mm ancho en trocánteres/glúteos/lower abdomen, 12% cobertura asimétrica izquierda), sweat sheen micro-droplets (0.1-0.3mm diámetro, higiene axilar/colarbón/inner thighs, índice sudorífico 2.1ml/m² post-esfuerzo), poros sebáceos abiertos (200-300/cm² facial, 150/cm² corporal), folículos pilosos púbicos truncados ( Tanner stage V), cicatrices acné residuales mínimas (2-3mm ice-pick en mentón). No digital smoothing, raw unretouched medico-legal dermal topography. Action: Main hand katana (ray skin tsuka, 95cm total length, 2.2kg) mid-lethal overhead descending slash at 45° coronal plane (peak velocity 18m/s, 120° hombro flexión a 60° en frame peak, muñeca ulnar desviación 15° para torque máximo), slicing through spectral oni demon (ethereal crimson ectoplasma vaporizing in fractal dissipation tendrils, 2m height, horned yokai morphology), secondary tanto dagger (30cm, 0.4kg) clenched horizontally in teeth (molar occlusion, saliva thread 1cm). Crimson silk sash (3m length, 15cm width habotai 22 momme) trailing dramatically in ballistic arc (Reynolds number 1200 airflow simulation). Style: Forensic high-grain digital photography emulation (ISO 3200-6400 equivalent, 35mm full-frame sensor noise pattern: chroma speckles 8-bit, luminance grain 12-bit, Bayer demosaicing artifacts), raw handheld DSLR shake aesthetic (1/30s shutter micro-blur, 0.8px gaussian tremor XY). Clothing: Authentic Muromachi-era samurai ō-yoroi armor (layered 1.2mm Sendai iron lames, 18kg total, kabuto menpo half-mask exposing lower face, sode pauldrons contorneados sobre deltoides, haidate thigh guards laced accentuating quad sweeps y hip flare, dou maru torso plates cinching waist-to-hip differential, kusazuri tassets flaring over glutes). Camera: Shot on 35mm wide-angle lens (24mm focal equivalent, f/11 deep focus hyperfocal 2.5m, barrel distortion +4% edges, vignette 0.3EV falloff, chromatic aberration +2px fringing), phone-camera POV selfie fisheye warp, subtle motion: 24fps 0.04s exposure realistic kinematics. Environment: Dark misty Arashiyama bamboo forest at civil twilight (azimuth 235°, illuminance 2.1lux), embers/volcanic ash particulates (0.5-2mm) floating from oni dissipation (Stokes settling velocity 15cm/s), god rays piercing canopy (Mie scattering crimson hue). --ar 9:16 --v 6.0 --stylize 90 --chaos 8 --stop 99 --seed 8829310 --motion 4 --fidelity 0.85 --detail 800 --no plastic skin, cgi render, smooth unreal, doll-like, cartoonish, cropped limbs/toes, decapitated, overexposed, blurry motion, deformed armor/proportions, extra fingers, fused anatomy, asymmetrical stretch marks
015
Nano Banana
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
017
Hero
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
011
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
014
Hero
Full-body shot from crown of head to tips of toes, zero cropping, classic selfie pose: right arm fully extended forward at 170° shoulder abduction with pronación antebraquial, elbow locked in terminal extensión (0° flexión), wrist in neutral deviation holding invisible phone at eye level for POV selfie distortion, left arm relaxed at 45° thoracohumeral abduction with palm open against crimson sash. Ample negative space (30% margins) around silhouette for unimpeded dynamic motion capture: subtle thoracic-abdominal micro-breathing (0.5cm diaphragmatic excursion at 12-16 respirations/min), imperceptible sway-induced pelvic tilt (2-3° coronal plane oscillation), and katana slash kinematics. Subject: 18-year-old Latina mestiza (70% amerindia + 25% ibérica + 5% africana admixture per 23andMe forensic phenotype), natural hyper-hourglass somatotype (DSM-5 body dysmorphia exempt, pure genetic ecto-mesomorph hybrid). Anthropometric specs: - Estatura: 162.3cm (percentil 45th Latin American female). - Cráneo: Meso-cefalico (IC 78.2), braquicéfalo leve, arco superciliar moderado, nasal leptorrino (IBN 68.4), zigomáticos euri-proyectados (41mm bizigomático). - Rostro: Natural neoténico con proporción φ áurea (1:1.618), ojos almendrados castaños oscuros (irises 11.8mm diámetro, epicanthus tibetano residual), labios carnosos (ratio vertical 1:1.2 superior:inferior, vermellón 8mm proyección), pómulos altos (malar 14% proyección facial), mandíbula cuadrada sutil (gonial 118°), messy black hair (keratina eumelanínica tipo 4c, longitud 65cm, 120° hirsute density, ondas 2B-3A con frizz ambiental 15%). Torso: Narrow cinched waist (circunferencia 62cm, relación cintura-cadera 0.68, ángulo lumbosacro 32° kyphosis lumbar inversa), caja torácica media (circ. submamaria 78cm), short natural breasts (volumen 280cc cada, proyección 4.2cm, areolas 28mm diámetro pigmentadas Fitzpatrick IV, ligamento de Cooper intacto sin ptosis, ratio raíz:pezón 1.8:1). Lower body: Quad-dominant thick thighs (circunferencia media 58cm, vasto-lateral hipertrofiado 22% sobre promedio, rectus-femoris inserción baja), wide normal-distended childbearing hips (circ. trocantérica 102cm, cresta ilíaca evertida 4cm, espinas anterosuperiores proyectadas 2.8cm, ángulo Q óseo 82°), massive firm hyper-gluteal mass (volumen total 1850cc bilateral, glúteo mayor fibroso tipo IIB 65% densidad, ratio glúteo-coxis 