SLMAC (SHORT PATH DISTILLATION) WASTE & USED LUBE OIL REFINING PROCESS ALMOST ZERO CLAY TECHNOLOGY ABOUT US Arslan Enginery Private Limited Company is an esteemed company based in India. We offer technical solutions and projects related primarily to hydrocarbon processing. We are engaged in setting up Turn Key projects overseas, Designing, Engineering & Supply and Installation & Commissioning of trouble free projects. We wish to create a pollution minimized atmosphere by following our mission of protecting the nature with innovative ideas for Recycling Waste Lube Oil, Petroleum Jelly plants, Blending plants, and Diesel plants.
Arslan Enginery offers tailor made designs & technology. Our Turnkey project provisions include: Engineering Procurement Commissioning Our Plant Design Team is working on latest 3D base software to develop the best plant and project for much higher quality experience. 2
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SLMAC WASTE/USED LUBE OIL REFINING PROCESS ZERO CLAY TECHNOLOGY (DE METALIZE + DE ASH + DE CARBON) SLMAC is an indigenous used lube oil products. Some of its astute characteristics are: SLMAC uses No Hazardous or Banned chemicals. SLMAC removes Halogens, heavy metals, Sulfur and oxidized products and bring them within permissible limits. SLMAC yields high quality base stock with better Color and Oxidation Stability with ALMOST ZERO CLAY. SLMAC Save Complete process Energy Consumption by 30%, as compared to other Processes. SLMAC Prevents equipment fouling, corrosion, and coking of process equipment such as heat exchangers and vacuum system. SLMAC process separates bottom from feedstock which can be used as asphalt extender, rubber process oil, base for black printing ink, axle grease manufacturing and as rust proofing compound. 4
WASTE LUBE OIL (WLO) Lube oil is a fraction of crude oil distillate which is generally taken for granted by us. But, vehicle numbers are at a high and are still rocketing. The Lube Oil s quality during its tenure is deterred mainly by contaminants such as Cotton Waste, Bolt, Nuts, metals (in ppm), free and emulsified water. These contaminants in the used lube oil may be treated and converted to a cleaner and usable form by not involving any chemical treatment via our method. Various Sources of Used Oil Include: Car & locomotive Gear boxes and engines. Generators. Hydraulic cylinders of Heavy & Light machinery. Electrical Transformers. Any Lube oil application machinery of industry. Chief oil contaminants may be categorized under various headings such as: o COMBUSTION PRODUCTS 5
WATER SOOT AND CARBON LEAD FUEL o ABRASIVES ROAD DUST WEAR METALS o CHEMICAL PRODUCTS OXIDATION PRODUCTS DEPLETED ADDITIVE REMNANTS WASTE LUBE OIL (WLO) CHARACTERISTICS SR. NO. PARAMETER MAXIMUM PERMISSIBLE LIMIT 1 Color 8 Hazen Units 2 Water 5 to 15 % 3 Density 0.85 to 0.95 4 Kinematic Viscosity CST at 100 C 10 to 32 5 Dilutents 15% by volume 6 Neutralization Number 3.5 mg KOH/grams 7 Saponification Value 18 mg KOH/grams 8 Total Halogens 4000 ppm 9 Polychlorinated Biphenyls (PCB s) Below Detection Limit 6
10 Lead 100 ppm 11 Arsenic 5 ppm 12 Cadmium + Chromium + Nickel 500 ppm 13 Polyaromatic Hydrocarbons 6 % SPECIFICATION OF USED OIL IDEAL FOR DMAC RE - REFINING SR.NO. PARAMETERS MAX PERMISSIBLE LIMIT 1. COLOUR 8 hazen units. 2. Water 3-5% max. 3. Density 0.85 to 0.92 4. Kinematic viscosity CST at 100 Celsius 10 To 32 5. Diluents ( additives) 15% by vol 6. Neutralization Number 3.5 mg KOH/grams. 7. Saponification value 18 mg KOH/grams. 8. Total halogens 4000 PPM 9. Polychlorinated biphenyls (PCB s) Below detection limits. 10. Lead 100 PPM 11. Arsenic 5 PPM 12. Cadmium+chromium+ Nickle 500 PPM 13. Polyaromatics Hydrocarbons (PAH) 6% 7
