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Bitumen Presentation

Bitumen Presentation. 1st year of deregulation. PETROLEUM PRODUCTS DEMAND. Historical. Going forward. Consumption grew at a CAGR of 3.4% p.a. over the last 5 years Production registered a CAGR of 12.5% p.a. during the same period.

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Bitumen Presentation

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  1. Bitumen Presentation 1st year of deregulation

  2. PETROLEUM PRODUCTS DEMAND Historical Going forward • Consumption grew at a CAGR of 3.4% p.a. over the last 5 years • Production registered a CAGR of 12.5% p.a. during the same period • Demand expected to grow at a CAGR of 3.7% p.a. during next 5 years • Demand registered over 5% growth during FY2003 Source: Company estimates FY03 MOP&NG Sub-group report for X Plan submitted to Planning Commission Source: PPAC, FY03 company estimates

  3. CRUDE SELF SUFFICIENCY The gap being met through imports • Self sufficiency levels declined over the years Source: Hydrocarbon Vision 2025

  4. INDIAN ROAD SECTOR

  5. INDIAN ROAD NETWORK Total – 3.3 MILLION Kms INDIAN ROADS CARRY 85 % OF PASSENGER TRAFFIC & 70 % OF FREIGHT TRAFFIC

  6. ROAD CONSTRUCTIONSHIFTS TO HIGHER GEAR • HIGHWAYS BUILT 1947-97 2 Kms / Day • PROPOSED NHDP LENGTH 14000 Kms • DAILY PROGRESS 1998-03 5 Kms / Day • DAILY EXPENSES OF NHDP 10 ML. USD • FINAL PROGRESS OF NHDP 11 Kms/Day • ASSURED FUNDING MECHANISM IN PLACE

  7. MAJOR PROJECTS • JAN 1999 – TARGET OF DEC 2004 FOR 4/6-LANING OF 5846 KMs HIGHWAY IN FIRST PHASE - GOLDEN QUADRILATERAL • SECOND PHASE ON 7300 KMs NE-SW CORRIDOR TO BEGIN ON JAN 2004 WITH TARGET OF DEC 07 • SIMULTANEOUS DEVELOPMENT OF PORT ROADS, RURAL ROADS, STATE ROADS INTENSIFIED • B.R.O. PROJECTS

  8. BITUMEN AND ITS PROPERTIES

  9. BITUMEN DEMAND GROWTH • Bitumen demand is likely to grow at 12% per year for next five years • At this rate the demand in year 2004-05 would be 3900 TMT

  10. BITUMEN SEASONALITY

  11. Bitumen - An introduction • LAST RESIDUE OF CRUDE OIL TREATED TO PRODUCE BITUMEN. • USED IN BUILDING AND PAVING SINCE ANCIENT TIMES. • OLDEST ADHESIVE KNOWN TO MAN. • USED IN 3500 B.C. AS MORTAR FOR BUILDING STONES AND PAVING BLOCKS IN MESOPOTAMIA. • USED FOR WATER TIGHTENING OF RESERVOIRS, CANALS, BATHING POOLS & EMBANKMENTS OF RIVERS IN INDUS VALLEY.

  12. Bitumen - An introduction (Contd.) • Streets of Babylon constructed in 2000 B.C. still in good shape. • Used for Mummification in 300 B.C. • Rock Asphalt used for flooring/sidewalks in France in 1800 A.D. • First road surfacing done in New Jersey in 1870 A.D. • From 1900 onwards Bitumen produced from Refineries being used extensively.

  13. Types of Bitumen • Conventional Bitumen • Paving Grade Bitumen • Industrial Grade Bitumen • Bitumen Emulsions • Modified Bitumen

  14. Production Process • Produced by fractional distillation of Crude oil. • Crude Oil heated to 300 – 350OC in distillation column. Lighter fractions separated at different column heights. Bottom product called long residue. • Long residue heated upto 450OC in Vacuum distillation column. Bottom residue (short residue) used for manufacturing Bitumen. • Hot air is blown through short residue OR blended with superior quality bottom products to achieve desired consistency / penetration.

  15. Advantages of Bituminous Roads • Initial saving : fast construction + low cost. • Ageless – rehabilitation is inexpensive. • Stage Construction - in ribbons, not in slabs. • Safe: High skid resistance + Good Visibility • Better riding quality Less wear & tear of vehicle, Low noise while cruising • Can be fully recycled.