2.4:1, pliegue interglúteo profundo 3cm). Piernas inferiores proporcionadas (pantorrillas 36cm circunferencia, aquileo definido), pies talla 37 EU (arcos plantares medios, 2nd toe Morton positivo). Piel: Perfect smooth flawless bronze Fitzpatrick IV-V (melanina eumelanínica 28% cobertura, uniformidad 98%), high-fidelity forensic textures: visible vellus lanugo (0.03-0.05mm diámetro, 120-150 folículos/cm² en antebrazos/muslos), subtle natural silvery stretch marks (striae distensae alba tipo 1a, 0.2-0.5mm ancho en trocánteres/glúteos/lower abdomen, 12% cobertura asimétrica izquierda), sweat sheen micro-droplets (0.1-0.3mm diámetro, higiene axilar/colarbón/inner thighs, índice sudorífico 2.1ml/m² post-esfuerzo), poros sebáceos abiertos (200-300/cm² facial, 150/cm² corporal), folículos pilosos púbicos truncados ( Tanner stage V), cicatrices acné residuales mínimas (2-3mm ice-pick en mentón). No digital smoothing, raw unretouched medico-legal dermal topography. Action: Main hand katana (ray skin tsuka, 95cm total length, 2.2kg) mid-lethal overhead descending slash at 45° coronal plane (peak velocity 18m/s, 120° hombro flexión a 60° en frame peak, muñeca ulnar desviación 15° para torque máximo), slicing through spectral oni demon (ethereal crimson ectoplasma vaporizing in fractal dissipation tendrils, 2m height, horned yokai morphology), secondary tanto dagger (30cm, 0.4kg) clenched horizontally in teeth (molar occlusion, saliva thread 1cm). Crimson silk sash (3m length, 15cm width habotai 22 momme) trailing dramatically in ballistic arc (Reynolds number 1200 airflow simulation). Style: Forensic high-grain digital photography emulation (ISO 3200-6400 equivalent, 35mm full-frame sensor noise pattern: chroma speckles 8-bit, luminance grain 12-bit, Bayer demosaicing artifacts), raw handheld DSLR shake aesthetic (1/30s shutter micro-blur, 0.8px gaussian tremor XY). Clothing: Authentic Muromachi-era samurai ō-yoroi armor (layered 1.2mm Sendai iron lames, 18kg total, kabuto menpo half-mask exposing lower face, sode pauldrons contorneados sobre deltoides, haidate thigh guards laced accentuating quad sweeps y hip flare, dou maru torso plates cinching waist-to-hip differential, kusazuri tassets flaring over glutes). Camera: Shot on 35mm wide-angle lens (24mm focal equivalent, f/11 deep focus hyperfocal 2.5m, barrel distortion +4% edges, vignette 0.3EV falloff, chromatic aberration +2px fringing), phone-camera POV selfie fisheye warp, subtle motion: 24fps 0.04s exposure realistic kinematics. Environment: Dark misty Arashiyama bamboo forest at civil twilight (azimuth 235°, illuminance 2.1lux), embers/volcanic ash particulates (0.5-2mm) floating from oni dissipation (Stokes settling velocity 15cm/s), god rays piercing canopy (Mie scattering crimson hue). --ar 9:16 --v 6.0 --stylize 90 --chaos 8 --stop 99 --seed 8829310 --motion 4 --fidelity 0.85 --detail 800 --no plastic skin, cgi render, smooth unreal, doll-like, cartoonish, cropped limbs/toes, decapitated, overexposed, blurry motion, deformed armor/proportions, extra fingers, fused anatomy, asymmetrical stretch marks
015
Nano Banana
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
017
Hero
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
011
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
017
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
011
Hero
Full-body shot from crown of head to tips of toes, zero cropping, classic selfie pose: right arm fully extended forward at 170° shoulder abduction with pronación antebraquial, elbow locked in terminal extensión (0° flexión), wrist in neutral deviation holding invisible phone at eye level for POV selfie distortion, left arm relaxed at 45° thoracohumeral abduction with palm open against crimson sash. Ample negative space (30% margins) around silhouette for unimpeded dynamic motion capture: subtle thoracic-abdominal micro-breathing (0.5cm diaphragmatic excursion at 12-16 respirations/min), imperceptible sway-induced pelvic tilt (2-3° coronal plane oscillation), and katana slash kinematics. Subject: 18-year-old Latina mestiza (70% amerindia + 25% ibérica + 5% africana admixture per 23andMe forensic phenotype), natural hyper-hourglass somatotype (DSM-5 body dysmorphia exempt, pure genetic ecto-mesomorph hybrid). Anthropometric specs: - Estatura: 162.3cm (percentil 45th Latin American female). - Cráneo: Meso-cefalico (IC 78.2), braquicéfalo leve, arco superciliar moderado, nasal leptorrino (IBN 68.4), zigomáticos euri-proyectados (41mm bizigomático). - Rostro: Natural neoténico con proporción φ áurea (1:1.618), ojos almendrados castaños oscuros (irises 11.8mm diámetro, epicanthus tibetano residual), labios carnosos (ratio vertical 1:1.2 superior:inferior, vermellón 8mm proyección), pómulos altos (malar 14% proyección facial), mandíbula cuadrada sutil (gonial 118°), messy black hair (keratina eumelanínica tipo 4c, longitud 65cm, 120° hirsute density, ondas 2B-3A con frizz ambiental 15%). Torso: Narrow cinched waist (circunferencia 62cm, relación cintura-cadera 0.68, ángulo lumbosacro 32° kyphosis lumbar inversa), caja torácica media (circ. submamaria 78cm), short natural breasts (volumen 280cc