SCHEMATICS AND PROCESS FLOW DIAGRAMS a. PROCESS PROFILE A proposal for processing used lube oil, mineral oils and industrial oils, using high vacuum molecular distillation technology is presented here. The various steps involved in the projects are given below: Step # 1: Step#2: Step# 3: The used & mineral oils are pre-treated with two types of polymer, which will flocculate the carbon sludge substantially and separated by centrifuging/filtering The used & mineral oil from the previous step is passed through phase separators, coalescer filters to remove free and emulsified water. These used and mineral oils are passed through a thin film evaporator, under medium vacuum and temperature, to remove, diesel, dissolved water if any and some lighter fractions Step# 4: The undistilled used and mineral oils are passed through a molecular distillation Plant, under higher vacuum and temperature, to distill off lighter oil (approximately equal to SAE 20 in viscosity). Step#5: The undistilled used and mineral oils subjected to high vacuum, high temperature in an induction heated molecular distillation plant. The distilled oil will have a viscosity of about SAE 40 at ambient. Step #6: The distilled oils are bleached with very less quantity of active clay to get very light colored base oils, to be blended with additives to get finished oils for the automotive and industrial applications. Step# 7: The final residue is semi solid at ambient and can be processed for manufacturing asphalt or briquettes, finished to make offspeck heavy fuel oil or to make greases for slow moving machineries. 8
Step# 8: The used clay can be reclaimed, re-activated 3-4 times, by using solvent extraction and high temperature activation process. The entire project can be installed in 6 modular structures and capacities of the plant can be increased later by adding modules b. PROCESS DISCRIPTIONS The following process stage has to be followed to obtain quality base oil as per ministry of petroleum and environments: 1) Pre-treatment: Stripping, Centrifuging 2) Decantation & Dehydration 3) Thin film molecular distillation using high vacuum 4) Bleaching & Neutralization 5) Filtration 6) Blending 7) Waste water treatment plant & Oxidizer to re-use waste & to become environment friendly. 1) Pre-treatment: The used Lubricating oils usually contains aromatics,carbons,heavy particals gets settle,steam stripped & the filtered & clarified using centrifuge. 2) Decantation & Dehydration: The used Lubricating oils usually contains aromatics etc., and free water which can be separated by way of decantation and heating at high temperature to remove emulsified 9
water and gas oil i.e., mixed lighter fractionators fuel oils under vacuum heated by thermic fluid heater. 3) Thin film molecular distillation: After decantation and dehydration the used oil will be transferred for high vacuum distillation and taken the distillate out as a distilled oil. And residue will be separated - stored & supplied for further use. 4) Bleaching & Neutralization: After distillation, the treated oil may need very les quantity i.e. not more than 2% activated fuller s earth by volume and it has to be neutralized before taking in for blending of various grade of lubricants. For filtration the spent clay which has been added for neutralization has to be removed through plate and frame filter press as well as centrifuge and thus we obtained the base oil for blending. 5) Blending: The base oil has to be degraded for application of industrial lubricating oil after adding required additives. 10
