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Gilsonite is crude oil that, over thousands of years, through earthquakes, pressure, temperature, and time, loses its volatile components, leaving behind a glossy, brittle, and glassy substance that resembles coal. The name “Gilsonite” was chosen because the first person to discover and commercially market this product was Samuel Gilson. After registering this brand, he led the American Gilsonite Company, and today the whole world recognizes this product by his name.
This valuable product contains over 100 elements and can be combined and homogenized with 160 other substances. Its softening point ranges from 148 to 240 degrees Celsius, and its permeability is up to 0.04 millimeters.
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Pure Gilsonite Uses: Drilling, Asphalt, Waterproofing, and Casting
Difference between Gilsonite and Coal
The difference lies in the primary source material:
- Coal is derived from the decomposition of plants and trees.
- Gilsonite is obtained from the decomposition of animals.
The thermal value and carbon content of coal are significantly higher than those of Gilsonite. A simple test can distinguish between the two: by testing the solubility in CS2 (carbon disulfide). Higher solubility indicates Gilsonite, while lower solubility points to coal.
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Gilsonite Mines in Iran
Approximately 30 active Gilsonite mines in Iran collectively extract up to 400,000 tons annually, with 260,000 tons exported. These mines are mainly concentrated in the provinces of Kermanshah, Ilam, Lorestan, and parts of Bushehr (Assaluyeh). Extraction is both surface and underground. One of the largest open-pit mines is in Qasr-e Shirin, with a daily extraction potential of up to 500 tons. The quality of extraction depends on the method of exploitation and the location.
Applications of Gilsonite
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Oil Well Drilling
- Used as an additive in drilling mud, its usage varies based on drilling type, depth, soil density, and layer pressure. Gilsonite helps control fluid loss (FLC) and melts to absorb drill heat, lubricating the drill bit.
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Asphalt Industry
- Enhances asphalt stability, creating high adhesion between macadam and bitumen. This prevents cracking and inhibits plant growth. It also reduces asphalt thickness and bitumen consumption. Gilsonite-modified asphalt doesn’t soften in the sun and remains stable under heavy truck braking. Many airports use Gilsonite in asphalt for durability against heat and friction.
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Waterproofing (Insulation)
- Predominantly used in producing waterproof membranes. Mixed with calcium carbonate, bitumen, and oil, it creates a composite with high thermal resistance and uniform coverage.
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Paint and Ink
- Increases the adhesion and durability of printer ink, particularly in newsprint. Low softening points and ash content under 3% are crucial. Gilsonite-based ink stabilizes and facilitates the flow of materials, suitable for various types of inks like printer, newspaper, lithographic, offset, gravure, and flexographic.
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Casting
- Acts as a resin in molding sand, enhancing adhesion between sand and other materials. During casting, sublimated Gilsonite gas creates pressure, aiding in mold release and resulting in smooth surfaces.
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Coke Production
- With 70-80% carbon content, Gilsonite creates a reducing environment when added to molten steel. It can be used alongside coking materials like coal. Certain types can be used in the sugar industry.
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Steel Production
- As an additive in steel products, Gilsonite is added to limestone, magnesium lime, and calcium carbide systems, displacing impurities like sulfur, silica, and phosphorus to the slag. When mixed with molten steel at 1900°F, 75% of Gilsonite’s volatile components help transfer impurities to the slag.
Gilsonite Granulation
Granulation varies by use, starting from 10 mesh produced by hammer mills, with capabilities up to 100 mesh. From 100 to 400 mesh requires a ball mill or a combination with an air separator, and from 400 to 600 mesh requires jet milling. Fine granulation needs a closed system to avoid environmental dust pollution, with 200 mesh being the most commonly used in various industries. According to the 200 mesh standard, typically, 80% passes through the sieve.
Gilsonite Solubility
Solubility varies with different solvents, but it generally dissolves well in most petroleum-based solvents. Solubility percentage indicates product quality and its mixing capability with hydrocarbons and resins. Lower ash content usually means higher solubility, but this also depends on the type and formation time of Gilsonite. Filtration can reduce ash content and produce up to 99% solubility.
Gilsonite Analysis
Analysis includes physical and chemical methods, both destructive and non-destructive, using XRF (X-ray fluorescence) and XRD (X-ray diffraction) to determine elemental composition. Elements found in crude oil are typically present in this mineral as well.