Modular Waste Lube Oil PDF

MFD
Ltd.
Machinery Facilities Design Consulting
Modular Waste Lube Oil Re-refining Unit
MFD
Ltd.
Modular Waste Oil Re-Refining Unit
15,000 MTPY
CONTENT 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 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, Wing Tuck Comm. Centre, 177-183 Wing Lok Street, Sheung Wan, Hong Kong
Mobile : + (852) 9631 4892 (HK) Mobile : + (33) 6 85 10 78 65 (France) @mail : daniel@mfd-c.com - Website : www.mfd-c.com
August 2012
MFD
Ltd.
15,000 MTPY
1.0
FOREWORD The proposed Modular Waste Lube Oil Re-refining Unit is a complete skid mounted facility ready for immediate installation. The range of capacity of the Modular Unit is 15,000 MTPY. 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, electrical and structural material, predefined according to the basic sequence of the re-refining scheme. Modules are assembled and tested in the workshop and are delivered as package system. Equipments, piping, instruments and electrical equipments located in the module are installed and plug in the workshop before delivery. The modules are erected and interconnected on site.
August 2012
MFD
Ltd.
15,000 MTPY
2.0
UNIT DESIGN The MFD Re-refining Units are designed to obtain high quality base oil products, high recovery rate and no environment impact installation. 2.1 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 - 10 6-8 70 15-17
Before Project execution, 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. 2.2 Regenerated Base Oil Products Two regenerated Base Oil are produced: - Light Base Oil SN-150 - Heavy Base Oil SN-400/500 Typical characteristics of Base Oil products are shown herebelow. Characteristics Specific gravity @ 15C Viscosity, cst at 40C Colour TAN, mg KOH/g Viscosity index CCR, %wt Flash point COC, C Metals content, ppm
Light Base Oil (SN-150) 0.87 25-35 1.5 0.01 98 0.05 210 min 5 max
Heavy Base Oil (SN-400/500) 0.89 80-95 2.5 0.01 95 0.05 240 min 5 max
August 2012
MFD
Ltd.
15,000 MTPY
2.3
By Products By products are Gasoil and Residue. Their typical characteristics are reported herebelow:
2.3.1 Gas oil Characteristics Specific gravity @ 15C Viscosity, cst at 40C TAN, mgKOH/g Flash point COC, C LHV, Kcal/Kg Cetane index The Gasoil may be used as diesel oil or fuel oil. 2.3.2 Residue Characteristics Specific gravity @ 15C Viscosity, cst at 40C at 120C Ash content, % wt Softening point, C Value 1.0 1.2 70,000 4,000 10 12 15 - 20 Value 0.86 35 0.05 70 10,000 50
As fuel after flushing with fuel oil or gas oil, in cement factories where the impurities are fixed in the klincker blocks, or in blast furnaces. As a mixing component for the formulation of bitumen and asphalt extender. For example 80/100 bitumen may be obtained by mixing 20% of residue with 80% of 40/50 bitumen. For recovery of lead and zinc and for ink manufacturing.
Residues may be used:
August 2012
MFD
Ltd.
15,000 MTPY
2.4
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, 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.
August 2012
MFD
Ltd.
15,000 MTPY
3.0 PROCESS DESCRIPTION The re-refining process proposed by MFD Ltd. consists of Waste Lube Oil Pretreatment, Gasoil removal, Vacuum Distillation and Fractionation by Thin Film Evaporator and Finishing. Oil recovery by evaporation is more effective than by other chemical or physical methods proposed by other technologies. Product yield is definitively higher and operation is less expensive because of lower utility consumption. 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. Pretreatment, including preheating additive injection and dehydration to remove water, gasoline, light contaminants (solvents, glycols, lighter organic) and separate heavy contaminants which remain in suspension in the oil. Gasoil removal, to separate gasoil from the base oil for flash point specification and recovered a valuable gasoil fraction. Vacuum distillation and Fractionation by Thin Film Evaporator, to separate lube oil products from heavier than contaminants and produce two oil fractions. This operation is achieved by the combination of high vacuum distillation and thin film technology. Finishing by NMP solvent extraction of the oil fraction, to improve base oil quality and produce regenerated base oil SN-150 and SN-400/500
As it is well know, distillation is an attractive unit operation for the separation of components. Distillation achieves high selectivity and oil purification from metals, heavy polymers, carbon, dust, and involves only heating/cooling, without use of chemical agents causing noxious byproducts. 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. 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, by means of rotating blades. By the action of rotor (electrically driven) an high turbulence and back mixing occur in the thin layer of the oil film.
August 2012
MFD
Ltd.
15,000 MTPY
