Waste Used Lube Oil Re-Refining Plant
Everyone hopes to find usefulness for waste products, such that nothing really goes waste at all. In this article, ARAV C&E will like to broaden your smile with the Waste oil, Used oil, Motor oil Recycling Plant Process.
The Black, Waste or Used Lube Oil or Motor Oil is the said to be used or contaminated type of automotive lube oil and industrial used oil. Waste Oil is simply waste oil, any petroleum or synthetic oil that has already finished its work in the engine it was used to lubricate. Used Lube Oil is defined as the petroleum derived or synthetic oil which remains after the application of Lube Oil in lubrication, cutting purposes, etc. Lube Oil has a lot of usefulness for our machines, not just cars but other machines such as lawnmowers, and many others. It becomes Waste or Used Oil after it has been used, a time when elements (impurities) such as water, metal scrapings, dirt etc., must have been mixed with it. The build-up of temperature degrades the lubricating oil, thus leading to the reduction in properties such as; Viscosity, Specific Gravity, etc. As a result, the waste/used lube oil doesn’t perform as well as the virgin motor oil. Hence, such Waste Oil is replaced with New Lube Oil or re-refined oil, and that ends the work of the now waste used oil in most cases.
About Us
ARAV CONTRACTORS & ENGINEERS was founded in 1998 with a single mission: to be the most successful, creative and ground-breaking Engineering & consulting Firm in Dhaka Bangladesh. We approach each of our clients with fresh eyes to develop customized, unique strategies.
Though we’ve grown since our founding, we’re still the same firm at heart to continue research and upgraded design. Let us help make your dreams a reality. Are you ready to set your brand or business on the path to success? Give us a call today and see what we can do for you.
ARAV CONTRACTORS & ENGINEERS Services
ARAV CONTRACTORS & ENGINEERS exists to solve the critical issues facing our clients, both large and small. Our unique approach is not only what differentiates us, but also what makes us successful. We provide a broad range of services and solutions to help organizations facilitate change, achieve their vision and optimize performance and productivity.
Used Motor Oil or Waste Lube Oil can really be useless and toxic to lives.
-
It is slow to degrade
-
It is the major ingredient of oil contamination of waterways and
-
It ends up polluting sources of drinking water.
This suggests that it must be properly disposed of because it has more harmful possibilities than usefulness when unrefined, What if it can be re-refined, recycled and made fit for re-use? Before I go into the Waste Oil Plant Process, let me differentiate between the three oil types. Not assuming if you do or do not know it all, the three types of oil are VIRGIN OIL, RECYCLED OIL AND RE-REFINED OIL.
As the name connotes, VIRGIN OIL is simply virgin oil i.e. it is crude oil that has never been used since it has passed through the refining process. It is the most used, and it sets the standard for oil quality generally.
RECYCLED OIL is simply used oil that has passed through a filtration system (maybe a Used Oil Recycling Plant) to remove any and every insoluble impurity. It does not go back to being pure again, and this is because the impurities removed do not include chemical contaminants. It can however be re-used.
RE-REFINED OIL is recycled oil that goes through more processes, removing both soluble and insoluble impurities. It goes through the same distillation stack that is used in making virgin oil so that the water molecules and other contaminants are removed. It could be rated as the same base oil standard as the virgin oil if API qualifies it. This is what our Used Oil Recycling Plant does.
Did you see that? Re-refined Oil becomes same as Virgin Oil; meaning it can be re-used!
ARAV C&E is basically expert and richly experienced in Used Oil Recycling/Re-Refining or Motor Oil Recycling Engineering Mechanism.
PROCESS OFFERED BY ARAV C&E FOR USED AND WASTE OIL RECYCLING
We offer technical solutions and projects related primarily to oil processing. We wish to create a pollution minimized atmosphere by following our mission of protecting the nature with innovative ideas for Recycling Waste and Used Lube Oil, through our Waste Oil Recycling Plants.
We make use of the TFE followed by continuous process clay treatment involved for the recycling (Re-refining) of Used/Waste Lube Oil to Base Oil group I, group II and group II+ with zero environmental waste; no air, no solid and no liquid pollution. Perfect! The TFE is ideally suited to process hard-to-handle, heat sensitive and viscous materials. These are just some of the many and varied products that the TFE processes. It is designed to carry out deodorization, distilling, concentration, reboiling, clay treatment then re-refined oil is ready for lube oil blending stage. ARAV C&E offers tailor-made designs & technology for Waste Lube oil projects, Our Turnkey project provisions include:
-
Basic & Detailed Engineering.
