MFD

Ltd.

Machinery Facilities Design Consulting

Modular Waste Lube Oil Re-refining Unit

0 7. Wing Tuck Comm.com .0 8.com August 2012 2 .0 4. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.MFD Ltd.mfd-c.0 6.000 MTPY CONTENT 1.0 10.0 2. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.0 5. Centre. Sheung Wan. 177-183 Wing Lok Street.0 FOREWORD UNIT DESIGN PROCESS DESCRIPTION MATERIAL BALANCE UTILITIES AND CHEMICALS CONSUMPTION UNIT DESCRIPTION AND FLOW SCHEME MODULES DESCRIPTION SCHEDULING COMMISSIONING & START-UP FINANCING MFD Ltd – Room 1507.0 3.0 9.Website : www.

mfd-c.Website : www. Sheung Wan. The modules are erected and interconnected on site. instruments. MFD Ltd – Room 1507. electrical and structural material. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. predefined according to the basic sequence of the re-refining scheme. Wing Tuck Comm. The range of capacity of the Modular Unit is 15.000 MTPY.com . piping. 177-183 Wing Lok Street.MFD Ltd. Modules are assembled and tested in the workshop and are delivered as package system.0 FOREWORD The proposed Modular Waste Lube Oil Re-refining Unit is a complete skid mounted facility ready for immediate installation. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.com August 2012 2 .000 MTPY 1. Equipments. Modular realization is particularly advisable in such range of Unit capacity and consists in the use of prefabricated and pre-assembled skid mounted systems including equipments. instruments and electrical equipments located in the module are installed and plug in the workshop before delivery. Centre.

89 80-95 2. 2.5 0.MFD Ltd.10 6-8 70 15-17 Before Project execution. ppm MFD Ltd – Room 1507.0 UNIT DESIGN The MFD Re-refining Units are designed to obtain high quality base oil products. %wt Flash point COC.01 95 0. mg KOH/g Viscosity index CCR.05 210 min 5 max Heavy Base Oil (SN-400/500) 0. cst at 40°C Colour TAN.05 240 min 5 max Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. °C Metals content.com August 2012 2 .Heavy Base Oil SN-400/500 Typical characteristics of Base Oil products are shown herebelow.000 MTPY 2. Characteristics Specific gravity @ 15°C Viscosity. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.Light Base Oil SN-150 . Centre.5 0. a representative sample of Waste Lube Oil will be submitted to laboratory analysis and pilot test to check the waste lube oil composition and confirm the design of the Unit.com .87 25-35 1.01 98 0.1 Waste Lube Oil Characteristics The typical composition of the waste lube oil feedstock is reported herebelow : Component Water and Light Ends : Gasoil : Lube Oil Fraction : Residue : %wt 5 . Hong Kong Light Base Oil (SN-150) 0. Wing Tuck Comm. 2. Sheung Wan.Website : www.mfd-c. 177-183 Wing Lok Street. high recovery rate and no environment impact installation.2 Regenerated Base Oil Products Two regenerated Base Oil are produced: .

°C LHV. or in blast furnaces. mgKOH/g Flash point COC.com August 2012 2 .3. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.2 70. 177-183 Wing Lok Street.3 By Products By products are Gasoil and Residue. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. cst at 40°C TAN. Their typical characteristics are reported herebelow: 2.1 Gas oil Characteristics Specific gravity @ 15°C Viscosity.mfd-c.000 50 - As fuel after flushing with fuel oil or gas oil.86 3–5 0.MFD Ltd.com . % wt Softening point.2 Residue Characteristics Specific gravity @ 15°C Viscosity. cst at 40°C at 120°C Ash content. 2.05 70 10. Residues may be used: MFD Ltd – Room 1507. in cement factories where the impurities are fixed in the klincker blocks. Sheung Wan.000 MTPY 2.Website : www. °C Value 1. Wing Tuck Comm. For example 80/100 bitumen may be obtained by mixing 20% of residue with 80% of 40/50 bitumen.000 4. As a mixing component for the formulation of bitumen and asphalt extender. Centre.000 10 – 12 15 .3.0 – 1. For recovery of lead and zinc and for ink manufacturing.20 Value 0. Kcal/Kg Cetane index The Gasoil may be used as diesel oil or fuel oil.

