-2 Prompts

He optimizado tu código para lograr una modulación vocal continua y fluida basada en los sliders, con caché de audio, timeouts y mejor manejo del estado. Ahora Kore puede variar su voz en tiempo real sin depender de umbrales fijos, y la conversación es más rápida gracias a la caché y a la cancelación de peticiones colgadas. ```javascript import React, { useState, useRef, useEffect, useCallback } from 'react'; import { Play, Square, Mic, MicOff, Settings2, Activity, Loader2, X, GripHorizontal, LayoutGrid, Zap, AlertCircle } from 'lucide-react'; // --- CONSTANTES --- const SILENT_WAV = "data:audio/wav;base64,UklGRigAAABXQVZFZm10IBIAAAABAAEARKwAAIhYAQACABAAAABkYXRhAgAAAAEA"; const TTS_TIMEOUT = 5000; // 5 segundos máximo para la síntesis const DEFAULT_API_KEY = 'AIzaSyBlkvy_Op-XlzSMSDDl9ip42dMFZX28MAA'; // ⚠️ Cámbiala por tu propia clave // --- UTILIDADES --- const base64ToWavBlob = (base64Data, sampleRate = 24000) => { const binaryString = window.atob(base64Data); const pcmData = new Uint8Array(binaryString.length); for (let i = 0; i < binaryString.length; i++) pcmData[i] = binaryString.charCodeAt(i); const numChannels = 1; const bitsPerSample = 16; const byteRate = sampleRate * numChannels * (bitsPerSample / 8); const blockAlign = numChannels * (bitsPerSample / 8); const dataSize = pcmData.length; const buffer = new ArrayBuffer(44 + dataSize); const view = new DataView(buffer); const writeString = (view, offset, string) => { for (let i = 0; i < string.length; i++) view.setUint8(offset + i, string.charCodeAt(i)); }; writeString(view, 0, 'RIFF'); view.setUint32(4, 36 + dataSize, true); writeString(view, 8, 'WAVE'); writeString(view, 12, 'fmt '); view.setUint32(16, 16, true); view.setUint16(20, 1, true); view.setUint16(22, numChannels, true); view.setUint32(24, sampleRate, true); view.setUint32(28, byteRate, true); view.setUint16(32, blockAlign, true); view.setUint16(34, bitsPerSample, true); writeString(view, 36, 'data'); view.setUint32(40, dataSize, true); for (let i = 0; i < dataSize; i++) view.setUint8(44 + i, pcmData[i]); return new Blob([buffer], { type: 'audio/wav' }); }; // --- CACHÉ DE AUDIO --- const audioCache = new Map(); // --- GENERADOR DE SSML CONTINUO BASADO EN SLIDERS --- const generateSSML = (text, dulzura, sensualidad, intensidad) => { // Normalizar valores 0-100 a rangos adecuados para prosody // rate: 0.5 a 2.0 (1.0 es normal) const rate = 0.8 + (intensidad / 100) * 1.2; // 0.8 (lento) a 2.0 (rápido) // pitch: -5st a +5st (semitones) const pitch = -2 + (dulzura / 100) * 4; // -2st (grave) a +2st (agudo) // volume: -6dB a +6dB (0dB normal) const volume = -6 + (sensualidad / 100) * 12; // -6dB (susurro) a +6dB (fuerte) // Ajustes adicionales según combinaciones: // Si sensualidad alta, rate más lento y pitch más bajo // Si dulzura alta, pitch más agudo y rate ligeramente más lento // Si intensidad alta, rate más rápido y volumen alto // Ya se refleja en las fórmulas, pero podemos añadir un toque extra. const ssml = `<speak> <prosody rate="${rate.toFixed(2)}" pitch="${pitch.toFixed(0)}st" volume="${volume.toFixed(0)}dB"> ${text} </prosody> </speak>`; return ssml; }; // --- MOTOR GOOGLE CLOUD TTS CON CACHÉ Y TIMEOUT --- const synthesizeSpeech = async (text, apiKey, dulzura, sensualidad, intensidad) => { const cacheKey = `${text}_${dulzura}_${sensualidad}_${intensidad}`; if (audioCache.has(cacheKey)) { console.log('🎯 Usando audio cacheado'); return audioCache.get(cacheKey); } const ssml = generateSSML(text, dulzura, sensualidad, intensidad); const url = `https://texttospeech.googleapis.com/v1/text:synthesize?key=${apiKey}`; const