BASIC DESIGN OF BNA PLANT

PT ASTON JAWARA JAYA

2010
1. Plant Capacity

The plant will be designed to produce:

100 MT BNA per day or 400 MT BNA Blend ( 25% BNA to 75 % Oil Asphalt ) per
day, or 182 MT per day pure( extracted buton asphalt )
.
Assumed plant availability will be 20 hours per day, 320 days per Year consist of 4
lines of process. The capacity of each line will be 25 MT BNA/day or 100 MT BNA
Blend ( 25/75 )

BNA is purified product of raw Buton asphalt (asbuton), BNA contain 50 -60 %
bitumen, 40-50 % of natural filler and conforming with the specification of TLA
( Trinidad lake asphalt )

1. Raw Material and Product configuration

       
Capacity Unit Per day Per line Per batch
Product        
Pure ( MC 45% ) ton 182 45 0,45
BNA ton 100 25 0,25
BNA Blend (25/75) ton 400 100 1
         
Raw Material        
Buton Rock asphalt ton 250 62,5 0,63
         
Solvent        
H2SO4 conc ton 94 23 0,23
         
Process water M3 94 23 0,23
         
3 Utility Consumption

         
Utility Unit Per day Per line Per batch
Water M3 457 114 11.4
Diesel oil M3 14 3.5 0.35
Coal ton 28 7 0.7
Electricity Kwh 16000  4000  
         

4 Generated Waste

         
Generated waste Unit Per day Per line Per batch
Solid waste ton 124 31,0 3,1
Liquid waste        
o From
Reactor M3 106 26,4 2,6
o From
Washing M3 364 90,9 9,1
CO2 ton 33 8,2 0,8
         
5 Product Specification

BNA Blend Binamarga

Parameter Unit BNA 25/75 standard
o
C 121 55.8 Min. 55
Softening point (R & B)

Penetration @ 25 oC dmm 3 51 Min. 50

Specific gravity @ 250oC g/cc 1.496 1.109 Min.1

Ductility cm 1 62 Min.50

o
Flash point C 250 300 Min.225

Solubility- TCE Wt % 58.1 90.3 Min. 90

6 Process Configuration

The BNA plant consist of 5 process section area which are :

Preparation section

Raw material of asbuton from stock yard were grinded using course and fine
chopper. Pulverized asbuton and then is fed to the reactor .

Extraction/Reaction section

Pulverized asbuton will be extracted using H2SO4 in reactor which designed by

PT Aston. The reaction of asbuton are as follows :

CaCO3 + H2SO4 -------------- CaSO4 + CO2 + H2O

During extraction bitumen contained in asbuton will released and discharged from
upper side of reactor, while minerals of gypsum discharged from bottom side.
Washing section

Bitumen named as “pure” and then wash using clear water,

Dewatering section

Wet “pure” is leak through and pressed to removed water from wet pure.

Melting section

Dry “pure” was melted at 200 C using heating vessel, to produce BNA..

Blending section

Oil asphalt was blend with BNA product to desire composition.

7 Materials Balance ( per batch )

Asbuton = 0.63 ton

SIZE : 5 -10 CM

CRUSHER 1

SIZE : 3 – 5 CM

Water = 0.23 m3 CRUSHER 2

H2SO4 = 0.23 Ton

SIZE : 0.5 – 1 CM

0.08 Ton to CO2

scrubber
REACTOR

Solid waste= 0.31 Ton

WASHING

Wet Pure (MC 45 %) = 0.45 Ton

Dry Pure =1.0 Ton

DEWATERING
MELTING
@ 200 oC

Dry Pure ( MC 25 %) = 0.25 Ton

BNA = 0.76 Ton

8 Main Equipments

7.1 Equipments list

NO EQUIPMENT NAME SPECIFICATION MATERIAL QTY

         
1 BELT CONVEYOR 1 TYPE V BELT, CAP 8 TON/HR RUBBER 1
       
2 CRUSHER 1 ( COURSE) CAPACITY MIN.5 TON/HR STEEL 1
    KNIVES GAP 50  
       
3 BELT CONVEYOR 2 TYPE V BELT, 8 TON/HR RUBBER 1
       
4 CRUSHER 2 ( FINE ) CAPACITY MIN 5 TON/HR STEEL 1
    KNIVES GAP 20  
       
5 BELT CONVEYOR 3 TYPE V BELT, CAP 8 TON/HR STEEL 1
       
6 REACTOR VERTICAL CYLINDER 2,1 M3 FRP 2
 DIMENSION : Ø1145;H 1950; t
25.
     
7 WASHER ROTARY SWEEPER, 20 MESH CHAIN/RB 1
 5000 X 2000 X 750
     
8 DEWATERING VIBRATING SCREEN, 20 MESH SS 304 1
 5000 X 2000 X 750
     
9 ROLLER PRESS DOUBLE ROLL MS 3
 CAPACITY : 10 TON/H
     
10 MELTING TANK VERTICAL CYLINDER 1,5 M3 MS 5
    WITH PIPE HEATING  
       
11 ACID TANK VERTICAL CYLINDER 5 M3 FRP 1
       
12 BNA DAILY TANK VERTICAL CYLINDER , 100 M3 MS 2
    WITH COIL HEATING  
 DIMENSION : Ø5800;H 4500; t
6.
     
 13 BNA BLEND TANK VERTICAL CYLINDER , 3000 M3 MS 1
 DIMENSION : Ø20000; H9500;
t 12.
     
14 OIL ASPHALT TANK VERTICAL CYLINDER , 5000 M3 MS 1
DIMENSION : Ø25000;H10500;
t 12.
       

7.2 Pump list

No PUMP SPECIFICATION OTY

1 Water pump
2 Sulfuric acid pump
3 BNA transfer pump
4 Oil asphalt pump
5 Diesel oil pump
Centrifugal, Q=30 m3/h, H= 40 m 1+1
 Centrifugal, Q = 10 m3/h, H = 20 m, SS 304 1 + 1
 Gear, Q = 20 m3/h, H= 30 m 1+1
 Gear, Q = 20 m3/h, H= 30 m 1+1
 Centrifugal, Q = 15 m3/h, H = 20 m 1

7.3 Utility equipments

- Diesel engine generator 150 KVA 2 set

- Emergency diesel engine generator 50 KVA 1 set

8 Plant Location

The proposed BNA Plant will be located in Gresik, Jawa-Timur, Indonesia. The
BNA plant site is located near to the existing BNA factory. The BNA plant to be set
up in area of 50,000 M2 ,

General arrangement of BNA Plant

No Area Size M2
     
1 Stock yard 39 x 28 m 1092
2 Main Process 25 x 20 m 500
3 Product and distribution 21 x 20 m 330
4 Waste water pond 1 22 x 20 m 440
5 Waste water pond 2 28 x 20 m 560
6 Clear water pond 1 4x2m 8
7 Power house 21 x 7 m 8
8 Asphalt storage area 20 x 20 m 400
Acess road - 1000 
     
9 PROCESS TIME CYCLE

Equip Batch Time ( minutes )

No No 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120

Reaction
( 15 MIN)
R - 101 A 1
R - 101 B 2
R - 101 A 3
R - 101 B 4
R - 101 A 5
R - 101 B 6

Melting
( 3 HRS )
MT - 301A I
MT - 301B II
MT - 301C III 30 '
MT - 301D IV
MT - 301E V