-
Procurement of all equipment.
-
Construction and Erection of complete project.
-
Process Description of ARAV C&E Technology code AR-703 for Used Lube oil Re-Refining Plant.
Used lubricating oil to SN150 grade Light Base Oil & SN500 grade Heavy Base Oil in distillation + TFE plant Used Oil Refining Process consists of two sections:
-
Pre-treatment (De-metallization /Ash Removal)
-
Separation of light ends by Distillation
-
Separation of oil fractions by thin film evaporation.
-
Finishing stage with clay treatment process
A) Separation of light ends by Column tower:
Dehydrated and filtered used lube oil from storage is pumped by the feed pump(P-101A/B) through the filters (ST-101 A/B) to the distillation column (C-101).Filters are provided as additional step to remove any solids from the feed.
Distillation Column (C-101) is operated under vacuum and used to separate light fraction from used lube oil. In distillation column, diesel oil (and water) is obtained as a top product which is condensed and collected in the receivers by gravity.
Bottom product from D-101 is fed to the thin film evaporation system for further separation through TFE-I feed pump.
Cooling water is used in condenser to condense of top vapors from column and hot oil (thermic fluid) is used in Reboiler shell as heating medium. ARAV C&E
B) Separation of oil fractions by TFE:
TFE system consists of two evaporators, TFE-101 & TFE-102 to recover SN-150 & SN-500 grade base oil respectively. Thin film evaporator consists of vertical cylindrical surface enclosed in a heating jacket with an internal rotor. Rotor distributes feed in the form of the thin film layer on the heated wall by means of a wiper blade. The internal condenser is provided to condense the vapors generated by the hot surface. TFE-101 is operated at <0.5 kpa vacuum & 280◦ C heating temperature by thermic fluid in jacket. The feed free from diesel from column bottom is fed to TFE-1, (TFE-101) where SN-150 is obtained as a product and collected in product receivers and residue in residue receivers by gravity. SN-150 is transferred to main storage tank by pump. Residue from TFE-101 is pumped & fed to the TFE-2 (TFE-102) by rotary gear pump. In W-102 SN-500 is obtained as a product and collected in product receiver tank and residue in residue collection tank by gravity. TFE-102 is operated at <0.02kpa vacuum & 320◦ C heating temperature by thermic fluid in jacket. ARAV C&E
C) Finishing Stage with Option of Solvent /Clay Treatment Process –
In This stage come the last filtration process which take place by continuous process which improve the color & smell of base oil. We use specific equipment for filtration process that comes along with regenerate process, if the client is looking for ultimate western quality of base oil group 2+ oil we can go with Hydro-fining finishing process.
Used Lube Oil Re-Refining Process
Technology code AR-703 – High Vacuum Distillation using (TFE) and Clay Treatment Technology.
Lube Oil & Used Lube Oil
Lube Oil:
Lubricating oil are viscous liquids used for lubricating moving parts of engines and machines.
E.g. Engine oils, gear oils, hydraulic oils, turbine oils etc.
Used Lube Oil:
-Used lube oil is defined as the petroleum derived or synthetic oil which remains after applications in lubrication, cutting purposes, etc.
-Buildup of temperature degrades the lubricating oil, thus leading to reduction in properties such as: Viscosity, Specific gravity, etc.
Major Compositions in Used Lube Oil
Base Oil – 75%, Water - 5%, Diesel – 7%, Residue asphalt – 13%
List of Major Equipments
Used Lube Oil Intermediate Feed Storage TankPreheaterColumn (Dehydration & Defueling)CondensersReflux & Separator DrumUsed Lube Oil Intermediate Feed Storage TankPreheaterColumn (Dehydration & Defueling)CondensersReflux & Separator DrumReboilerHolding TanksTFE (TFE-1 & TFE-2)ReceiversThermic Fluid HeaterCooling TowerVacuum SystemPumpsInstrumentsFilters & StrainersValvesPiping & FittingsLight viscosity lubricants suitable for fuel oil applications,Low viscosity lubricants for automotive and industrial applications, andHigh viscosity lubricants for heavy-duty applications.