Website : www. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.000 MTPY 2.com August 2012 2 . and final out put water meets international specifications of 15 ppm max hydrocarbon content. The Unit does not produce gaseous effluent since all process off gases are burnt in the Hot oil Heater. The only gaseous effluent are the flue gases released from the chimney stack of the Hot Oil Heater. These gases will be discharged in accordance with the limit values allowed by the local standard for air pollution and environmental protection. 177-183 Wing Lok Street.MFD Ltd. Sheung Wan.com . Centre. MFD Ltd – Room 1507.mfd-c.4 Effluents Liquid waste effluents of the Unit consist of process water from ejector sets and oily water. Process water and oily water are sent to waste water treatment. Wing Tuck Comm.

including preheating additive injection and dehydration to remove water. and involves only heating/cooling. Due to the high distillation temperature required and the thermally unstable nature of the contaminants this step is carried out in a special thin film evaporator under high vacuum conditions.MFD Ltd. carbon. dust. consists of Waste Lube Oil Pretreatment. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. to improve base oil quality and produce regenerated base oil SN-150 and SN-400/500 ✔ ✔ ✔ As it is well know.000 MTPY 3. Centre. Vacuum Distillation and Fractionation by Thin Film Evaporator and Finishing. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. The thin film evaporator consists of a vertical cylindrical surface enclosed in an heating jacket and an internal rotor which distributes a thin layer of oil on the heated wall. 177-183 Wing Lok Street. Vacuum distillation and Fractionation by Thin Film Evaporator. By the action of rotor (electrically driven) an high turbulence and back mixing occur in the thin layer of the oil film. Finishing by NMP solvent extraction of the oil fraction. Gasoil removal. ✔ Pretreatment.com . glycols. by means of rotating blades. Product yield is definitively higher and operation is less expensive because of lower utility consumption.mfd-c. lighter organic) and separate heavy contaminants which remain in suspension in the oil. to separate gasoil from the base oil for flash point specification and recovered a valuable gasoil fraction. to separate lube oil products from “heavier than” contaminants and produce two oil fractions. gasoline. Distillation achieves high selectivity and oil purification from metals.com August 2012 2 . light contaminants (solvents. without use of chemical agents causing noxious byproducts. Gasoil removal. MFD Ltd – Room 1507. Sheung Wan. heavy polymers. Wing Tuck Comm.0 PROCESS DESCRIPTION The re-refining process proposed by MFD Ltd. This operation is achieved by the combination of high vacuum distillation and thin film technology. The process consists of the following steps each provided to selectively remove one or more categories of contaminants and recover a high quality lube oil product. distillation is an attractive unit operation for the separation of components. Oil recovery by evaporation is more effective than by other chemical or physical methods proposed by other technologies.Website : www.

com August 2012 2 . low wall temperature and high flow turbulence Lube oil products are recovered as distillate while heavy components consisting of additives.High heat transfer rate through the film .com . Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. Wing Tuck Comm.000 MTPY The main features of the evaporator are : .Website : www.Short residence time (in the order of magnitude of 10 seconds) by mechanical agitation of oil on the heat transfer surface .MFD Ltd.Efficient and regenerative cleaning of the contact surface Cracking and fouling problems are avoided by keeping low residence time. metals and degradation products are concentrated in the bottom as residue BLOCK SCHEME MFD Ltd – Room 1507.mfd-c. Centre. Sheung Wan. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. 177-183 Wing Lok Street.

com August 2012 2 . Wing Tuck Comm. Kcal/hr .Additive .000 Ton/year 15. Kg .000 100 98 1.0 MATERIAL BALANCE The material balance of the Rerefining Unit depends from waste oil composition.000 tons/year waste lube oil.NMP make up. Kg/hr 1. Kwh . Centre.200 2% 5 MFD Ltd – Room 1507. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.Electric power.000 5. for a re-refined capacity of 15.Fuel.Cooling water.050. m3 (DT = 10°C) .500 900 2. . 6% gasoil content) is shown herebelow. The material balance of the Unit based on typical waste lube oil composition (8% water and light.400 _____ 15.com .200 10. 177-183 Wing Lok Street.mfd-c.000 MTPY 4.MFD Ltd.MP Steam. Sheung Wan.0 UTILITIES AND CHEMICALS CONSUMPTION Utilities and chemicals consumption during normal Unit operation and per ton of waste lube oil are as follows. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. Feedstock Waste lube oil Products Off gases (water.Website : www. light ends and losses) Base Oil (SN 150 and SN 400/500) Gas oil Residue 1.