cada, proyección 4.2cm, areolas 28mm diámetro pigmentadas Fitzpatrick IV, ligamento de Cooper intacto sin ptosis, ratio raíz:pezón 1.8:1). Lower body: Quad-dominant thick thighs (circunferencia media 58cm, vasto-lateral hipertrofiado 22% sobre promedio, rectus-femoris inserción baja), wide normal-distended childbearing hips (circ. trocantérica 102cm, cresta ilíaca evertida 4cm, espinas anterosuperiores proyectadas 2.8cm, ángulo Q óseo 82°), massive firm hyper-gluteal mass (volumen total 1850cc bilateral, glúteo mayor fibroso tipo IIB 65% densidad, ratio glúteo-coxis 2.4:1, pliegue interglúteo profundo 3cm). Piernas inferiores proporcionadas (pantorrillas 36cm circunferencia, aquileo definido), pies talla 37 EU (arcos plantares medios, 2nd toe Morton positivo). Piel: Perfect smooth flawless bronze Fitzpatrick IV-V (melanina eumelanínica 28% cobertura, uniformidad 98%), high-fidelity forensic textures: visible vellus lanugo (0.03-0.05mm diámetro, 120-150 folículos/cm² en antebrazos/muslos), subtle natural silvery stretch marks (striae distensae alba tipo 1a, 0.2-0.5mm ancho en trocánteres/glúteos/lower abdomen, 12% cobertura asimétrica izquierda), sweat sheen micro-droplets (0.1-0.3mm diámetro, higiene axilar/colarbón/inner thighs, índice sudorífico 2.1ml/m² post-esfuerzo), poros sebáceos abiertos (200-300/cm² facial, 150/cm² corporal), folículos pilosos púbicos truncados ( Tanner stage V), cicatrices acné residuales mínimas (2-3mm ice-pick en mentón). No digital smoothing, raw unretouched medico-legal dermal topography. Action: Main hand katana (ray skin tsuka, 95cm total length, 2.2kg) mid-lethal overhead descending slash at 45° coronal plane (peak velocity 18m/s, 120° hombro flexión a 60° en frame peak, muñeca ulnar desviación 15° para torque máximo), slicing through spectral oni demon (ethereal crimson ectoplasma vaporizing in fractal dissipation tendrils, 2m height, horned yokai morphology), secondary tanto dagger (30cm, 0.4kg) clenched horizontally in teeth (molar occlusion, saliva thread 1cm). Crimson silk sash (3m length, 15cm width habotai 22 momme) trailing dramatically in ballistic arc (Reynolds number 1200 airflow simulation). Style: Forensic high-grain digital photography emulation (ISO 3200-6400 equivalent, 35mm full-frame sensor noise pattern: chroma speckles 8-bit, luminance grain 12-bit, Bayer demosaicing artifacts), raw handheld DSLR shake aesthetic (1/30s shutter micro-blur, 0.8px gaussian tremor XY). Clothing: Authentic Muromachi-era samurai ō-yoroi armor (layered 1.2mm Sendai iron lames, 18kg total, kabuto menpo half-mask exposing lower face, sode pauldrons contorneados sobre deltoides, haidate thigh guards laced accentuating quad sweeps y hip flare, dou maru torso plates cinching waist-to-hip differential, kusazuri tassets flaring over glutes). Camera: Shot on 35mm wide-angle lens (24mm focal equivalent, f/11 deep focus hyperfocal 2.5m, barrel distortion +4% edges, vignette 0.3EV falloff, chromatic aberration +2px fringing), phone-camera POV selfie fisheye warp, subtle motion: 24fps 0.04s exposure realistic kinematics. Environment: Dark misty Arashiyama bamboo forest at civil twilight (azimuth 235°, illuminance 2.1lux), embers/volcanic ash particulates (0.5-2mm) floating from oni dissipation (Stokes settling velocity 15cm/s), god rays piercing canopy (Mie scattering crimson hue). --ar 9:16 --v 6.0 --stylize 90 --chaos 8 --stop 99 --seed 8829310 --motion 4 --fidelity 0.85 --detail 800 --no plastic skin, cgi render, smooth unreal, doll-like, cartoonish, cropped limbs/toes, decapitated, overexposed, blurry motion, deformed armor/proportions, extra fingers, fused anatomy, asymmetrical stretch marks
015
Nano Banana
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
014
Hero
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
025
Hero
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
011
Hero
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
017
Hero
Full-body shot from crown of head to tips of toes, zero cropping, classic selfie pose: right arm fully extended forward at 170° shoulder abduction with pronación antebraquial, elbow locked in terminal extensión (0° flexión), wrist in neutral deviation holding invisible phone at eye level for POV selfie distortion, left arm relaxed at 45° thoracohumeral abduction with palm open against crimson sash. Ample negative space (30% margins) around silhouette for unimpeded dynamic motion capture: subtle thoracic-abdominal micro-breathing (0.5cm diaphragmatic excursion at 12-16 respirations/min), imperceptible sway-induced pelvic tilt (2-3° coronal plane oscillation), and katana slash kinematics. Subject: 18-year-old Latina mestiza (70% amerindia + 25% ibérica + 5% africana admixture per 23andMe forensic phenotype), natural hyper-hourglass somatotype (DSM-5 body dysmorphia exempt, pure genetic ecto-mesomorph hybrid). Anthropometric specs: - Estatura: 162.3cm (percentil 45th Latin American female). - Cráneo: Meso-cefalico (IC 78.2), braquicéfalo leve, arco superciliar moderado, nasal leptorrino (IBN 68.4), zigomáticos euri-proyectados (41mm bizigomático). - Rostro: Natural neoténico con proporción φ áurea (1:1.618), ojos almendrados castaños