The Output at this juncture is called as re-refined base oil (RRBL).
The Last step is to blend additives into the three grades of oil products to produce final products with the right detergent and anti-friction qualities. Then each product is then tested again for quality and purity before being released for sale to the public. (If Needed)
EFFECT OF THE WASTE/USED LUBE OIL PLANT PROCESS ON THE ENVIRONMENT
RESIDUAL SOLIDS: Residual solids from the Used Lube Oil will remain in the evaporator bottoms, which will be sold as a 6 industrial boiler fuel or asphalt extender.
Extract: This can be used as fuel in the plant or can be sold outside as a fuel or base oil for low price calcium based grease manufacturing.
WATER: The water, if any of the original waste oil (majorly in waste oil, the water of 4- 5% is expected) is taken to a specially designed distillation system. All the water will be distilled off and the remaining residue will be mixed with Asphalt residue coming from the distillation plant. The water thus recovered during the process of the Waste Oil Recycling will be used for watering the trees and plants in the factory premises.
BENEFITS OF RE-REFINING USED OIL AND USING IT
Without a doubt, it will be widely accepted for Waste oil to be made fit for use again than to dispose it on the earth, polluting everywhere with it! This will reduce wastage, and also be of great benefits to the environment. Recycled Waste Used the motor oil can be re-refined into new Virgin oil or Base Oil processed into fuel oils and used as raw materials for the petroleum industry.
Used oil must be managed properly by local waste management authorities or automotive repair shops to prevent contaminating the environment. Used oil filters pose similar waste concerns. If properly drained, they can be safely recycled or disposed off.
gies, and in turn, your company. We’re proud to help shape and improve how our clients structure and manage their business.
TRANSFORMER OIL REGENERATION PLANT
ARAV currently manufactures Transformer Oil Regeneration equipment with sorbent and reactivation capability technology. Oil regeneration plants are of modular design with a variable number of columns and a rotating equipment skid for housing pumps, controls and control cabinet. Transformer oil treatment plants are available in different oil flow ranges from 1500 l/h up to 12 000 l/h. Oil treatment plants feature highly efficient design to achieve the most efficient dehydration, degasification and finishing Transformer Oil. Oil treatment equipment uses double stage high vacuum technology together with a variable flow to efficiently control the oil speed.
Description Of Oil Regeneration Process:
Most power equipment is using transformer oil for its di-electric properties for cooling, insulating and protecting the active parts. Transformer oils are highly refined oils that consist mainly of a mixture of hydrocarbons. Over a period of time, due to oxidation, by-products start to form in the oil. Increase in oxidation by-products result in the increase of acidity (neutralization number) and decrease the interfacial tension of the oil. At this stage, sludge starts to form, and oil starts losing its di-electric properties because it is getting old. To prevent further deterioration of oil and possible damage to the active part of the transformer, oil needs to be regenerated. Oil regeneration equipment regenerates oil in steps. At the inlet of the equipment, oil is filtered through a coarse filter to prevent any particles from entering the equipment.
It is then heated to the desired temperature to elevate the regeneration effect. After the oil has been heated, it enters the back section of the equipment. Oil is pumped through the back section which houses columns with sorbent media. It is in this section where the oil is stripped of all impurities and ageing by-products. Oil is then pumped through a vacuum breaking valve into the degassing section where it is dehydrated and degassed. Treated oil is then pumped back to the transformer oil tank by the outlet pump. After a given period, sorbent in the back section of the equipment achieves full saturation and is no longer able to regenerate oil. At this stage, the sorbent needs to be reactivated or to be restored to its original state to be able to regenerate oil.
Reactivation stage starts by draining the columns in the back section saturated oil tank. After the oil has been drained, a vacuum is created and maintained throughout the whole reactivation process in the back section. Then by selective use of heating elements on the top parts of individual columns, the reactivation process is initiated. During the process, the impurities are removed from the sorbent to restore it to its original state. This entire process can be repeated many times until the sorbent starts to lose its properties and needs to be replaced.