2 Gasoil Removal Gasoil is removed from the waste lube oil in the gasoil stripper for the correction of oil flash point and recovery of gasoil fraction.1 Waste Lube Oil Pre-Treatment Waste lube oil pre-treatment consists of preheating.MFD Ltd. 6. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. Centre. Vapor from flash drum overhead contains mainly water and gasoline and is routed to the off gas system and used as fuel gas for the hot oil heater. Gasoil is obtained as overhead and then sent to storage. thus preventing their penetration into the lube oil distillate. Sheung Wan. Dehydrated oil from the bottom is fed to the Gasoil Stripper. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. additive injection and dehydration in order to: Ÿ Remove water and light components and produce lubricating oils having the required specification for initial volatility.Website : www. Ÿ Remove unstable additives and degradation products by hot processing. (Refer to Process Flow Diagram attached hereto).000 MTPY 6. The bottom reboiler is heated by hot oil and provides the stripping heat.0 UNIT DESCRIPTION AND FLOW SCHEME The description of the Re-refining is reported hereinafter.com . Waste lube oil from storage is pumped by the feed pump through the feed filters. The mixture is sent to the flash drum.mfd-c. 6. where light hydrocarbons and water are eliminated by flash. then preheated by hot oil and mixed with chemical additive for pre-treatment. 177-183 Wing Lok Street. MFD Ltd – Room 1507. Wing Tuck Comm. Stripped oil from the bottom is sent to the vacuum distillation section.com August 2012 2 . Part of the gasoil is returned to the stripper as reflux.

MFD Ltd. Uncondensed vapors from vacuum systems are vented to the hot oil heater firebox. Sheung Wan. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.e. This effect combined with the low residence and contact time avoids high film temperatures from being reached and allows to process the oil at extremely high temperature with the following results : n n High process yield (high recovery of lube oil fraction) Absence of fouling or equipment blockage The heating medium is hot oil. distillation temperature is extremely high and pressure is maintained at very low value. broken down additives. The generated vapor flow upwards through the large open area within the evaporator. By the action of the rotor (electrically driven) a high turbulence and constant back mixing occurs in the film.3 Vacuum Distillation and Fractionation Vacuum distillation and fractionation is carried out under high vacuum and by means of thin film evaporator to recover lube oil from heavy residue and separate lube oil cuts. Wing Tuck Comm. by means of wiper blades.Website : www. degradation products. The bottom product of the evaporator is the asphaltic residue. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. Centre.com . In order to obtain maximum lube oil recovery. with internal rotor which distribute a thin layer of oil on the heated wall. The vapor distillate from the top of the evaporator is washed and condensed in the distillation column and fractionated into two lube oil cuts.mfd-c.) are concentrated in the bottom residue. In order to prevent fouling due to thermal degradation of the oil at very high temperature.000 MTPY 6. Process sour water and light hydrocarbons from vacuum systems are collected and sent to waste water treatment. enclosed in a heating jacket. TFE consists of a vertical cylindrical surface. All the impurities contained in the waste lube oil (i. 177-183 Wing Lok Street. namely light base oil SN. etc.150 and heavy base oil SN-400/500. which is pumped to storage. a thin film evaporator (TFE) is used for oil distillation. MFD Ltd – Room 1507. Any entrainment is separated in the bottom section of the distillation column C-102.com August 2012 2 . metals.

separately treated. Solvent Purification by Flash and Dehydration of solvent through distillation. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.Website : www. Oil and extract stripping. Finishing by NMP solvent extraction includes: Ÿ Ÿ Ÿ Extraction. The system includes the following equipment: n n n n n Hot oil heater Hot oil circulation pumps Hot oil expansion drum Hot oil surge drum Hot oil filling pump The hot oil system is a liquid phase system using synthetic oil as heat transfer fluid. is the Finishing. to remove the last water fractions from the NMP and to recycle pure solvent. Hot oil is pumped by the circulation pump to the process users and to the high temperature tracing system.4 Finishing by NMP Solvent The final step of the process. 6. through the action of NMP solvent. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. Sheung Wan. A bypass stream is provided on the distribution loop to take up any variations of users requirements and to ensure a minimum flow through the heater.com .com August 2012 2 .MFD Ltd.mfd-c. which improves base oil quality.000 MTPY 6.5 Hot Oil System An independent hot oil system is provided as heating belt of the Re-refining Unit. MFD Ltd – Room 1507. Wing Tuck Comm. Meantime has been produced a perfect regenerated base oil SN-150 or SN-400/500. where contaminants are removed from each intermediate base oil (SN-150 and SN-400/500). to allow recovery of the last fractions of NMP from both the oils and extract. Centre. 177-183 Wing Lok Street. Reheating of the circulating hot oil is provided by the hot oil heater and hot oil temperature is controlled by regulating the fired fuel oil.