The main features of the evaporator are : - Short residence time (in the order of magnitude of 10 seconds) by mechanical agitation of oil on the heat transfer surface - High heat transfer rate through the film - Efficient and regenerative cleaning of the contact surface Cracking and fouling problems are avoided by keeping low residence time, low wall temperature and high flow turbulence Lube oil products are recovered as distillate while heavy components consisting of additives, metals and degradation products are concentrated in the bottom as residue BLOCK SCHEME
August 2012
MFD
Ltd.
15,000 MTPY
4.0
MATERIAL BALANCE The material balance of the Rerefining Unit depends from waste oil composition. The material balance of the Unit based on typical waste lube oil composition (8% water and light, 6% gasoil content) is shown herebelow. Feedstock Waste lube oil Products Off gases (water, light ends and losses) Base Oil (SN 150 and SN 400/500) Gas oil Residue 1,200 10,500 900 2,400 _____ 15,000 Ton/year 15,000
5.0
UTILITIES AND CHEMICALS CONSUMPTION Utilities and chemicals consumption during normal Unit operation and per ton of waste lube oil are as follows, for a re-refined capacity of 15,000 tons/year waste lube oil. - Fuel, Kcal/hr - Electric power, Kwh - Cooling water, m3 (DT = 10C) - MP Steam, Kg - Additive - NMP make up, Kg/hr 1,050,000 100 98 1,200 2% 5
August 2012
MFD
Ltd.
15,000 MTPY
6.0
UNIT DESCRIPTION AND FLOW SCHEME The description of the Re-refining is reported hereinafter. (Refer to Process Flow Diagram attached hereto). 6.1 Waste Lube Oil Pre-Treatment Waste lube oil pre-treatment consists of preheating, additive injection and dehydration in order to: Remove water and light components and produce lubricating oils having the required specification for initial volatility. Remove unstable additives and degradation products by hot processing, thus preventing their penetration into the lube oil distillate. Waste lube oil from storage is pumped by the feed pump through the feed filters, then preheated by hot oil and mixed with chemical additive for pre-treatment. The mixture is sent to the flash drum, where light hydrocarbons and water are eliminated by flash. 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. Dehydrated oil from the bottom is fed to the Gasoil Stripper. 6.2 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. Gasoil is obtained as overhead and then sent to storage. Part of the gasoil is returned to the stripper as reflux. Stripped oil from the bottom is sent to the vacuum distillation section. The bottom reboiler is heated by hot oil and provides the stripping heat.
August 2012
MFD
Ltd.
15,000 MTPY
6.3
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. All the impurities contained in the waste lube oil (i.e. metals, broken down additives, degradation products, etc.) are concentrated in the bottom residue. In order to obtain maximum lube oil recovery, distillation temperature is extremely high and pressure is maintained at very low value. In order to prevent fouling due to thermal degradation of the oil at very high temperature, a thin film evaporator (TFE) is used for oil distillation. TFE consists of a vertical cylindrical surface, enclosed in a heating jacket, with internal rotor which distribute a thin layer of oil on the heated wall, by means of wiper blades. By the action of the rotor (electrically driven) a high turbulence and constant back mixing occurs in the film. 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. The generated vapor flow upwards through the large open area within the evaporator. Any entrainment is separated in the bottom section of the distillation column C-102. The vapor distillate from the top of the evaporator is washed and condensed in the distillation column and fractionated into two lube oil cuts, namely light base oil SN- 150 and heavy base oil SN-400/500. The bottom product of the evaporator is the asphaltic residue, which is pumped to storage. Process sour water and light hydrocarbons from vacuum systems are collected and sent to waste water treatment. Uncondensed vapors from vacuum systems are vented to the hot oil heater firebox.
August 2012
MFD
Ltd.
15,000 MTPY
6.4
Finishing by NMP Solvent The final step of the process, which improves base oil quality, is the Finishing. Finishing by NMP solvent extraction includes: Extraction, where contaminants are removed from each intermediate base oil (SN-150 and SN-400/500), separately treated, through the action of NMP solvent. Oil and extract stripping, to allow recovery of the last fractions of NMP from both the oils and extract. Solvent Purification by Flash and Dehydration of solvent through distillation, to remove the last water fractions from the NMP and to recycle pure solvent.
Meantime has been produced a perfect regenerated base oil SN-150 or SN-400/500. 6.5 Hot Oil System An independent hot oil system is provided as heating belt of the Re-refining Unit. 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. Hot oil is pumped by the circulation pump to the process users and to the high temperature tracing system. 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. 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.