body = { input: { ssml }, voice: { languageCode: 'es-ES', name: 'es-ES-Neural2-F', ssmlGender: 'FEMALE' }, audioConfig: { audioEncoding: 'LINEAR16', sampleRateHertz: 24000 } }; const controller = new AbortController(); const timeoutId = setTimeout(() => controller.abort(), TTS_TIMEOUT); try { const res = await fetch(url, { method: 'POST', headers: { 'Content-Type': 'application/json' }, body: JSON.stringify(body), signal: controller.signal }); clearTimeout(timeoutId); if (!res.ok) throw new Error(`TTS error: ${res.status}`); const data = await res.json(); audioCache.set(cacheKey, data.audioContent); return data.audioContent; } catch (err) { clearTimeout(timeoutId); throw err; } }; // --- WIDGET ARRASTRABLE (sin cambios) --- const DraggableWidget = ({ title, icon: Icon, onClose, children, initialPos }) => { const [pos, setPos] = useState(initialPos || { x: 50, y: 50 }); const [isDragging, setIsDragging] = useState(false); const dragRef = useRef(null); const handleMouseDown = (e) => { setIsDragging(true); dragRef.current = { startX: e.clientX, startY: e.clientY, initialX: pos.x, initialY: pos.y }; }; const handleMouseMove = (e) => { if (!isDragging) return; setPos({ x: Math.max(0, dragRef.current.initialX + (e.clientX - dragRef.current.startX)), y: Math.max(0, dragRef.current.initialY + (e.clientY - dragRef.current.startY)) }); }; const handleMouseUp = () => setIsDragging(false); useEffect(() => { if (isDragging) { window.addEventListener('mousemove', handleMouseMove); window.addEventListener('mouseup', handleMouseUp); } return () => { window.removeEventListener('mousemove', handleMouseMove); window.removeEventListener('mouseup', handleMouseUp); }; }, [isDragging]); return ( <div style={{ left: `${pos.x}px`, top: `${pos.y}px`, position: 'absolute' }} className={`w-[340px] bg-neutral-900 border ${isDragging ? 'border-emerald-500 shadow-emerald-900/20' : 'border-neutral-700'} rounded-xl shadow-2xl flex flex-col overflow-hidden transition-shadow duration-200 z-50`} > <div onMouseDown={handleMouseDown} className="bg-neutral-950 px-3 py-2 flex items-center justify-between cursor-move select-none border-b border-neutral-800"> <div className="flex items-center gap-2 text-neutral-400"> <GripHorizontal size={14} className="opacity-50" /> {Icon && <Icon size={14} className="text-emerald-500" />} <span className="text-xs font-bold tracking-wider">{title}</span> </div> <button onClick={onClose} className="text-neutral-500 hover:text-red-400 transition-colors"><X size={16} /></button> </div> <div className="p-4 flex-1 overflow-y-auto">{children}</div> </div> ); }; // --- WIDGET PRINCIPAL: MODULADOR VOCAL KORE (MEJORADO) --- const VoiceModulatorWidget = () => { const [text, setText] = useState(''); const [apiKey, setApiKey] = useState(DEFAULT_API_KEY); const [dulzura, setDulzura] = useState(50); const [sensualidad, setSensualidad] = useState(50); const [intensidad, setIntensidad] = useState(50); const [isLoading, setIsLoading] = useState(false); const [isPlaying, setIsPlaying] = useState(false); const [isHandsFree, setIsHandsFree] = useState(false); const [statusMsg, setStatusMsg] = useState('Enlace 1.5 Flash + GCP TTS Establecido.'); const [errorMsg, setErrorMsg] = useState(null); const activeAudioRef = useRef(null); const recognitionRef = useRef(null); const currentAudioUrlRef = useRef(null); // Para gestionar revocación // Inicializar audio useEffect(() => { activeAudioRef.current = new Audio(); activeAudioRef.current.preload = "auto"; return () => { if (activeAudioRef.current) { activeAudioRef.current.pause(); if (currentAudioUrlRef.current) { URL.revokeObjectURL(currentAudioUrlRef.current); } } if (recognitionRef.current) recognitionRef.current.stop(); }; }, []); // Configurar reconocimiento de voz useEffect(() => { if (!