Waste lube oil re refining

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Information about Waste lube oil re refining
Technology

Published on February 8, 2014

Author: alihassan34245

Source: slideshare.net

Description

Final year project

1 2/7/2014

PROJECT TITLE 2

Group Members Hafiz Mohammad Tahir Ali Hassan Hafiz Mohammad Zohaib Waqar Younus 3

 Introduction  Process Selection  Capacity Selection  Process Description  Material Balance  Energy Balance 2/7/2014 4

Base oil consist of hydrocarbons with 20 to 50 carbon atoms and boiling point range of 550-1050oF 2/7/2014 5

Base Oils Primary Sources Natural Chemical Synthesis Crude Oil 2/7/2014 Non-Crude oil 6

GROUP VISCOSITY INDEX SATURATES SULPHUR CONTENTS I 80-120 upto 90% Upto 0.03% 2/7/2014 7

What is Waste Lube Oil  Water  Dirt  Broken down components  Varnish  Oil quality gradually decreases 2/7/2014 8

Waste lube oil  Used as Fuel - Direct - Indirect  Re-Refining 2/7/2014 9

Reasons of re-refining  Environment pollution to a great extent 2/7/2014 10

Reasons of re-refining  Base Oil fraction obtained from crude oil is obtained at the cost of other valuable fraction  Re-refining used oil takes about 1/3 of the energy needed to refine crude oil to lubricant quality 2/7/2014 11

composition of feed is given below: Feed Mass (lb/hr) Mass% Water + light ends Gasoil Lube oil +S compound Residue Total 301.37 226.03 2637 602.74 3767.12 8 6 70 16 100 2/7/2014 12

2/7/2014 13

Methods of waste lube oil refining 1) Acid - Clay Process 2) Solvent Extraction Process 3) Vacuum Distillation i) Thin/Wiped Film Evaporator 2/7/2014 14

Quick comparison of different process Acid-clay process Corrosion of equipment Pollution Lowe yield Solvent extraction process Involves operational solvent losses Explosion hazard High yield Vacuum distillation No corrosion and solvent loses No pollution High yield 2/7/2014 15

Capacity Selection 2/7/2014 16

 Current production of lube base oil is 176,200TPA at National Refinery Limited (NRL)  Total consumption of lube base oil reported at 2013 was 400,000TPA  Difference is 223,800TPA which is being met through import 2/7/2014 17

2/7/2014 18

 This deficit is met through import of lube base oil  Import of lube base oil in year 2013 was 5,136,660US$ 2/7/2014 19

 Current import can be cut down by re-refining the Waste Lube Oil  The maximum Capacity of our plant to process lube oil is 15000 tonne/year  This could reduces the import by 6.7% 2/7/2014 20

PROCESS STEPS 1. Dehydration 2. Gas oil removal 3. Lube oil separation 4. Hydro-treatment 2/7/2014 21

2/7/2014 22

2C8H6S + 5H2 C8H10 + C8H8 C9H8S + 3H2 C9H12 + H2S C12H8S + 5H2 C12H16 + H2S 0.7 C13H10S + 2H2 C13H12 + H2S 0.67 C14H12S + 2H2 C14H14 + H2S 0.63 2/7/2014 + 2H2S 0.76 0.77 23

Basis Processing of 3767 lb/hr of waste lube oil for the production of base oil 2/7/2014 24

• It is very important for physical properties calculation of petroleum fractions such as enthalpy and molecular weight. 2/7/2014 25

Two methods  Mathematically  Graphically

Compound ∆H (Btu/lb) at 77oF ∆H (Btu/lb) at 320oF ∆H (Btu/lb) at 590oF ∆H (Btu/lb) at 620oF ∆H (Btu/lb) at 662oF Water + light 80 190 344 370 385 Gas oil 98 222 405 429 450 Bas oil 95 218 400 426 445 Residue 70.5 168.9 395 401 412