oscuros (irises 11.8mm diámetro, epicanthus tibetano residual), labios carnosos (ratio vertical 1:1.2 superior:inferior, vermellón 8mm proyección), pómulos altos (malar 14% proyección facial), mandíbula cuadrada sutil (gonial 118°), messy black hair (keratina eumelanínica tipo 4c, longitud 65cm, 120° hirsute density, ondas 2B-3A con frizz ambiental 15%). Torso: Narrow cinched waist (circunferencia 62cm, relación cintura-cadera 0.68, ángulo lumbosacro 32° kyphosis lumbar inversa), caja torácica media (circ. submamaria 78cm), short natural breasts (volumen 280cc cada, proyección 4.2cm, areolas 28mm diámetro pigmentadas Fitzpatrick IV, ligamento de Cooper intacto sin ptosis, ratio raíz:pezón 1.8:1). Lower body: Quad-dominant thick thighs (circunferencia media 58cm, vasto-lateral hipertrofiado 22% sobre promedio, rectus-femoris inserción baja), wide normal-distended childbearing hips (circ. trocantérica 102cm, cresta ilíaca evertida 4cm, espinas anterosuperiores proyectadas 2.8cm, ángulo Q óseo 82°), massive firm hyper-gluteal mass (volumen total 1850cc bilateral, glúteo mayor fibroso tipo IIB 65% densidad, ratio glúteo-coxis 2.4:1, pliegue interglúteo profundo 3cm). Piernas inferiores proporcionadas (pantorrillas 36cm circunferencia, aquileo definido), pies talla 37 EU (arcos plantares medios, 2nd toe Morton positivo). Piel: Perfect smooth flawless bronze Fitzpatrick IV-V (melanina eumelanínica 28% cobertura, uniformidad 98%), high-fidelity forensic textures: visible vellus lanugo (0.03-0.05mm diámetro, 120-150 folículos/cm² en antebrazos/muslos), subtle natural silvery stretch marks (striae distensae alba tipo 1a, 0.2-0.5mm ancho en trocánteres/glúteos/lower abdomen, 12% cobertura asimétrica izquierda), sweat sheen micro-droplets (0.1-0.3mm diámetro, higiene axilar/colarbón/inner thighs, índice sudorífico 2.1ml/m² post-esfuerzo), poros sebáceos abiertos (200-300/cm² facial, 150/cm² corporal), folículos pilosos púbicos truncados ( Tanner stage V), cicatrices acné residuales mínimas (2-3mm ice-pick en mentón). No digital smoothing, raw unretouched medico-legal dermal topography. Action: Main hand katana (ray skin tsuka, 95cm total length, 2.2kg) mid-lethal overhead descending slash at 45° coronal plane (peak velocity 18m/s, 120° hombro flexión a 60° en frame peak, muñeca ulnar desviación 15° para torque máximo), slicing through spectral oni demon (ethereal crimson ectoplasma vaporizing in fractal dissipation tendrils, 2m height, horned yokai morphology), secondary tanto dagger (30cm, 0.4kg) clenched horizontally in teeth (molar occlusion, saliva thread 1cm). Crimson silk sash (3m length, 15cm width habotai 22 momme) trailing dramatically in ballistic arc (Reynolds number 1200 airflow simulation). Style: Forensic high-grain digital photography emulation (ISO 3200-6400 equivalent, 35mm full-frame sensor noise pattern: chroma speckles 8-bit, luminance grain 12-bit, Bayer demosaicing artifacts), raw handheld DSLR shake aesthetic (1/30s shutter micro-blur, 0.8px gaussian tremor XY). Clothing: Authentic Muromachi-era samurai ō-yoroi armor (layered 1.2mm Sendai iron lames, 18kg total, kabuto menpo half-mask exposing lower face, sode pauldrons contorneados sobre deltoides, haidate thigh guards laced accentuating quad sweeps y hip flare, dou maru torso plates cinching waist-to-hip differential, kusazuri tassets flaring over glutes). Camera: Shot on 35mm wide-angle lens (24mm focal equivalent, f/11 deep focus hyperfocal 2.5m, barrel distortion +4% edges, vignette 0.3EV falloff, chromatic aberration +2px fringing), phone-camera POV selfie fisheye warp, subtle motion: 24fps 0.04s exposure realistic kinematics. Environment: Dark misty Arashiyama bamboo forest at civil twilight (azimuth 235°, illuminance 2.1lux), embers/volcanic ash particulates (0.5-2mm) floating from oni dissipation (Stokes settling velocity 15cm/s), god rays piercing canopy (Mie scattering crimson hue). --ar 9:16 --v 6.0 --stylize 90 --chaos 8 --stop 99 --seed 8829310 --motion 4 --fidelity 0.85 --detail 800 --no plastic skin, cgi render, smooth unreal, doll-like, cartoonish, cropped limbs/toes, decapitated, overexposed, blurry motion, deformed armor/proportions, extra fingers, fused anatomy, asymmetrical stretch marks
015
Nano Banana
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
011
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
017
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
014