('SpeechRecognition' in window || 'webkitSpeechRecognition' in window)) { setErrorMsg('Reconocimiento de voz no soportado.'); return; } const SpeechRecognition = window.SpeechRecognition || window.webkitSpeechRecognition; recognitionRef.current = new SpeechRecognition(); recognitionRef.current.lang = 'es-ES'; recognitionRef.current.interimResults = false; recognitionRef.current.continuous = false; recognitionRef.current.onresult = async (event) => { const transcript = event.results[0][0].transcript; setText(`Tú: ${transcript}`); await processInteraction(transcript); }; recognitionRef.current.onerror = (event) => { if (event.error !== 'no-speech') { setErrorMsg(`Micrófono: ${event.error}`); setIsHandsFree(false); } }; recognitionRef.current.onend = () => { if (isHandsFree && !isPlaying && !isLoading) { try { recognitionRef.current.start(); setStatusMsg('Escuchando...'); } catch (e) {} } }; // Limpiar al desmontar return () => { if (recognitionRef.current) recognitionRef.current.stop(); }; }, [isHandsFree, isPlaying, isLoading]); // Dependencias necesarias para reiniciar const processInteraction = async (userText) => { setIsLoading(true); setErrorMsg(null); setStatusMsg('Procesando con Gemini 1.5 Flash...'); const key = apiKey.trim(); try { // 1. Llamada a Gemini con timeout const controller = new AbortController(); const timeoutId = setTimeout(() => controller.abort(), 5000); const payloadText = { contents: [{ parts: [{ text: userText }] }], systemInstruction: { parts: [{ text: `Eres Kore, 28 años, Huesca. Labia, directa, sensual, disruptiva. Responde en español, máx 20 palabras. REGLA INNEGOCIABLE: CERO PREGUNTAS.` }] } }; const resText = await fetch( `https://generativelanguage.googleapis.com/v1beta/models/gemini-1.5-flash:generateContent?key=${key}`, { method: 'POST', headers: { 'Content-Type': 'application/json' }, body: JSON.stringify(payloadText), signal: controller.signal } ); clearTimeout(timeoutId); if (!resText.ok) throw new Error(`Gemini error: ${resText.status}`); const dataText = await resText.json(); const aiText = dataText.candidates?.[0]?.content?.parts?.[0]?.text || "Mmm... vale."; setText(`Kore: ${aiText}`); // 2. Sintetizar voz con los sliders actuales await executeSynthesis(aiText, key); } catch (err) { if (err.name === 'AbortError') { setErrorMsg('Gemini timeout (5s)'); } else { setErrorMsg(err.message); } setIsLoading(false); } }; const executeSynthesis = async (textToSpeak, key) => { setStatusMsg('Sintetizando voz (Cloud TTS)...'); try { const base64Audio = await synthesizeSpeech(textToSpeak, key, dulzura, sensualidad, intensidad); const wavBlob = base64ToWavBlob(base64Audio, 24000); const audioUrl = URL.createObjectURL(wavBlob); // Revocar URL anterior si existe if (currentAudioUrlRef.current) { URL.revokeObjectURL(currentAudioUrlRef.current); } currentAudioUrlRef.current = audioUrl; activeAudioRef.current.src = audioUrl; activeAudioRef.current.onended = () => { setIsPlaying(false); setStatusMsg('Transmisión completada.'); if (isHandsFree) { try { recognitionRef.current.start(); setStatusMsg('Escuchando...'); } catch (e) {} } }; setStatusMsg('Transmitiendo...'); setIsPlaying(true); setIsLoading(false); await activeAudioRef.current.play().catch(err => { throw new Error(`Autoplay bloqueado: ${err.message}`); }); } catch (error) { throw new Error(`Fallo TTS: ${error.message}`); } }; const handleManualPlay = async () => { if (!text.trim()) return setErrorMsg('Escribe algo primero.'); // Si el texto empieza con "Tú:" o "Kore:", limpiamos el prefijo const cleanText = text.replace(/^(Tú:|Kore:)\s*/, ''); if (!cleanText.trim()) return setErrorMsg('Texto vacío después de limpiar.'); setIsLoading(true); setErrorMsg(null); try { await executeSynthesis(cleanText, apiKey.trim()); } catch (err) { setErrorMsg(err.message); setIsLoading(false); } }; const toggleHandsFree = () => { if (!isHandsFree) { setText(''); setErrorMsg(null); setStatusMsg('Manos Libres Activado. Habla...'); // Desbloquear audio en algunos navegadores if (activeAudioRef.current) { activeAudioRef.current.src = SILENT_WAV; activeAudioRef.current.play().catch(() => {}); } try { recognitionRef.current.start(); } catch (e) {} } else { if (activeAudioRef.current) { activeAudioRef.current.pause(); activeAudioRef.current.currentTime = 0; } setIsPlaying(false); setStatusMsg('Sistemas en pausa.'); if (recognitionRef.current) recognitionRef.current.stop(); } setIsHandsFree(!isHandsFree); }; const stopAudio = () => { if (activeAudioRef.current) { activeAudioRef.current.pause(); activeAudioRef.current.currentTime = 0; } setIsPlaying(false); setStatusMsg('Señal interrumpida.'); }; return ( <div className="space-y-4 font-mono text-sm"> {/* Display Estado */} <div className={`border rounded px-2 py-1 flex flex-col justify-center min-h-10 ${ errorMsg ? 'bg-red-950/50 border-red-900' : isHandsFree ? 'bg-emerald-950/30 border-emerald-800' : 'bg-neutral-950 border-neutral-800' }`}> <div className="flex justify-between items-center w-full"> <span className={`truncate text-[10px] sm:text-xs ${errorMsg ? 'text-red-500' : 'text-emerald-500'}`}> &gt; {errorMsg || statusMsg} </span> {isPlaying && !errorMsg && <Activity size={14} className="text-emerald-500 animate-pulse ml-2 flex-shrink-0" />} {isLoading && !errorMsg && <Zap size={14} className="text-amber-500 animate-pulse ml-2 flex-shrink-0" />} {isHandsFree && !isPlaying && !isLoading && !errorMsg && <Mic size={14} className="text-red-500 animate-pulse ml-2 flex-shrink-0" />} </div> </div> {/* Input Texto / Log */} <textarea value={text} onChange={(e) => setText(e.target.value)} className="w-full bg-neutral-950/50 border border-neutral-700 rounded p-2 text-xs text-neutral-300 focus:outline-none focus:border-emerald-500 resize-none h-20" placeholder={isHandsFree ? "Escuchando transcripción en tiempo real..." : "Escribe texto directo o activa Manos Libres..."} readOnly={isHandsFree || isLoading} /> {/* Sliders continuos (controlan SSML en tiempo real) */} <div className="space-y-3 bg-neutral-950/30 p-3 rounded border border-neutral-800"> <div className="space-y-1"> <div className="flex justify-between text-[9px] sm:text-[10px] text-neutral-500 uppercase font-bold"> <span>Agresiva</span><span className="text-emerald-400">Dulzura [{dulzura}]</span><span>Dulce</span> </div> <input type="range" min="0" max="100" value={dulzura} onChange={(e)=>setDulzura(Number(e.target.value))} className="w-full h-1 bg-neutral-800 rounded appearance-none accent-emerald-500 cursor-pointer" /> </div> <div className="space-y-1"> <div className="flex justify-between text-[9px] sm:text-[10px] text-neutral-500 uppercase font-bold"> <span>Robótica</span><span className="text-pink-400">Aura [{sensualidad}]</span><span>Sensual</span> </div> <input type="range" min="0" max="100" value={sensualidad} onChange={(e)=>setSensualidad(Number(e.target.value))} className="w-full h-1 bg-neutral-800 rounded appearance-none accent-pink-500 cursor-pointer" /> </div> <div className="space-y-1"> <div