An hot oil surge drum is used to collect drainage of the system.500 sqmt.com August 2012 2 . which is pressurized by fuel gas or nitrogen to avoid air entry and hot oil oxidation.000 MTPY Hot oil from users is returned to the circulation pump suction.000 sqmt are required including utilities. The preliminary layout and elevation of the Re-refining Plant are shown in the hereinafter drawing. MFD Ltd – Room 1507. Sheung Wan. as described at para 7. 6.0 hereinafter. The Re-refining Unit is a very compact realization made of skid mounted modules.6 Re-refining Plant Location The area required for the installation of the Unit is about 1. The Re-refining Unit is controlled by DCS (Distributed Control System) located in controlroom. when required and provide the necessary make up to compensate any possible mechanical loss or refill the system by the P202 installed on the surge drum. Also connected to the pump suction is the hot oil expansion drum. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.5 Instrument Control System The operation of the Rerefining Unit is fully automatic. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.Website : www. Wing Tuck Comm. offsite and tank farm. 177-183 Wing Lok Street. In total 7.MFD Ltd. 6.. Centre.com .mfd-c.

mfd-c. because of process and mechanical requirement. MFD Ltd – Room 1507. piping. All terminal connections are provided at convenient point to allow easy interconnecting among the skid or to the external systems. insulation and coating. piping. electrical and instrument material.com .MFD Ltd. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. Wing Tuck Comm.com August 2012 2 . Modules are skid mounted shop assembled and include equipment. Sheung Wan. Centre. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. Equipment not installed on modules (off skid equipment).Website : www.000 MTPY 7. Piping inside the skid terminates at the skid edge with companion flanges. Skids-modules are realized by steel frames and include equipments. but they are pre-assembled in workshop for commissioning and start-up. Instrument/electrical cables terminate at the skid edge with junction boxes and plugs. are located on the process still structures.0 MODULES DESCRIPTION The Unit is realized by skid mounted modules which allocate most of the equipment. 177-183 Wing Lok Street. instrumentation and electrical material as necessary for the proper operation of the Unit.

Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. CONCEPT : The design aimed at fulfilling the following criteria : ✔ ✔ ✔ ✔ Easy assembly in isolated areas without heavy technical support.Website : www.com . Quick assembly and disassembly without dedicated specialists.com August 2012 2 .000 MTPY The modules include instrumentation and control for minimum supervision during operation and skids layout is arranged to allow easy access for maintenance. 177-183 Wing Lok Street. The modules are assembled and tested at shop and are delivered as package system. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. motors and pumps are operated and instrument and electrical components completely wired and tested.mfd-c. Skids modules are delivered on 20 feet/40 feet open top containers. Sheung Wan. Wing Tuck Comm. Before shipping. Transportation and handling by common means. MFD Ltd – Room 1507. the modules are fully hydrotested. Piping interconnecting among modules and off skid equipment is realized at site. Electrical connections for electric motors and instruments from module’s junction box to electrical substation and control room is realized on site.MFD Ltd. Centre. The modules are furnished with lifting devices to allow lifting operations during transportation and erection. Full construction and real production tests in factory before shipping.

Centre. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.MFD Ltd.com . Sheung Wan. 177-183 Wing Lok Street.mfd-c.Website : www. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.000 MTPY MFD Ltd – Room 1507.com August 2012 2 . Wing Tuck Comm.

Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.Website : www. Wing Tuck Comm. Sheung Wan.mfd-c. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.000 MTPY MFD Ltd – Room 1507.MFD Ltd. 177-183 Wing Lok Street.com August 2012 2 . Centre.com .

MFD Ltd – Room 1507. Sheung Wan.Website : www.com .mfd-c. Centre. (about 6 months) by construction and Start-up unit.MFD Ltd. Erection time is also reduced (about 2 to 3 weeks).0 SCHEDULING Modular concept allows to reduce appreciably the global project delay.com August 2012 2 . Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15. 177-183 Wing Lok Street. in cancealed time in workshop. Wing Tuck Comm.000 MTPY 8.

Site Works. Centre. etc. 10.Website : www. Offsite Facilities. which depend on local country conditions and site. 177-183 Wing Lok Street.com August 2012 2 . the modular conception demonstrated saving time and costs with regard to traditional contruction. this operations is realized in real production in the workshop of construction. Indeed. The expected payout time of the overall investment is around 5 years. which foresees an annual global 3 millions euros net profit with very conservative units selling prices : MFD Ltd – Room 1507. It’s one of numerous advantages of this design. before shipping so cancelled risks frequent and difficult to foresee. Buildings.0 Million Euro. A detailed business plan exists.com .000 MTPY 9. Sheung Wan. Roads.. Utilities Systems.mfd-c. Hong Kong Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.0 COMMISSIONING & START-UP During these often critical phases.0 FINANCING The estimated budgetary cost of the investment is 15. The cost does not include local facilities as Tank Farm. depending on local taxation and used oil collection rate. Wing Tuck Comm. Machinery Facilities Design Consulting Modular Waste Oil Re-Refining Unit 15.MFD Ltd. FOB European port.

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