FLOW DIAGRAMS: 1.PRETREATMENT SECTION: 11
2.DEHYDRATION SECTION: 12
3.WIPED FILM EVAPORATORSECTION: 13
4.BLEACHING & NEUTRALIZATION SECTION: 14
5.WASTE WATER TREATMENT PLANT 15
6.THERMAL EXHAUST & AIR POLLUTION CONTROL SYSTEM 16
POSSIBLE RCOVERIES FROM USED OIL COMPONENT PERCENTAGE (%) Water & VOC 5 Diesel (Fuel) 7 Losses 1 Asphalt 15 SN 150 15 SN 500 57 Total 100 17
OVERALL MASS BALANCE LIST OF EQUIPMENT IN THE SCOPE OF ARSLAN ENGINERY (INDIVIDUAL PROCESSES) SR. NO. PRE TREATMENT AND DEHYDRATION DESCRIPTION QTY (*) 1 USED LUBE OIL TRANSFER TO PHE PUMP (CENTRIFUGAL PUMP) 2 PLATE HEAT EXCHANGER 3 PURIFIER (WITH MOTOR) 18
4 PURIFIED OIL TRANSFER PUMP 5 DMAC OIL PROCESSING KETTLE 6 DMAC OIL TRANSFER TO DMAC OIL SETTLING TANKS 7 DEMAC DEHYDRATION CONDENSOR 8 DMAC RECEIVER 9 DMAC RECEIVED OIL TRANSFER TO MIXING TANK 10 DMAC RECEIVED WATER TRANSFER TO DRAIN LINE 11 GEAR BOX FOR DMAC KETTLES 12 MOTOR FOR DAMAC KETTLE 13 CLARIFIER (WITH MOTOR) 14 DMAC OIL TRANSFER FROM STOARAGE TANKS TO CLARIFIER 15 MECHANICAL BOOSTER 16 DRY VACUUM PUMP 17 CHILLER 18 OIL ENTRAP SECTION 19 OIL POT 20 HEAT EXCHANGER 21 DISTILLATION/FRACTIONATION TOWER 22 USED LUBE OIL TRANSFER TO PHE PUMP ( CENTRIFUGAL PUMP ) 23 DISTILLATION CONDENSOR 24 LIGHT BASE OIL RECEIVER 19
25 26 LIGHT BASE OIL TRANSFER TO SLUDGE MIXING TANK (CENTRIFUGAL PUMP ) DISTILLATE OIL TRANSFER TO FEED BUFFER TANK (CENTRIFUGAL PUMP ) 27 MECHANICAL BOOSTER 28 DRY VACUUM PUMP 29 CHILLER CONDENSOR 30 OIL ENTRAP SECTION 31 OIL POT THIN FILM EVAPORATION SR. NO. DESCRIPTION QTY (*) 1 FEED BUFFER TANK 2 WIPED FILM EVAPORATOR 3 PRIMARY CONDENSER 4 SECONDARY CONDENSER 5 WFE RESIDUE RECEIVER 6 RESIDUE TRANSFER PUMP 7 BASE OIL RECEIVER(SN 150,SN 300/500) 8 DISTILLED LUBE OIL TRANSFER TO PROCESS TANK 9 MULTIBAG POLISHING FILTER(5 Micron) 10 BASE OIL RECEIVER 11 ELECTRO STATIC TRAP 12 VAPOUR TRAP 20
13 MECHANICAL BOOSTER 14 MECHANICAL BOOSTER 15 DRY VACUUM PUMP 16 CHILLER CONDENSOR 17 OIL ENTRAP SECTION 18 OIL POT 19 CHILLER PLANT FOR WFE 20 CHILLED WATER TRANSFER TO WFE SYSTEM (CENTRIFUGAL PUMP ) 21 CHILLER POT 22 VAPOUR TRAP UTILITY SECTION SR. NO. DESCRIPTION QTY (*) 1 CHILLER 2 COOLING TOWER 3 COOLING WATER RECIRCULATION (CENTRIFUGAL PUMP) 4 BOILER UNITS 5 EXPANTION TANK 6 DE-AERATION TANK 7 HOT OIL DRAIN TANK 8 THERMIC FLUID HEATER-295 DEGREES 9 THERMIC FLUID HEATER-320 DEGREES 21
10 THERMAL EXHAUST OXIDIZER 11 FUEL OIL SERVICE TANK 12 CIRCULATION PUMP 13 FUEL PUMP 14 OIL FILTER 15 PUMP 16 STEAM GENERATOR WASTE WATER TREATMENT SR. NO. DESCRIPTION QTY (*) 1 OIL WATER SKIMMER 2 SKIMMED WATER TRANSFER TO MIXING TANK (CENTRIFUGAL PUMP) 3 MIXING TANK 4 SETTLING TANK 5 FILTRER BED 6 FILTERED WATER TO MIXED BED (CENTRIFUGAL PUMP) 7 MIXED BED FILTER 8 WATER TRANSFER FROM MIXED BED TO CARBON FILTER (CENTRIFUGAL PUMP) 9 CARBON FILTER 22
LIST OF INSTRUMENTS SR. NO. DESCRIPTION QTY (*) 1 CONTROL VALVE- MOTORISD 2 LEVEL INDICATOR 3 PRESSURE INDICATOR 4 TEMPERATURE INDICATOR 5 FLOW METER 6 LEVEL TRANSMITTERS 7 PRESSURE/VACUUM TRANSMITTERS 8 TEMPERATURE TRANSMITTERS 9 LEVEL SWITCHES 10 VACUUM SWITCHES 11 PLC CONTROL PANEL-AUTOMATION 12 SUB PANNEL 23
SUMMARY OF UTILITIES CONSUMPTION UTILITY UNIT Electricity kw hr -1 Energy Required Cooling/chilling Steam LP Kcal Kcal Kg Water m 3 Aditive-ARSLAN 44 Water treatment chemicals Hot Oil Kg Kg Mg PRODUCT LIST NAME Volatile Diesel SN 150 SN 500 Residue 24