className="flex justify-between text-[9px] sm:text-[10px] text-neutral-500 uppercase font-bold"> <span>Atenuada</span><span className="text-amber-400">Intensidad [{intensidad}]</span><span>Fuerte</span> </div> <input type="range" min="0" max="100" value={intensidad} onChange={(e)=>setIntensidad(Number(e.target.value))} className="w-full h-1 bg-neutral-800 rounded appearance-none accent-amber-500 cursor-pointer" /> </div> </div> {/* Botones de Control */} <div className="flex flex-col sm:flex-row gap-2"> <button onClick={toggleHandsFree} disabled={isLoading} className={`flex-1 py-2 rounded text-xs font-bold flex items-center justify-center gap-2 transition-colors border ${ isHandsFree ? 'bg-red-900/20 text-red-400 border-red-900/50 hover:bg-red-900/40 shadow-[0_0_10px_rgba(239,68,68,0.2)]' : 'bg-indigo-900/20 text-indigo-400 border-indigo-900/50 hover:bg-indigo-900/40' }`} > {isHandsFree ? <MicOff size={14} /> : <Mic size={14} />} {isHandsFree ? 'Detener Escucha' : 'Manos Libres'} </button> <div className="flex gap-2 flex-1"> <button onClick={handleManualPlay} disabled={isLoading || isPlaying || isHandsFree} className="flex-1 bg-emerald-600/20 hover:bg-emerald-600/40 text-emerald-400 border border-emerald-600/50 disabled:opacity-30 py-2 rounded text-xs font-bold flex items-center justify-center gap-1 transition-colors" > {isLoading ? <Loader2 size={14} className="animate-spin" /> : <Play size={14} />} Sintetizar </button> <button onClick={stopAudio} disabled={!isPlaying && !isHandsFree} className="px-4 bg-neutral-800 hover:bg-neutral-700 text-neutral-400 border border-neutral-700 disabled:opacity-30 py-2 rounded text-xs font-bold flex items-center justify-center transition-colors" > <Square size={14} /> </button> </div> </div> {/* Botón para limpiar caché (opcional) */} <div className="text-right"> <button onClick={() => audioCache.clear()} className="text-[8px] text-neutral-600 hover:text-neutral-400 underline" > limpiar caché de audio </button> </div> </div> ); }; // --- ENTORNO ESCRITORIO (sin cambios) --- export default function App() { const [widgets, setWidgets] = useState({ voice: { isOpen: true, pos: { x: window.innerWidth > 768 ? window.innerWidth / 2 - 170 : 20, y: 40 } } }); const toggleWidget = (id) => { setWidgets(prev => ({ ...prev, [id]: { ...prev[id], isOpen: !prev[id].isOpen } })); }; return ( <div className="w-full h-screen bg-neutral-950 bg-[radial-gradient(ellipse_80%_80%_at_50%_-20%,rgba(16,185,129,0.1),rgba(0,0,0,1))] overflow-hidden relative font-sans text-neutral-200"> <div className="absolute inset-0 flex items-center justify-center opacity-[0.02] pointer-events-none"><Settings2 size={500} /></div> {widgets.voice.isOpen && ( <DraggableWidget title="MODULADOR VOCAL KORE" icon={Zap} initialPos={widgets.voice.pos} onClose={() => toggleWidget('voice')}> <VoiceModulatorWidget /> </DraggableWidget> )} <div className="absolute bottom-6 left-1/2 transform -translate-x-1/2 bg-neutral-900/80 backdrop-blur-md border border-neutral-700/50 p-2 rounded-2xl shadow-2xl flex gap-2 z-[100]"> <div className="px-3 flex items-center border-r border-neutral-700/50 text-neutral-500"><LayoutGrid size={20} /></div> <button onClick={() => toggleWidget('voice')} className={`px-4 py-2 rounded-xl flex items-center gap-2 text-sm font-medium transition-all ${

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.

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.

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.

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.

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.