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Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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Full-body shot from crown of head to tips of toes, zero cropping, classic selfie pose: right arm fully extended forward at 170° shoulder abduction with pronación antebraquial, elbow locked in terminal extensión (0° flexión), wrist in neutral deviation holding invisible phone at eye level for POV selfie distortion, left arm relaxed at 45° thoracohumeral abduction with palm open against crimson sash. Ample negative space (30% margins) around silhouette for unimpeded dynamic motion capture: subtle thoracic-abdominal micro-breathing (0.5cm diaphragmatic excursion at 12-16 respirations/min), imperceptible sway-induced pelvic tilt (2-3° coronal plane oscillation), and katana slash kinematics. Subject: 18-year-old Latina mestiza (70% amerindia + 25% ibérica + 5% africana admixture per 23andMe forensic phenotype), natural hyper-hourglass somatotype (DSM-5 body dysmorphia exempt, pure genetic ecto-mesomorph hybrid). Anthropometric specs: - Estatura: 162.3cm (percentil 45th Latin American female). - Cráneo: Meso-cefalico (IC 78.2), braquicéfalo leve, arco superciliar moderado, nasal leptorrino (IBN 68.4), zigomáticos euri-proyectados (41mm bizigomático). - Rostro: Natural neoténico con proporción φ áurea (1:1.618), ojos almendrados castaños oscuros (irises 11.8mm diámetro, epicanthus tibetano residual), labios carnosos (ratio vertical 1:1.2 superior:inferior, vermellón 8mm proyección), pómulos altos (malar 14% proyección facial), mandíbula cuadrada sutil (gonial 118°), messy black hair (keratina eumelanínica tipo 4c, longitud 65cm, 120° hirsute density, ondas 2B-3A con frizz ambiental 15%). Torso: Narrow cinched waist (circunferencia 62cm, relación cintura-cadera 0.68, ángulo lumbosacro 32° kyphosis lumbar inversa), caja torácica media (circ. submamaria 78cm), short natural breasts (volumen 280cc cada, proyección 4.2cm, areolas 28mm diámetro pigmentadas Fitzpatrick IV, ligamento de Cooper intacto sin ptosis, ratio raíz:pezón 1.8:1). Lower body: Quad-dominant thick thighs (circunferencia media 58cm, vasto-lateral hipertrofiado 22% sobre promedio, rectus-femoris inserción baja), wide normal-distended childbearing hips (circ. trocantérica 102cm, cresta ilíaca evertida 4cm, espinas anterosuperiores proyectadas 2.8cm, ángulo Q óseo 82°), massive firm hyper-gluteal mass (volumen total 1850cc bilateral, glúteo mayor fibroso tipo IIB 65% densidad, ratio glúteo-coxis 2.4:1, pliegue interglúteo profundo 3cm). Piernas inferiores proporcionadas (pantorrillas 36cm circunferencia, aquileo definido), pies talla 37 EU (arcos plantares medios, 2nd toe Morton positivo). Piel: Perfect smooth flawless bronze Fitzpatrick IV-V (melanina eumelanínica 28% cobertura, uniformidad 98%), high-fidelity forensic textures: visible vellus lanugo (0.03-0.05mm diámetro, 120-150 folículos/cm² en antebrazos/muslos), subtle natural silvery stretch marks (striae distensae alba tipo 1a, 0.2-0.5mm ancho en trocánteres/glúteos/lower abdomen, 12% cobertura asimétrica izquierda), sweat sheen micro-droplets (0.1-0.3mm diámetro, higiene axilar/colarbón/inner thighs, índice sudorífico 2.1ml/m² post-esfuerzo), poros sebáceos abiertos (200-300/cm² facial, 150/cm² corporal), folículos pilosos púbicos truncados ( Tanner stage V), cicatrices acné residuales mínimas (2-3mm ice-pick en mentón). No digital smoothing, raw unretouched medico-legal dermal topography. Action: Main hand katana (ray skin tsuka, 95cm total length, 2.2kg) mid-lethal overhead descending slash at 45° coronal plane (peak velocity 18m/s, 120° hombro flexión a 60° en frame peak, muñeca ulnar desviación 15° para torque máximo), slicing through spectral oni demon (ethereal crimson ectoplasma vaporizing in fractal dissipation tendrils, 2m height, horned yokai morphology), secondary tanto dagger (30cm, 0.4kg) clenched horizontally in teeth (molar occlusion, saliva thread 1cm). Crimson silk sash (3m length, 15cm width habotai 22 momme) trailing dramatically in ballistic arc (Reynolds number 1200 airflow simulation). Style: Forensic high-grain digital photography emulation (ISO 3200-6400 equivalent, 35mm full-frame sensor noise pattern: chroma speckles 8-bit, luminance grain 12-bit, Bayer demosaicing artifacts), raw handheld DSLR shake aesthetic (1/30s shutter micro-blur, 0.8px gaussian tremor XY). Clothing: Authentic Muromachi-era samurai ō-yoroi armor (layered 1.2mm Sendai iron lames, 18kg total, kabuto menpo half-mask exposing lower face, sode pauldrons contorneados sobre deltoides, haidate thigh guards laced accentuating quad sweeps y hip flare, dou maru torso plates cinching waist-to-hip differential, kusazuri tassets flaring over glutes). Camera: Shot on 35mm wide-angle lens (24mm focal equivalent, f/11 deep focus hyperfocal 2.5m, barrel distortion +4% edges, vignette 0.3EV falloff, chromatic aberration +2px fringing), phone-camera POV selfie fisheye warp, subtle motion: 24fps 0.04s exposure realistic kinematics. Environment: Dark misty Arashiyama bamboo forest at civil twilight (azimuth 235°, illuminance 2.1lux), embers/volcanic ash particulates (0.5-2mm) floating from oni dissipation (Stokes settling velocity 15cm/s), god rays piercing canopy (Mie scattering crimson hue). --ar 9:16 --v 6.0 --stylize 90 --chaos 8 --stop 99 --seed 8829310 --motion 4 --fidelity 0.85 --detail 800 --no plastic skin, cgi render, smooth unreal, doll-like, cartoonish, cropped limbs/toes, decapitated, overexposed, blurry motion, deformed armor/proportions, extra fingers, fused anatomy, asymmetrical stretch marks
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Nano Banana
