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Refined Mineral Bitumen

Natural or mineral bitumen, commonly known as "Gilsonite", is a hydrocarbon material in the aromatic class with a chain-like molecular structure. It is similar to refinery Bitumen but has formed over millions of years as crude oil components moved up to the Earth's surface due to geological processes. This substance has a higher softening and melting point compared to refined Bitumen, making it extremely versatile in various industries. Due to its limited global reserves, it is highly valued.

When crude oil's volatile components gradually evaporate over time due to weathering, a black substance remains, known as natural bitumen. Natural bitumens are semi-solid or solid mixtures of hydrocarbons, with approximately 50% carbon and hydrogen compounds, particularly heterocyclic hydrocarbons. They may also contain non-mineral components such as sulfur, oxygen, nitrogen, and heavy metals, including iron, nickel, vanadium, copper, and more, dispersed within the carbon network. Bitumens soluble in carbon disulfide typically have a hydrogen/carbon ratio of approximately 1.2 to 1.5 and a density ranging from 1.02 to 1.14. These bitumens are categorized into three groups: waxes, natural asphalt, and asphaltites, with Gilsonite, or natural bitumen, being one of the most prized and renowned within the natural bitumen family. It can exist in various physical states, including liquid, semi-solid, and solid, depending on its purity and lifespan. Due to its unique properties, Gilsonite has several key differences compared to conventional asphalt. It is an exceedingly valuable and distinctive material (Grout and Verbeek, 1993).
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In the United States, this product is commonly referred to as Gilsonite, derived from the name of its discoverer, Gilson. Natural bitumen is soluble in aliphatic and aromatic solvents. In its lump form, it is highly brittle and glossy black, while in its powdered form, it appears as a dark brown substance.

It is worth noting that this polymer has evolved naturally over millions of years. Considering the vast reserves of aged polymer in our land, when properly rejuvenated, it can be utilized in the production of various chemical products. The presence of valuable heavy metal compounds suitable for pharmaceutical applications is a crucial aspect of this product.
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Limited sources of natural bitumen exist worldwide, with the majority of these reserves located in North America, including minor reserves in South America, significant reserves in the United States, and Canada. Iran is home to the third-largest natural bitumen reserves, with over 80% of these reserves situated in the Kermanshah province and approximately 20% located in the Ilam and Lorestan provinces.

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Applications of Refined Natural Bitumen​​​​​​​

As previously mentioned, due to its molecular structure and historical significance, refined natural bitumen is recognized as an aged polymer. After refinement and rejuvenation, it finds application in a wide spectrum of industries, including but not limited to:
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• In the field of road construction for use in asphalt, insulation, and bridge deck coatings.
• In construction for insulation and roofing.
• In the manufacture of pipe coatings for oil, gas, and water pipelines.
• In drilling mud used in oil and water well drilling.
• In the petrochemical industry for various polymer productions.
• In the production of high-surface-area activated carbon for specialized applications.
• In ink production.
• In the production of laser printer toner powder.
• In the paint and ceramic industries.
• In foundry for mold coatings.
• In the oil sector for the preparation and extraction of diesel and kerosene from natural bitumen.
• In the chemical industry for resins and adhesives.
• In the cosmetic and hygiene industries.
​​​​​​​• In pharmaceutical industries using heavy metal compounds.

In general, the printing process in single-color laser printers involves registering characters and shapes on paper. One of the most critical factors in this process is the toner powder stored in a compartment called a cartridge, depending on its capacity. In the cartridge, there is a component called the drum, which carries out the task of depositing toner powder particles on paper based on the commands sent to the printer through the laser component, creating characters or relevant shapes. The paper then passes through hot rollers and adheres to the paper permanently, completing the printing process.

The technology for manufacturing cartridges and the toner powder inside them was initially developed by major printer manufacturers such as HP, Xerox, Canon, Epson, and others. Later, various other companies gained knowledge about cartridge production, with only a limited number obtaining the knowledge for toner powder production, and they entered the market. Given the high cost of cartridges and their extensive consumption, along with the fact that cartridges still have the capability to print after running out of toner, some individuals resorted to refilling and recharging them.

This practice received tremendous attention in the market. Therefore, in addition to cartridge manufacturers, cartridge refill service companies also became part of the consumers of these products. This created a vast market for toner powder and prompted us to initiate research in this field. After spending considerable time and conducting numerous tests, we succeeded in defining the formulation and ultimately producing a laboratory sample product.
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It is worth noting that natural bitumen (Gilsonite) has numerous applications in various industries, and our research and development team is capable of handling all stages of work, including formulating, setting up a laboratory pilot line and preparing samples, creating a business model, feasibility study, designing machines, preparing drawings, monitoring construction, and ultimately launching a production line according to the requests of our customers in all these stages.​​​​​​​

Tarrex 105 in Ink Industry

During drilling operations, various unconventional conditions may arise due to different factors, often referred to as drilling challenges. These challenges include issues such as increased drilling mud volume, mud losses, sloughing or caving while drilling, bit balling, hole bridging, and nozzle plugging due to the heat.

These drilling challenges are classified according to the severity and location of occurrence within the wellbore. The systematic approach for economically and effectively controlling these issues includes both prevention and treatment. Current methods for controlling drilling fluid losses (mud losses) include:

• Injecting Lost Circulation Material (LCM) for mild mud losses (less than 10 barrels per hour).
• Installing cement plugs for severe mud losses. However, issues related to cement plug installation include:
      a. Causing significant interruptions to the drilling schedule.
      b. Deviating the wellbore from its intended path.
      c. Low resistance of hole-casing cement and potential plug failure, especially with bentonite cement.

Mechanical equipment and specialized tools that can be easily transported to the loss zone or impact the loss area can provide a quick solution to overcome these challenges. The installation of casing pipes to reduce the severity of mud losses, due to its step-by-step nature, tends to reduce the tendency to use this method. Studies show that by using drilling mud enhancers, the effects can be controlled, and the performance of water-based and oil-based drilling fluids can be improved.

One of these enhancers, FLC, produced from modified Gilsonite, is effective not only in controlling drilling fluid losses but also in enhancing the quality and performance of drilling mud. Some of the improvements include reducing fluid loss, reducing the gel strength, better bit rotation during drilling, cooling the bit, and preventing the loss of drilling mud.

In summary, the advantages of modified natural bitumen or Gilsonite-based enhancers in drilling include:
• Lightweight mud without the need for excessive water, reducing high-pressure issues due to solid particles.
• Compatibility with other additives.
• Resistance to premature hydration and dehydration, maintaining mud from the unexpected loss of water.
• Resistance to corrosive and alkaline/acidic fluids.
• Resistance to medium pressure from water intrusion, with adequate flexibility to withstand deformation under pressure.
• No compression tendency, retaining its compressibility.
• Effective below 350 degrees Fahrenheit.
• Resistance to dissolution due to oil.
​​​​​​​• Gilsonite-based mud enhancers provide economical solutions for preventing cement filtration loss and wellbore bridging          during cementing.
• Due to its plastic filtration property, it seals fractures and fissures during oil well cementing.

In the drilling industry, Tarrex 105 is often used for these purposes.​​​​​​​

Tarrex 105 in Drilling Industry