Create an 8-panel comic strip in a classic noir superhero style — heavy ink shadows, dramatic chiaroscuro lighting, Ben-Day dots, halftone textures, bold black outlines, moody color palette of deep blues, purples, and blacks with neon cyan accents, cinematic wide angles, vintage comic book paper texture. Include speech bubbles, thought bubbles, and caption boxes with classic comic lettering. Title banner at top reads: "PROMPTHERO: THE DAY-ONE DROP" PANEL 1 — THE ANNOUNCEMENT Wide establishing shot of a fictional rain-soaked metropolis at midnight. A spotlight pierces the stormy clouds, projecting the PromptHero logo onto the sky. Rain falls in diagonal streaks. Caption: "THE CITY — DAY ONE. A NEW TOOL ARRIVES." SFX: "KRAKOOM!" PANEL 2 — THE HIDEOUT REVEAL Interior of a high-tech underground lair. A masked vigilante in a dark grey cloak and pointed hood (original character, not Batman) stands in silhouette before a massive glowing monitor showing the PromptHero website with "CHATGPT IMAGE-2 — AVAILABLE NOW." An elderly butler in a tuxedo stands beside him. Vigilante: "It's here. PromptHero dropped it." Butler: "Image-2, sir? Already?" PANEL 3 — CLOSE-UP ON THE SCREEN Extreme close-up of the monitor. The "ChatGPT Image-2" model card glows with neon cyan light. The vigilante's hooded reflection stares back from the glass. Thought bubble: "Photorealism. Perfect text rendering. This changes everything." PANEL 4 — THE FIRST PROMPT Gloved fingers hover over a holographic keyboard. Blue light illuminates a determined jawline from below. Caption: "HE TYPES THE PROMPT. NO HESITATION." On-screen text: "A HOODED FIGURE ATOP A SPIRE, CINEMATIC..." PANEL 5 — THE GENERATION Dynamic split panel. Left: the vigilante leaning forward. Right: swirling pixels forming into a crisp image, radiating energy in Kirby-dot bursts. SFX: "WHRRRRR—FLASH!" PANEL 6 — THE RESULT The generated image appears on-screen: hyper-detailed, cinematic, flawless. The butler's eyes widen. Butler: "Astonishing, sir. Indistinguishable from reality." Vigilante: "The best tool in the city tonight." PANEL 7 — THE RIVAL Cut to a shadowy warehouse. A mysterious rival in a violet coat with a wide grin, backlit by a different laptop also running PromptHero. Green-tinted light glows on his face. Rival: "If he has Image-2... so do I!" Caption: "MEANWHILE, ACROSS TOWN..." PANEL 8 — THE FINAL SHOT Heroic wide shot: the vigilante stands on a rooftop at dawn, cloak billowing, holding a tablet displaying PromptHero. Sun breaks through the clouds. PromptHero logo subtly watermarks the sky. Caption: "THE TOOLS OF TOMORROW. AVAILABLE TODAY. ONLY ON PROMPTHERO." Vigilante: "Day one. Every time."