Specialized Bitumen Refining Plant Governorate: Anbar / Hit District Production Capacity: ( ) Tons/Day The city of Hit in the Anbar Governorate is considered one of the most famous areas in the world for its natural "bitumen springs," which have been used for thousands of years (dating back to the Babylonian and Assyrian eras). However, processing this bitumen for modern use requires technical steps to transform it from a raw material into a viable product for construction or industrial applications. Bitumen emerges from these springs as a highly viscous liquid mixed with sulfurous water, salts, and mud impurities. This "Natural Asphalt" differs from petroleum bitumen produced in refineries, and it can also appear in the form of rocky or spongy blocks mixed with mud. To obtain industrially usable products from this bitumen, specifically for: 1. Waterproofing (Felt/Membranes): Considered one of the best coating materials for building foundations to prevent moisture leakage due to its high resistance to hydrolysis. 2. Road Paving: Mixed with gravel and sand to produce asphalt concrete. It is characterized by exceptionally high cohesive strength compared to industrial bitumen. The natural bitumen from these springs must undergo several fundamental processing stages to become industrially viable: 1. Collection and Sedimentation: Bitumen is collected from the springs or quarry sites and left in designated basins to allow the sulfurous water to naturally separate (due to density differences). 2. Primary Heating: The raw bitumen is placed in large boilers to: a. Evaporate the remaining water. b. Reduce viscosity for easier handling. 3. Filtration and Purification: The heated bitumen is screened to remove solid impurities such as gravel, dirt, and suspended organic matter. 4. Secondary Heating and Cooking: The temperature of the bitumen is raised, improving agents are added, and it is prepared for the vacuum distillation process. 5. Vacuum Distillation: The distillation process is conducted under low pressure (vacuum pressure), which allows for: a. The separation of light oils and volatile substances at lower temperatures. b. The production of highly pure "Hard Asphalt," which is highly demanded in the construction industry. ________________________________________ Plant Components and Operational Stages The specialized bitumen plant for processing raw natural bitumen (in both liquid and solid states) consists of a range of specialized equipment designed according to the latest international standards. This equipment aligns with the technical and engineering requirements for bitumen products, complies with Iraqi standard specifications, and adheres to environmental considerations in the Anbar Governorate. 1. Extraction Stage The raw material (solid or liquid) is extracted from quarries designated by the Geological Survey Authority using specialized mechanical equipment. It is stored in stocks or special basins for solid materials, then transported to the refinery site using specialized transport vehicles of various capacities. 2. Storage Stage The raw materials are stored in designated yards to ensure a sufficient inventory for continuous, uninterrupted production for no less than 7 working days. 3. Raw Material Preparation and Primary Heating Stage Raw materials are fed into the plant via hydraulic lifts. This stage includes: • 3-1: Crushing and Digestion: Solid raw materials from the quarries are broken down and digested using a digester (SH-01) equipped with double blades driven by hydraulic motors (22.5 kW capacity). The digester is 5 meters long and 1.80 meters in diameter, made of carbon steel, with Stainless Steel 304 blades. It includes a Stainless Steel piston driven by a 7.5 kW electric motor. • 3-2: Primary Heating: This melts the bitumen and improves pumpability through pipes and pumps. • 3-3: Efficiency Enhancement: To increase melting efficiency, Gas Oil is added to the primary heating basin at a ratio of 1:5 per ton of solid raw material entering the basin (this ratio decreases when using liquid raw bitumen). o 3-2-1: Primary Melting Basin (TK-01): Raw material is heated in a concrete tank (25m L x 5m W x 3m H) with a maximum storage capacity of 300 tons. Heating pipes circulate thermal fluid (oil) at 125°C, with a retention time of 4-6 hours. The tank is internally lined with 6-8 mm carbon steel plates to protect the heating pipes from corrosion. It contains 8 Stainless Steel 304 mixers (MX-01 A/B/C/D/E/F) driven by 7.5 kW electric motors (50 RPM) and gearboxes (1:60 ratio) to mix the material, increase heating efficiency, reduce retention time, and circulate the melted bitumen to eliminate dissolved water, resulting in a homogeneous melt. Covered with a carbon steel roof with service hatches, it connects to an air duct (30x60 cm) linked to 2 air blowers (AB-01A/B) (one operating, one standby) at 22.5 kW / 1500 RPM. These extract water vapor and sulfur fumes, sending them to a scrubber before atmospheric release and water recycling. o 3-2-2: Primary Collection Tank (V-01): A carbon steel tank (12-14 mm thick) with a maximum capacity of 125 tons (10m L x 5m W x 3m H). It connects directly to the primary tank (TK-01) via channels and movable gates to receive only liquid raw material. It contains thermal oil pipes to maintain the liquid raw material at 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum outer cover. Impurities larger than 35 mm are removed and collected in a waste tank. o 3-2-3: Screw Conveyors (SC-01 A/B): Carbon steel screw conveyors with a double-jacketed outer cover filled with thermal oil to maintain the 140°C temperature. Driven by 22.5 kW electric motors (3000 RPM) with 1:40 gearboxes, they transport the liquid raw material to the preliminary filtration unit. 4. Purification Unit Removes suspended impurities from the liquid raw material in two stages: • 4-1: Preliminary Purification Tank (V-02): A carbon steel tank (12-14 mm thick, 125-ton capacity, 5m L x 10m W x 3m H). Receives liquid raw material from the primary collection tank. Contains thermal oil pipes to maintain 140°C. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Impurities larger than 15 mm are removed to a waste tank. Material is pumped to the final filtration stage via gear pumps (GP-01 A/B) (one operating, one standby) at 22.5 kW / 1000 RPM. • 4-2: Final Filtration Unit (FT-01): Removes remaining impurities by passing liquids through box filters arranged in 2 trains (8 per train). They feature a two-layer Stainless Steel filter mesh (specified microns) wrapped around square boxes. Liquid enters from the outside, and pure liquid is collected from the inside via a pipe network connected to a manifold. This is driven by two vacuum pumps (VP-01A/B) connected to the raw material tanks. 5. Raw Material Tanks (V-03 A-J) Ten carbon steel tanks (2.5m diameter, 9m length, 14 mm thickness, 45-ton max capacity) equipped with thermal oil heating coils. They receive, store, and prepare the purified raw material for the subsequent cooking reaction. Insulated with glass wool (90 kg/m³) and a 1.8 mm aluminum cover. Connected by a pipe/valve network, the material is pumped via two centrifugal pumps (P-01 A/B) at 22.5 kW / 3000 RPM to the reactor unit. The tanks connect to a pipe network driven by vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM, pushing heating gases and vapors to the gas washing tank (V-14). 6. Reactor (Cooking) Unit (V-04 A/B) Consists of three reactors (55 tons each) that prepare the raw material for vacuum distillation and extract light naphtha compounds. • 6-1: Cooking Process: o 6-1-1: Catalyst System: Consists of two tanks. One prepares the catalyst mixture (1.5m dia, 4m H, 8mm carbon steel) with a mixer (MX-03) driven by a hydromotor and 1:40 gearbox. The second stores Gas Oil added to the preparation unit (1.5m dia, 1m H, 5mm carbon steel) with a 0.5 HP centrifugal pump. o 6-1-2: Reaction Tanks (V-04/05/06A): Three carbon steel tanks (2.8m dia, 9m L, 14mm thick, 55-ton max). Each has 2 Stainless Steel mixers (MX-02 A/B/C/D/E/F) driven by a 7.5 kW motor (1500 RPM) with a 1:40 gearbox. Contains an internal heating system powered by a Gas Oil burner to raise the temperature to 180°C. Catalyst is injected via dosing pumps (DP-01A/B) to increase naphtha extraction efficiency. Material is circulated during cooking by two centrifugal pumps per reactor (P-04A/B/C/D/E/F) (one active, one standby) to reduce retention time to 3-4 hours. After cooking, material is moved to the attached tank (V-04/05/06B) for storage before distillation. Fully insulated. o 6-1-3: Cooked Material Tank (V-04/05/06B): Carbon steel tank (2.8m dia, 9m L, 14mm thick) with thermal oil pipes to maintain 190-200°C. Fully insulated. Material is pumped to the vacuum distillation tower via centrifugal pumps (P-05A/B) (one active, one standby) at 22.5 kW / 3000 RPM. 7. Raw Naphtha Storage Unit Collects and condenses naphtha extracted during cooking. • 7-1-1: Raw Naphtha Tanks (V-07A/B/C): Three vertical Stainless Steel 304 tanks (1.5m dia, 5m H) connected to three heat exchangers and two pump pairs. Equipped internally with water spray nozzles on a ring pipe to wash non-condensable gases. • 7-1-2: Heat Exchangers (HE-01A/B/C): Condense naphtha vapors from 140°C down to 40°C using water from the cooling tower. Connected in series. Shell & Tube type, carbon steel (510 mm dia, 6m L) with 70 tubes (0.75-inch dia) in two rows of 35. Includes internal baffles for efficiency. • 7-1-3: Supporting Pumps: Vacuum pumps (VP-01A/B) at 22.5 kW / 1500 RPM draw naphtha vapors from reactors to the heat exchangers, pushing non-condensable gases to the scrubber (V-14). Centrifugal pumps (P-02A/B) at 11.5 kW / 1500 RPM transport liquid raw naphtha to the Bleaching Unit. 8. Vacuum Distillation Unit The core of the plant, separating remaining light compounds and producing hard asphalt. • 8-1-1: Vacuum Distillation Tower: A vertical tower (~16m total height, 14mm carbon steel). Bottom section (Reboiler) is 3.5m dia x 1.2m H; top section is 1.5m dia x 12m H. Fully insulated. Fed with cooked material at 190-200°C via pumps (P-05A/B). To start extraction (remaining naphtha, Gas Oil, diesel), temperature is raised to 240-250°C using Heating Coil 1 via pumps (P-08A/B) at 55 kW / 3000 RPM, with continuous circulation via pumps (P-07A/B). Vacuum pumps (VP-03A/B) maintain 0.3-0.5 mbar pressure. Light compounds are extracted, condensed (HE-02A/B/C), and stored (V-08/09/10 A/B) over 2.5-3 hours. Afterward, material is heated via Heating Coil 2 to 320-340°C to