  16. Engineering Properties of Bitumen • A visco-elastic material : Deformation under stress a function of temperature & loading time. • At high temperature & loading it behaves as viscous liquids, whereas at very low temperature or low loading it behaves as elastic solids. • In the intermediate range of temperatures / pressure, more typical of the conditions in road service, bitumen has visco-elastic behaviour.

  17. Elemental Analysis Carbon 82 - 88 % Hydrogen 8 - 11 % Sulphur 0 - 6 % Oxygen 0 - 1.5 % Nitrogen 0 - 1 %

  18. Composition of Bitumen • Chemical composition depends on origin of Crude Oil and refining process. • Chemical composition is extremely complex. Astronomically large number of Molecules with different chemical structures. Not feasible to attempt a complete analysis of Bitumen. • Elemental composition of Bitumen provides little information of the types of molecular structure present in Bitumen.

  19. Properties of BitumenIS 73 : 1992 Characteristics 80/100 60/70 30/40 Specific gravity at 27OC 0.99 0.99 0.99 Softening Point OC 35 to 50 40 to 55 50 to 65 Penetration at 25OC, 100gm, 80 to 100 60 to 70 30 to 40 5 secs., 1/10 mm Ductility at 27OC, in cm min. 75 75 50

  20. BITUMEN TESTS AND THEIR SIGNIFICANCE • PENETRATION TEST / SOFTENING PT. • INDICATES CONSISTENCY • LOSS ON HEATING / THIN FILM OVEN TEST • RATE OF HARDENING ON ROAD • DUCTILITY TEST • AFFINITY FOR AGGREGATES

  21. Tests….. • TRICHOROETHYLENE SOLUBILITY • INDICATES PURITY OF BITUMEN • VISCOSITY / SPECIFIC GRAVITY

  22. Penetration • TRAVEL IN dmm OF A SPECIFIED NEEDLE UNDER 100 g Wt. FOR 5 SECONDS INTO BITUMEN AT 25 C. • DENOTES CONSISTENCY

  23. Softening Point • 3.5 GM STEEL BALL PLACED ON SAMPLE OF BITUMEN IN BRASS RING • BATH TEMP RAISED AT 5 DEGREES PER MINUTE

  24. DUCTILITY • Gives an indication of the extent to which a sample of the material can be stretched before breaking. • Length in cm. at breaking point is ductility

  25. FLASH POINT • Used to measure the temperature to which a sample of bitumen may be safely heated • The flash point is the temperature reached when the vapour causes an instantaneous flash.

  26. Recommended Handling Temperatures Characteristics 80/100 60/70 30/40 Min. Pumping Temp.27OC 105 110 125 Mixing/Coating Temp. OC 150 to 163 150 to 163 160 to 175 Laying Temp.OC 130 to 160 130 to 160 140 to 160 Spraying Temp.OC 170 - - Max. Safe Hdlng. Temp. OC 175 175 175

  27. Selection of Grade of Bitumen • Choice of Bitumen is based on • Climatic Conditions - Maximum & Minimum temperature & rainfall. • Intensity of Traffic - Number of vehicles per day & axle load of vehicles.

  28. Applications of 80/100 Grade • Less viscous grade. • Used in all climatic conditions. • Suited for traffic load of less that 1500 commercial vehicles/day. • Better suited for high altitude/snow bound regions irrespective of traffic intensity.

  29. Applications of 60/70 Grade • More viscous grade. Higher softening point. • Suited for traffic intensity of more than 1500 commercial vehicles/ day. • Can withstand heavier axle loads. • Suited for areas where difference between min. & max. temp. is more than 25 o C. • Reduced stripping of Bitumen from Aggregate in presence of water. • Better suited for highways, expressways & urban roads.

  30. Applications of 30/40 Grade • Suited for traffic intensity of more than 1500 commercial vehicles/ day. • Suited for areas where difference between min. & max. temp. is less than 25 o C. • Used in metropolitan areas / airport runways.