Compound ∆H (Btu/lb) at 320oF ∆H (Btu/lb) at 560oF ∆H (Btu/lb) at 590oF ∆H (Btu/lb) at 662oF Water + light 336 435 455 495 Gas oil 355 497 503 535 Bas oil 349 489 496 530 Residue 0 0 0 0

Component Stream 2 (lb/hr) Stream 3 (lb/hr) Stream 4 (lb/hr) Waste Lube Oil 3767.12 0 0 Water + light ends 0 179.04 122.33 Gasoil 0 7.66 218.37 Lube oil 0 0.83 2636.16 Residue 0 0 602.74 Total 3767.12 187.55 3579.57 Grand Total 3767.12 3767.12 2/7/2014 35

Units 1 2 Mass Flow Rate lb/hr 3767.13 3767.13 374.55 374.55 Weighted Enthalpy Values Btu/lb 0 118.044 0 1187.72 Temperature ᵒF 77 320 320 320 Q = ṁ ∆H Btu/hr 2/7/2014 444,860 steam in steam out 444,860 36

Units 3 21 Cold water in Hot water out Mass Flow Rate lb/hr 187.55 187.55 1112.38 1112.38 Weighted Enthalpy Values Btu/lb 0 0 43 Temperature ᵒF 77 77 104 Q = ṁ ∆H Btu/hr 2/7/2014 255.04 320 47832.75 47832.75 37

Balance Across Flash Drum: Units 2 2 OUT 3 4 Mass Flow Rate Weighted ∆H Values Temperature lb/hr Btu/lb ᵒF 3767.12 118.044 320 187.55 255.04 320 3579.75 110.85 320 Q = ṁ ∆H Btu/hr 444,680 47832.75 3968,47.25 Total Btu/hr 444,680 2/7/2014 444,680 38

Component Stream 4 (lb/hr) Stream 7 (lb/hr) Stream 8 (lb/hr) Water + light ends 122.33 122.33 0.00 Gasoil 218.37 216.17 2.18 Lube oil 2636.16 26.36 2609.79 Residue 602.74 0.00 602.74 Total 3579.57 364.86 3214.71 3579.57 3579.57 Grand Total 2/7/2014 39

Units 4 5 Hot product in Mass Flow Rate lb/hr 3579.74 3579.74 2379 Weighted Enthalpy Values Btu/lb Temperature Q = ṁ ∆H ᵒF Btu/hr 2/7/2014 188.34 320 2379 431 590 674,208 Cold product out 662 326 674,208 40

Units 6 7 Cold water in Hot water out Mass Flow Rate lb/hr 364.86 364.86 25,21 25,21 Weighted Enthalpy Values Btu/lb Temperature Q = ṁ ∆H ᵒF Btu/hr 2/7/2014 297 560 170 1108405 43 77 104 108,405 41

Units 20 9 Mass Flow Rate lb/hr 40.208 40.208 Weighted Enthalpy Values Btu/lb Temperature ᵒF Q = ṁ ∆H Btu/hr 2/7/2014 Steam in Steam out 546.696 601.5 620 24,601 546.696 45.09 620 650 625 24,601 42

Balance Across stripper: Units Mass Flow Rate lb/hr Weighted Enthalpy Values Temperature Q = ṁ ∆H Total Btu/lb OUT 8 7 3579.57 3214.97 364.6 . 188.34 164.95 394.35 ᵒF Btu/hr Btu/hr 590 620 560 674,208 530,326 143,882 674,208 674,208 2/7/2014 In 5 43

Component Stream 8 (lb/hr) Stream 10 (lb/hr) Stream 12 (lb/hr) Gasoil 2.18 2.12 0.07 Lube oil 2609.79 2367.38 242.41 Residue 602.74 17.16 585.58 Total 3214.71 2386.65 828.06 3214.71 3214.71 Grand Total 2/7/2014 44

Units 12 13 Mass Flow Rate lb/hr 3214.71 3214.71 Weighted Enthalpy Values Temperature Btu/lb Q = ṁ ∆H Btu/hr 2/7/2014 ᵒF 16.38 620 Steam Steam in out 1221.63 1221.63 44.205 662 54007.20 752 671 54002.2 45