ANNUAL TOTAL PRODUCT COST ESTIMATION ITEM Raw Material Operating Labor Utilities Maintenance & Repairs ARSLAN ROYALTY Cost of Finance Total COST(*) TOTAL PROFIT ANNUALLY RE REFINED LUBE OIL FROM OUR ARSLAN ENGINERY - DMAC PARAMETERS RE-REFINED LIGHT (SN-70) RE-REFINED LBO (SN-150) RE-REFINED HBO (SN-500) BOTTOM RESIDUE (ASPHALT) Density at 15 C 0.85-0.87 0.86-0.89 0.89-0.94 0.95-0.97 Viscosity 100 CST 2.5 3.5 5-6 11-12 30-32 Viscosity 40 C CST 10-14 30-34 90-105 180 200 Viscosity index 98-102 98-102 95-98 95 to 110 Color ASTM 0.5 1.5 1.5 2.5 2.5 to 3.5 8 hazel Tan, mg KOH/gm 0.01 0.01 0.05 max 0.05 max Flash Point COC >140 >180 >210 >300 Pour Point -4 C -4 C -6 C - 25
Sulphur % wt 0.5-1.0 0.7 1.2 1.0 1.5 1.5 1.6 Aniline Point 90-95 95-100 100-105 105-110 METALS (PPM) METAL Ba <2 <2 Ca <1 <1 Pb <2 <2 Zn <1 <1 Ph <5 <5 Cr <0.5 <0.5 Fe <0.5 <0.5 ENVIRONMENT FRIENDLY AND HAZARD FREE TECHNOLOGIES Environmental impact has become a primary concern for all involved firms. Hence our process makes sure that all waste products have a minimal impact on the environment. Every byproduct of the process is dealt in the following manner: WASTE RESIDUAL OIL from the Vacuum Distillation Asphalt which is 10 to 15% of the feed can be blended in to Heavy fuel oil, which further can be combusted with specially designed fuel burners. Asphalt can replace expensive Masticating Agents, such as Pine Tar in Various Industrial Rubber Application. Asphaltic residues with inherent Metals and Carbon can also be used in the form of Flap Oil, for mixing with Rubber. Asphaltic residues from our processes can also be used as an additive in tarmac, applied for Road Building. EXTERNAL WATER supply is not required. Any water generated during the distillation process (1200 to 1500 lts) is reutilized in the cooling towers only or for gardening purposes. AIR EMISSIONS emitted by the vacuum system are also oxidized under controlled temperature and environment at 390 C before exhausting to the atmosphere. The other gases exhausted are in the form of combustion OF FUEL for heating, and thermal oxidization of VOC and are as per the following : 26
APPROXIMATE COMPOSITION OF LUBE OIL COMPONENT PERCENTAGE (%) Water 6 VOC 2.3 Diesel (Fuel) 6 Losses 1.8 Asphalt 11.8 SN 150 32 SN 500 40.2 Total 100.1 OVERALL MASS BALANCE FEED (RAW MAERIAL) Waste Oil Hydrogen Steam PRODUCT Volatile Waste H2O Diesel SN150 SN 500 Residue Waste Gas H2S in Amine Solution Waste Water from Steam Strip MASS FLOW (kg hr -1) * 27
UTILITIES UTILITY UNIT Electricity kw hr -1 Energy Required Steam LP Kcal Kg Water m 3 Catalyst Amine Solvent Hot Oil Kg Kg Mg ANNUAL TOTAL PRODUCT COST ESTIMATION ITEM COST (*) Raw Material Operating Labor Operating Supervision Utilities Maintenance & Repairs Laboratory Charges Other (Advertisement & Logistics) Total TOTAL PROFIT ANNUALLY 28
ADDITIONAL PROJECT POSSIBILITIES WITH RESPECT TO THE SAME COMPLEX -The Term (*) Means that number (value) will be added depending on capacity of plant required. 29
Some Images of Successfully Constructed Plants. 30
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ARSLAN ENGINERY Pvt.Ltd. Plot- 25/1, Additional-MIDC,AMBERNATH Pin Numb-421501 MUMBAI,MAHARASHTRA- INDIA Contact Number - +91-8983227333, (Tel) +91-251-6555300 Email- sales@arslanenginery.com, arslanenginery@gmail.com Web - www.arslanenginery.com, www.indiamart.com/arslanenginery Skype infoarslan 32