finalize extraction and produce hard bitumen. Product is extracted via pumps (P-07A/B) at ~320°C, cooled via cooling tower coils, and sent to final tanks (V-18A/B/C). Batch processing takes 6-7 hours daily; continuous operation is possible. • 8-1-2: Supporting Pumps: Vacuum pumps (VP-03A/B) at 5.5 kW / 3000 RPM draw light vapors for condensation. Circulation centrifugal pumps (P-08A/B) at 55 kW move hot material to heating coils; (P-07A/B) circulate material and pump final bitumen product. • 8-1-3: Heating Coils 1 & 2: Carbon steel 4-inch diameter coils heated externally by a Gas Oil burner. Connected in series to heat liquid bitumen in two stages to prevent degradation. • 8-2: Heat Exchangers (HE-02A/B/C): Condense light compound vapors from 240°C to 40°C. Shell & Tube type, carbon steel (600 mm dia, 6m L) with 80 tubes (1-inch dia) in two rows of 40, equipped with baffles. • 8-3: Light Compound Tanks (V-08A/B, V-09A/B, V-10A/B): Six horizontal carbon steel tanks (1.5m dia, 4.5m L, 14mm thick). Receive condensates, linked to heat exchangers and vacuum pumps. Liquids are pumped to the Bleaching Unit via centrifugal pumps (P-06A/B) at 7.5 kW / 1500 RPM. 9. Bleaching Unit Improves the specifications of raw light compounds for local use and marketing. • 9-1: Collection Tank (V-11): Horizontal carbon steel tank (1m dia, 2.5m L, 14mm thick) placed above the system to store and distribute light compounds to the bleaching columns. • 9-2: Bleaching Columns (V-12A/B/C): Three vertical carbon steel vessels (1m dia, 4.5m H, 14mm thick). Contain a 15 cm catalyst layer on trays to bleach raw liquids into high-quality compounds, collected in a bottom horizontal tank. The catalyst is a calcined mixture of Bentonite and Zinc Oxide granules (2-3 mm) homogenized in water, which can be reactivated with steam and 5% HCl. • 9-3: Supporting Pumps: Vacuum pumps (VP-04A/B) at 5.5 kW extract vapors to the scrubber. Centrifugal pumps (P-09A/B) at 7.5 kW push bleached liquids to final tanks. 10. Production Tanks (V-13 A-F & V-18 A-C) • Light Products: Six horizontal carbon steel tanks (2.8m dia, 9m L, 55-ton capacity). V-13A/B for light naphtha, V-13C/D for Gas Oil, V-13E/F for diesel. • Asphalt: Three vertical carbon steel tanks (V-18A/B/C) (5m dia, 9m H). Equipped with thermal oil heating coils to keep asphalt liquid. Fully insulated (90 kg/m³ glass wool, 1.8mm aluminum cover). 11. Supporting Systems • 11-1: Gas Washing (Scrubber) System: Treats non-condensable gases before atmospheric release. Contains V-14 washing tank (1m dia, 2.8m L), a 500mm Flare stack with 3 ignitors, and a 1m x 1m LPG tank (V-15) for ignition. • 11-2: Cooling Tower: Provides cooling water for heat exchangers. Galvanized pressed steel basin (16m L x 2.4m W x 2.8m H), FRP casing, top fans, water distributors, and fill media. Includes Accumulator tank V-20 (1.5m dia, 2m L) and 11 kW pushing pumps (P-14A/B). • 11-3: Thermal Oil Boilers: Includes oil tank, heating boiler, oil pumps, and heating accelerators. • 11-4: Distillation Tower Raw Boilers • 11-5: Power Generation System • 11-6: Production Laboratory • 11-7: Control and Operation Room • 11-8: Catalyst System: Contains a vertical diesel tank (1m dia, 1.5m H) with a 1 kW centrifugal pump (P-11). Two vertical carbon steel tanks (V-17A/B, 1.5m dia, 4.5m H) with an MX-03 hydromotor mixer (7.5 kW, 30 RPM). V-17A is for preparation, V-17B pumps catalyst to the reactor. ________________________________________ Catalyst Chemical Components & Formulations 1. Alumina (Al2O3): Enhances the cracking of chemical bonds in heavy bitumen chains and increases Gas Oil extraction yield. 2. Manganese Dioxide (MnO2): Accelerates the reaction, reduces reaction time, and acts as a gasoline improver. 3. Silicon Dioxide (SiO2): Increases acceleration and reduces reaction time. 4. Iron Oxides (Fe2O): Accelerates the reaction, prevents pipe corrosion, and stops sulfur and wax from sticking to pipes and pumps. Weight Ratios (WT/WT) to Produce One Barrel (200 Liters) of Catalyst: 1. Alumina: Varies by feed: 2-2.5% for Bitumen / 4-5% for Vacuum Residue (VR) / 2-2.5% for Heavy Fuel Oil (HFO). To increase Gas Oil/Diesel (Light fuel) yield, Alumina can be added up to a maximum of 10%. 2. Manganese Dioxide: 2-2.5% for HFO / 4-5% for VR and Bitumen. 3. Iron Oxides: 2-2.5% across all feeds. 4. Silicon Dioxide: 2-2.5% for HFO / 4-5% for Bitumen and VR. 5. Remaining Volume: Filled with C-oil. Note: One barrel (200 Liters) of this mixture is added for every 5 tons of HFO, VR, or Bitumen. Manufacturing Mechanism: All components are placed in a tank, initially mixed with water, and heated to 80-120°C with continuous mixing (20-30 RPM). Once foam is generated, the product is allowed to cool to 80°C. The heating process up to 120°C is repeated 3 or 4 times until foaming ceases. Finally, the temperature is raised to 150°C, and the mixture is topped off to 200 liters using C-oil. To further improve light compound specifications, Zinc Oxide (300 grams) is mixed with 20 kg of Bentonite in C-oil. This is added alongside the catalyst at a ratio of 1/5 barrel of catalyst added to the reactor.
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