STEPS OIL REGENERATION
Filtered through a coarse filter to prevent any particles from entering the equipment, it is then heated to the desired temperature to elevate the regeneration effect
After the oil has been heated, it enters the back section of the equipment. Oil is pumped through the back section which houses columns with sorbent media. It is in this section where the oil is stripped of impurities and ageing by-products
Oil is then pumped through a vacuum breaking valve into the degassing section where it is dehydrated and degassed. Treated oil is then pumped back to the transformer by the outlet pump
After a given period, sorbent in the back section of the equipment achieves full saturation and is no longer able to regenerate oil
At this stage, the sorbent needs to be reactivated (restored to its original state) to be able to regenerate oil again. Reactivation stage starts by draining the columns in the back section of saturated oil.
After the oil has been drained, a vacuum is created and maintained throughout the whole reactivation process in the back section.
Then by selective use of heating elements on the top parts of individual columns, the reactivation process is initiated. During the process, the impurities are removed from the sorbent to restore it to its original state. The off gases generated during this process are decomposed in thermal oxidizer before released to chimney.
This entire process can be repeated many times until the sorbent starts to lose its properties and needs to be replaced.
TECHNICAL CHARACTERISTICS OF OIL REGENERATION EQUIPMENT
Transformer oil regeneration process is completely automated by PLC and SCADA. Its inlet pump is a positive displacement rotary pump. The outlet pump is a centrifugally closed coupled high suction pump. For degassing the rotary vane, a vacuum pump and vacuum booster roots pump are used. For the reactivation phase, a rotary piston roots pump is used. All valves across the equipment are automatic ball valves, which are pneumatically controlled. Equipment is fully automatic, controlled by PLC logic and interfaced with a SCADA system. Numerous safety features are introduced throughout the unit to ensure the safety of the equipment as well as the operating personal. Aeration valves, overheating protection, and automatic level switches guarantee the safety of the equipment as well as its ability to identify a possible risk and to power down to prevent any accidents.
PERFORMANCE VALUES OF OIL REGENERATION EQUIPMENT
The level of contamination differs per transformer. The ageing process, as well as the utilization of a transformer, make it difficult to determine when and how will oil age to the point that it loses its di-electric properties. Regardless of the level of contamination, oil regeneration always delivers the result required by the IEC 60422 standard for mineral insulating oils in electrical equipment. However, our ARAV regeneration technology goes one step further and significantly improves on the values required by the IEC 60422 standard, with the returning oil having properties almost identical to new transformer.
with latest technologyMinimum contamination and reworkPLC Automated, with SCADA systemSkid mounted – Expandable, reduces set-up cost and timeModular constructionHandles a variety of lube oils
taking bold chances and making insightful decisions.
Grease Plant
The project/plant offered by us is the outcome of many years of technical and scientific experience.
Modern manufacturing equipment, scientifically developed formulations, the processes, careful supervision at every stage, vast manufacturing, fabrication and design experience are put together to create the project.
Accurate process controls, high manufacturing standards, quality controls, repeatable and reproducible conversion efficiency incorporated in the plant ensure very high manufacturing standards resulting in production of complete range of greases of proven qualities.
Outstanding characteristics of greases manufactured in our projected plant are:
Purity -Complete absence of corrosive or abrasive Ingredients that would be harmful to Bearings. Only highest quality fats are recommended to obviate rancidity.
Uniformity -Raw materials and finish products quality Control, Uniformity in process Parameters, consistency in all physical and chemical properties. Lube oils and Recommended are carefully selected to give excellent lubrication characteristics. The process parameters have been finalized and adopted after large number of Production batches.
Stability -Retention of homogeneity throughout their use and in storage.
Extra Qualities -Extra desirable qualities have been imparted to the greases – either by way of special manufacturing processes or by Addition of necessary additives.
Advantages of ARAV Grease Plants:
Single Source responsibility for complete plant design right from Civil-Mechanical-Electrical to Chemical process.
Client's scope of work limited to bare minimum.
Knowhow and training based on years of manufacturing experience.
Modern Laboratory set up to meet international specifications.
Plant design complies with international standards and safety features.
Reduced manpower requirement.
Plant List:
Pressurized Soap Kettle
Grease Filling Lines
Atmospheric Open Kettle
Grease Barrel Press
Milling Machines
Testing Equipments
Homogenizers
Automation And Scada
Deareators
Piping And Instrumentation
Self Cleaning Filters
Laboratory Grease Plants
Thermic Fluid Heaters
Skids And Platform Mounted Plants
Coolers/Heat Exchangers
What is Grease?