  31. VALUE ADDED BITUMEN Binder of the future

  32. RELATIVE PRICING OF VALUE ADDED BINDERS • BITUMEN 10000 • EMULSION 11000 • CRMB 12500 • NRMB 13500 • PMB 17000

  33. WHY MODIFIED BITUMEN? • INCREASING DEMANDS ON ROAD • INCREASING NUMBER OF VEHICLES • INCREASING AXLE LOAD • INSISTENCE BY CLIENTS • DESIRE TO MAINTAIN HIGHER SERVICEABILITY LEVEL • CHANGING PATTERN OF CONTRACTS • INCLUDES LONG TERM MAINTENANCE

  34. Modifiers under use Synthetic Elastomers SBS, SBR etc. Polymers Rubbers Plastics Crumb Rubber Natural Rubber (Latex) Plain Chemically Treated Thermoplastic EVA

  35. EMERGING DEMANDAN ASSESSMENT

  36. CURRENT MARKET FEATURES • DOMINATION BY CRMB • VALUE FOR MONEY BINDER • TEST TRACKS / RESEARCH WORK SHOW EXCELLENT RESULTS • HIGH COST OF PMB A DAMPENER • INSISTENCE BY CLIENTS ON REFINERY MODIFIED BINDERS • HIGH GROWTH RATE ASSURED • EMULSION MARKET STAGNATED • TACK COAT ORIENTED • HIGH VOLUME APPLICATIONS YET TO BEGIN

  37. CRUMB RUBBER MODIFIED BITUMEN

  38. Crumb Rubber Modified Bitumen Bitumen + Additives (Modifiers/Treated Crumb Rubber)

  39. What is Crumb Rubber Modified Bitumen? • Crumb Rubber Modified Bitumen is Conventional Bitumen with treated Crumb Rubber Additive at high temperature which results in • Lower susceptibility to temp. variation • Higher resistance to deformation at high temperature • Better Age Resistance Properties • Higher Fatigue Life of Mixes • Better Adhesion Properties

  40. Why Treat Crumb Rubber? • Be compatible with Bitumen. • Blend with Bitumen properly & thoroughly. • Improve temperature resistance of Bitumen. • Resist degradation of Bituminous mix. • Be capable of being processed by conventional mixing plants and laying machinery. • Produce coating viscosity at application temp. • Maintain premium properties during storage,application and in service. • Be cost-effective considering life cycle cost.

  41. Test and Trials with CRMB • Central Road Research Institute, New Delhi. • Highway Research Station, Chennai. • Gujarat Engineering Research Institute, Vadodara. • Indian Institute of Technology, Kharagpur. • Municipal Corporation of Delhi. • Research Station, P.W (R&B) Dept., Hyderabad., Andhra Pradesh.

  42. Circular Test track study conducted by Highway Research Station, Chennai

  43. Tests conducted in Circular Test Track Study • Surface Evaluation • Skid resistance • Texture depth • Depletion values

  44. STUDY RESULT • CRMB mixes indicate better resistance to deformation at high temperature - 1.5 times higher values of stability, Marshall quotient and stiffness modulus. • Higher indirect tensile strength and stiffness modulus - better resistance to cracking in structural layers. • Modified mixes in structural layers take higher traffic stresses due to higher values of stiffness modulus. • Tensile strength ratio before and after conditioning in water is higher - superior resistance to moisture damage.

  45. CIRCULAR TEST TRACK STUDY CONCLUSION The Highways Research Station has opined that the performance of modified bitumen stretch improves by 1.7 times than the conventional bitumen stretch.

  46. Guidelines on use of Modified Bitumen • MORTH letter No. RW/NH-34041/36/90-S&R(Vol. II) dated April 21, 1999 advised all States/UTs to use Modified Bitumen upto 10% for all works “as it has been proved by field trials that the life of the road increases by 1.5 times”. • IRC released new Specifications vide publication No. IRC-SP:53:2002 FOR USE OF MODIFIED BITUMEN in road development activities in India. • MORTH vide letter No. RW/NH-34041/36/90-S&R(Vol. II) dated 17, January 2000 requested all States to start using MODIFIED BITUMEN. • MORTH letter No. RW/NH-34041/36/90-S&R(Vol. II) dated April 14, 2000 requested MOP&NG to start Modified Bitumen production at Refinery level.

  47. Guidelines on use of Modified Bitumen • MORTH vide their letter No. RW/NH-35072/1/2001-S&R( R ) dated June 21, 2001 has requested all States to encourage use of Modified Bitumen in view of its various advantages and improved performance over conventional Bitumen. • MORTH vide their letter No. RW/NH-33041/3/2001-S&R dated June 13, 2002 has stated that “It has been decided that keeping in view its advantages, polymer/rubber modified bitumen may be adopted in surfacing for the whole length, subject to availability”.

  48. CRMB Performance on Road

  49. DEFORMATION OF SURFACE IN UNMODIFIED SECTION

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