August 2012
MFD
Ltd.
15,000 MTPY
Hot oil from users is returned to the circulation pump suction. Also connected to the pump suction is the hot oil expansion drum, which is pressurized by fuel gas or nitrogen to avoid air entry and hot oil oxidation. An hot oil surge drum is used to collect drainage of the system, 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.. 6.5 Instrument Control System The operation of the Rerefining Unit is fully automatic. The Re-refining Unit is controlled by DCS (Distributed Control System) located in controlroom. 6.6 Re-refining Plant Location The area required for the installation of the Unit is about 1,500 sqmt. In total 7,000 sqmt are required including utilities, offsite and tank farm. The Re-refining Unit is a very compact realization made of skid mounted modules, as described at para 7.0 hereinafter. The preliminary layout and elevation of the Re-refining Plant are shown in the hereinafter drawing.
August 2012
MFD
Ltd.
15,000 MTPY
7.0
MODULES DESCRIPTION The Unit is realized by skid mounted modules which allocate most of the equipment. Equipment not installed on modules (off skid equipment), because of process and mechanical requirement, are located on the process still structures, but they are pre-assembled in workshop for commissioning and start-up. Modules are skid mounted shop assembled and include equipment, piping, instrumentation and electrical material as necessary for the proper operation of the Unit. Skids-modules are realized by steel frames and include equipments, piping, electrical and instrument material, insulation and coating. Piping inside the skid terminates at the skid edge with companion flanges. Instrument/electrical cables terminate at the skid edge with junction boxes and plugs. All terminal connections are provided at convenient point to allow easy interconnecting among the skid or to the external systems.
August 2012
MFD
Ltd.
15,000 MTPY
The modules include instrumentation and control for minimum supervision during operation and skids layout is arranged to allow easy access for maintenance. The modules are assembled and tested at shop and are delivered as package system. Before shipping, the modules are fully hydrotested, motors and pumps are operated and instrument and electrical components completely wired and tested. Skids modules are delivered on 20 feet/40 feet open top containers. The modules are furnished with lifting devices to allow lifting operations during transportation and erection. Piping interconnecting among modules and off skid equipment is realized at site. Electrical connections for electric motors and instruments from modules junction box to electrical substation and control room is realized on site.
CONCEPT :
The design aimed at fulfilling the following criteria : Easy assembly in isolated areas without heavy technical support. Quick assembly and disassembly without dedicated specialists. Transportation and handling by common means. Full construction and real production tests in factory before shipping.
August 2012
MFD
Ltd.
15,000 MTPY
August 2012
MFD
Ltd.
15,000 MTPY
August 2012
MFD
Ltd.
15,000 MTPY
8.0
SCHEDULING
Modular concept allows to reduce appreciably the global project delay, (about 6 months) by construction and Start-up unit, in cancealed time in workshop. Erection time is also reduced (about 2 to 3 weeks).
August 2012
MFD
Ltd.
15,000 MTPY
9.0
COMMISSIONING & START-UP
During these often critical phases, the modular conception demonstrated saving time and costs with regard to traditional contruction. Indeed, this operations is realized in real production in the workshop of construction, before shipping so cancelled risks frequent and difficult to foresee. Its one of numerous advantages of this design. 10.0 FINANCING The estimated budgetary cost of the investment is 15.0 Million Euro, FOB European port. The cost does not include local facilities as Tank Farm, Utilities Systems, Offsite Facilities, Buildings, Roads, Site Works, etc., which depend on local country conditions and site. The expected payout time of the overall investment is around 5 years, depending on local taxation and used oil collection rate. A detailed business plan exists, which foresees an annual global 3 millions euros net profit with very conservative units selling prices :
August 2012

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MFD

Machinery Facilities Design Consulting

Modular Waste Lube Oil Re-refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Residues may be used:

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

Machinery Facilities Design Consulting

Modular Waste Oil Re-Refining Unit

COMMISSIONING & START-UP

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