Grease is a fine dispersion of an oil-insoluble thickening agent - usually soap in a fluid lubricant which is generally mineral lubricating oil. The soap is made up of fatty acid, tallow or vegetable oil saponified with alkali which can be hydrated lime, caustic soda, lithium hydroxide or aluminum hydroxide. The lubricating oil component is refined base oil-naphthenic, of medium viscosity index, or cylinder oil stock.
Structurally grease is a “water-in-oil” emulsion. Its appearance is smooth, mostly translucent, soft or hard
Properties essential for performance of grease are structural stability, lubricating quality, low and high temperature performance (which are provided by the selected lube oil base stock), where as properties such as water resistance, high temperature quality, resistance to break down through continuous use and ability of grease to stay in place are provided by the soap.
Additives e.g. Graphite, modified clay, asphalt, oxidation and corrosion inhibitors, extreme pressure additives molybdenum disulphide etc. are used to impart specific properties as required by end application.
Unit Processes and Unit Equipment in Grease Manufacturing
Pumping of raw material from storage tanks into day tanks
Raw materials measurement by volume or weight using weighing scales, meters, tank gauges etc.
Preparing the soap by heating and premixing fat and lube oil in kettles with counter rotating scraper stirrer operated by motor and reduction gear.
Cooling of the prepared soap and balancing with oil to prepare grease in a cooling kettle.
Formation of grease structure by dispersion in a milling machine under controlled moisture and temperature parameters.
Deareation using deareator.
Filtering through filter.
Filling using weigh scales/ filling machines.
Instrumentation - indicators/recorders for temperature and pressure.
Pumps- gear and centrifugal for lube oils, vegetables oils, liquid soap and grease at various stages of manufacturing.
Material handling equipment like hoist, pallet trucks, and forklifts to handle solid fats, additives, alkali, drums etc.
Safety and fire protection devices.
Lab equipment
Utilities like hot oil system, cooling system, air compressor, water etc
Type of Grease
Calcium Base:
Used for simple bearings, general purpose machinery and chassis lubrication for normal temperature applications. At about 80 deg. C. water binding the oil and soap is lost so they separate and lubrication property is lost. Calcium based greases are water resistant and are low in cost.
Soda Base:
Used quite generally for ball and roller bearings. Exceptionally good for sealed for life bearings. Exceptionally good for sealed for life bearings. Suitable for high temperature conditions up to 175 deg. C. Soda base greases are soluble in water. They have natural anti-corrosion and good rust protection properties. They do not separate at high rotational speed. Their cost is moderate.
Aluminum Base:
Their characteristics are similar to calcium base greases - water resistance and normal temperature applications. They have exceptional stringiness and adhesive properties. Generally they are semi fluid products, clear and transparent. They are used when adhesiveness is important.
Lithium Base:
Having combination of exceptionally good “lubricity”, high temperature stability, with good water resistance. These greases are selected for multipurpose industrial and automotive application. They are stable up to 175˚C. Where many types of machines or equipment are in operation over widely varying conditions, an inventory of several greases and grades must be maintained if only single purpose greases are used. Here lithium base multipurpose greases are attractive - offering in a single product- combination of many advantages of single use greases. Cost of lithium base is moderately high.
Barium Base:
Not much in use due to high cost and time and other manufacturing factors to produce to produce soap. They have outstanding shear stability and have multipurpose applications similar to lithium base greases.
Extreme Pressure (EP):
EP agents are added to conventional greases for use where unit pressures are high or where shock loads may be encountered. EP agents are lead, chlorine, sulphur or phosphorus compounds. Molybdenum, disulphide (Moly) is widely for automotive lubricating greases.
Complex Soap:
Conventional soap such as Calcium soap plus salt of low molecular weight acid such as calcium acetate provides thickener system of unique properties/characteristics e.g. superior anti-wear, extreme pressure, good oxidation stability, resistance to melting at high tempera getable oil saponified with alkali which can be hydrated lime, caustic soda, lithium hydroxide or aluminum hydroxide.
Other Grease Types:
Lithium Grease
Aluminum Complex Grease
Lithium Complex Grease
Calcium Sulfonate Grease
Calcium Grease
Synthetic Greases
Calcium Complex Grease
Silicon Grease
Chassis Grease
Moly Greases
PTFE Grease
Bentonite Grease
Poly Urea Grease