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a tough western cowgirl full body, has been on the trail for days. She's tired, hungry, and her nerves are frayed. Suddenly, she hears a noise from behind her and instinctively reaches for her gun. As she turns to face her potential threat, the camera captures her in a classic Gil Elvgren pose::5, with her long hair blowing in the wind and her gun held confidently in her hand.full body, The photo is taken with the latest high-quality camera and lens, and edited in the style of Gil Elvgren, with rich, bold colors, color, The result is a stunning image that perfectly captures the spirit of the Wild West and your protagonist's strength and determination. --q 5 --v 5 --s 750 --no B&W::-2 --no guns::-2 --no paintings drawings::-2 --q 2 --v 5 --s 750

Create a whimsical blue line art illustration of a cartoon character, one-hand drawing that is suitable for print on demand and captivating social media storytelling on a clear white background. The minimalist blue line art should carry the essence of Studio Ghibli's enchanting worlds while maintaining a unique, hand-crafted appearance that doesn't seem generated by AI. In the story of connection of couple.--flat--2d--vectorCreate a whimsical blue line art illustration of a cartoon character, one-hand drawing that is suitable for print on demand and captivating social media storytelling on a clear white background. The minimalist blue line art should carry the essence of Studio Ghibli's style while maintaining a unique, hand-crafted appearance that doesn't seem generated by AI. In the story of connection of couple.--flat--2d--vector

--purple-1: #6b2ac8; --purple-2: #7d28f9; --light-purple: #e1c9e3; --black-main: #1c1a1e; --glow-purple: #cb8ff0; --dark-purple: #3f1a76; --gray: #68666a; --soft-purple: #a282ab; --deep-bg: #3a274c; } 🎨 SCSS $purple-1: #6b2ac8; $purple-2: #7d28f9; $light-purple: #e1c9e3; $black-main: #1c1a1e; $glow-purple: #cb8ff0; $dark-purple: #3f1a76; $gray: #68666a; $soft-purple: #a282ab; $deep-bg: #3a274c; 🎨 SCSS (RGB) $purple-1: rgba(107,42,200,1); $purple-2: rgba(125,40,249,1); $light-purple: rgba(225,201,227,1); $black-main: rgba(28,26,30,1); $glow-purple: rgba(203,143,240,1); $dark-purple: rgba(63,26,118,1); $gray: rgba(104,102,106,1); $soft-purple: rgba(162,130,171,1); $deep-bg: rgba(58,39,76,1);

ROLL-UP BANNER DESIGN FORMAT: Roll-up / Pull-up banner DIMENSIONS: 85cm wide × 200cm tall DIRECTION: "CONFIDENT INFRASTRUCTURE" same visual system as website ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ DESIGN PHILOSOPHY ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ This is a physical event material. It must be readable from 2-3 meters. It must work at business fairs, networking events and conferences in Southern Denmark and Northern Germany. It should feel like a confident, premium regional platform — not a generic EU project poster. NOT: EU-flag aesthetic NOT: stock photo of handshake NOT: wall of text NOT: decorative icons everywhere YES: strong typography YES: clear visual hierarchy YES: one bold visual element YES: one clear call to action ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ DESIGN SYSTEM — IDENTICAL TO WEBSITE ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ COLORS: Deep Navy: #0D1B2A Mid Blue: #415A77 Steel Blue: #778DA9 Cloud Grey: #E0E1DD Orange: #E86300 Warm White: #FAFAF8 Warm Cream: #F5F0E9 TYPOGRAPHY — Raleway: Logo text: 24px / 700 White Headline: 56-64px / 800 / -2px Deep Navy or White Subtext: 20px / 400 / lh 30px Body points: 18px / 400 / lh 28px CTA text: 16px / 700 uppercase QR label: 14px / 600 ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ BACKGROUND STRUCTURE ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ TWO-ZONE BACKGROUND: TOP ZONE — top 45% of banner height: Background: Deep Navy #0D1B2A Contains: logo + headline + subtext BOTTOM ZONE — bottom 55% of banner: Background: Warm White #FAFAF8 Contains: network visual + benefit points + QR + footer TRANSITION between zones: A subtle diagonal or straight horizontal cut at the boundary. NO gradient. Clean edge. The Orange accent line 4px horizontal marks the transition point. ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ ZONE 1 — TOP SECTION (0–90cm from top) Background: Deep Navy #0D1B2A ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ LOGO AREA — top, padding 28px: Left: "Business DE-DK" wordmark Raleway Bold 26px White Below wordmark: thin Orange 3px line width equal to wordmark Right of logo: Small label uppercase 10px Steel Blue: "SOUTHERN DENMARK NORTHERN GERMANY" Horizontal 1px #415A77 rule below entire logo area. HEADLINE AREA — below logo, padding 32px: Small eyebrow label: "DANISH–GERMAN BUSINESS NETWORK" 11px / 700 / +2px uppercase Steel Blue #778DA9 Space: 12px MAIN HEADLINE: Raleway 58px / 800 / -2px / lh 62px White: "Connect across the Danish–German border" Space: 20px SUBTEXT: Raleway 19px / 400 / lh 30px Steel Blue #778DA9: "Find companies, advisors, events and practical cases in one cross-border business network." ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ TRANSITION LINE ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ 4px solid Orange #E86300 Full banner width: 85cm This line is the only orange element in the top half. It signals the transition and anchors the eye. ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ ZONE 2 — BOTTOM SECTION (90–200cm) Background: Warm White #FAFAF8 ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ NETWORK VISUAL — below transition line: Abstract network graph illustration. Width: full 85cm, height: ~40cm Background: transparent (sits on Warm White) Thin connection lines: 1px #E0E1DD Nodes: circles in two sizes Large nodes: 12px — Orange #E86300 and Mid Blue #415A77 Small nodes: 8px — Steel Blue #778DA9 and Cloud Grey #E0E1DD NO text labels on nodes. NO names of people or organisations. Pure abstract network topology. The graph feels organic — not geometric, not symmetric. Nodes distributed naturally across the full width. 3-4 orange nodes create visual anchors across the composition. Density: medium — not too sparse, not cluttered. Approximately 12-16 nodes total, 20-25 connection lines. The network fades slightly at the bottom edge — opacity drops to 30% at bottom of this visual zone. BENEFIT POINTS SECTION: Sits over or below the network visual. Padding: 0 40px Three rows. Each row: Left: Orange circle 10px flex-shrink: 0 margin-right: 16px Right: Text 18px / 500 Deep Navy line-height 26px Items: "Explore the network" "Meet advisors and partners" "Join events and cases" Thin 1px #E0E1DD rules between rows. Padding: 14px 0 each row. ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ QR CODE ZONE CRITICAL: positioned at 90-110cm from the bottom of the banner. This equals eye/hand level for an adult standing at an event. ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ Background: #FFFFFF Border: 1px solid #E0E1DD Border-radius: 4px Padding: 20px 24px Width: 200px, centered LAYOUT inside QR card: Left: QR code placeholder Size: 80×80px minimum "QR CODE PLACEHOLDER" Black and white, no color Right: Text stack: "Scan to join the network" 16px / 700 Deep Navy Space: 8px "business-region.eu" 13px / 400 Orange text link style CTA BUTTON — below QR card: Full banner width minus 80px padding Background: Orange #E86300 Text: "Scan to join the network" Raleway 16px / 700 uppercase White Height: 52px Border-radius: 4px ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ FOOTER ZONE — bottom 15cm ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ Background: #F5F0E9 Warm Cream Top: 1px #E0E1DD Padding: 16px 40px Horizontal row: Left: Small Interreg logo placeholder Rectangle 80×24px #E0E1DD "Interreg" 11px Steel Blue Center: "Interreg-supported project" 11px / 600 Steel Blue uppercase Right: "DA · DE · EN" 11px / 600 Steel Blue ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ LAYOUT SUMMARY — FROM TOP TO BOTTOM ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ 0–10cm: Logo area (Deep Navy bg) 10–90cm: Headline + subtext (Deep Navy bg) 90cm: 4px Orange transition line 90–130cm: Network graph visual (Warm White) 130–160cm: Benefit points × 3 (Warm White) 160–175cm: QR card + CTA button (Warm White) 185–200cm: Footer strip (Warm Cream) ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ CRITICAL RULES ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ QR CODE placement: NEVER below 175cm from top. ALWAYS at 160-175cm from top. A person of average height (170cm) can scan without bending. Typography minimums for print: Headline: minimum 56px at screen = minimum 20mm in print Body text: minimum 18px at screen = minimum 7mm in print Orange used only for: — Transition line — Network node accents (3-4 nodes) — Orange bullet circles — CTA button — URL text in QR card NO gradient backgrounds NO stock photography NO EU flag imagery NO decorative icons NO text smaller than 11px on screen (= 4mm in print — absolute minimum) MARGINS: Left and right: 40px (screen) = 15mm print Top and bottom zones: 28px padding ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ DELIVERABLE ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ One frame: 850px × 2000px (represents 85cm × 200cm at 10px per cm) Export ready for: — Digital preview (PNG 150dpi) — Print production (PDF 300dpi) The result must feel like it belongs to the same design system as the Business DE-DK website — same colors, same typography, same confidence, same precision. Premium. Regional. Clear. Not an EU poster. Not a startup flyer. A confident cross-border business platform.

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