Units 21 10 Mass Flow Rate lb/hr 828.26 828.26 Weighted Enthalpy Values Btu/lb Temperature Q = ṁ ∆H ᵒF Btu/hr 2/7/2014 343.9 662 Hot water 6329 43 170 284,835 Cold water 6329 77 104 284,835 46

Units 20 9 Cold water in Cold water out Mass Flow Rate lb/hr 2386.654 2386.65 31,52.45 31,52.45 Weighted Enthalpy Values Btu/lb Temperature ᵒF Q = ṁ ∆H Btu/hr 2/7/2014 568.106 620 45.09 620 1355,6119 77 104 1355,6119 47

Over All Balance Across Evaporator In 9 12 10 lb/hr 3214.71 2386.65 828.06 Btu/lb 16.838 411.71 485.391 ᵒF 620 662 Q = ṁ ∆H Btu/hr 73826245 660 2182,09 24 Total Btu/hr 367870.04 Units Mass Flow Rate Weighted Enthalpy Values Temperature 2/7/2014 OUT 286,050,.3 367870.04 48

• • • • Weighted Cp = 37.69 KJ/Kmole. K As, Cp – Cv = R Cv = Cp – R = 37.69 – 8.314 = 29.37 KJ/Kmole. K Heat of vap. = 416.00 kj/kg = 179.23 Btu/lb 2/7/2014 49

Temperature of Inlet = T1= 77 oF Pressure of Inlet =P1 = 1.013bar Pressure of Outlet = P2= 65 bar Temperature of outlet = T ᵧ=Cp/Cv=37.69/29.37=1.28 For adiabatic Compression, T2 = T1*(P2/P1)^( ᵧ - 1)/ ᵧ T2 = 77*(65/1.013)^(1.28-1)/1.28 T2 =191 ᵒF 50 2/7/2014

Converted lb/hr Stream 15 lb/hr C8H6S Stream 14 +20 (lb/hr) 11.776 8.946 2.830 C9H8S 11.776 9.061 2.712 C12H8S 14.142 9.892 4.252 C13H10S 9.408 6.296 3.112 C14H12S 9.405 5.919 3.486 H2 2.074 1.492 0.598 C8H10 0 0 3.546 C8H8 0 0 3.478 C9H12 0 0 7.271 C12H16 0 0 8.624 C13H12 0 0 5.359 C14H14 0 0 5.096 H2S 0 0 8.232 Total 58.58 Component 58.58 51

Component Gasoil Lube oil Residue 1H2 CO N2 Methane Ethylene Ethane Propylene Propane Butadiene Butylene Iso and nbutane C5+ H2S 2/7/2014 Total Stream 14 +20 (lb/hr) Stream 15 (lb/hr) 2.117 2367.378 17.155 2.074 0.021 0.249 1.327 0.498 0.747 0.166 0.166 0.003 0.012 2.120 2360.638 17.155 0.580 0.020 0.249 1.326 0.497 0.746 0.166 0.166 0.003 0.013 0.03 0.03 0.05 0 2392 0.05 8.23 2392

Q load = ∆H reactants + ∆H reaction + ∆H products ∆H reactants = m C pv (25-350) + m ∆H vaporization + m Cpl (25-350) ∆H reactants = (-66890240.9) + (-72946600.1) + (-58006636.4) + (-939187.59) ∆H reactants = -188,419,587.7 Btu/hr ∆H reactions = ∆Hr1+∆Hr2+∆Hr3+∆Hr4 ∆H reactions = -826,989.64 Btu/hr ∆H products = mCpl(350-25) + m C pv (350-25) + m ∆H vaporization 2/7/2014 53

∆H products = 58031595.5 + 904356.2 + 73180726 + 66861367.9 ∆H products = 1886,04782.6 Btu/hr Q load = -188,419,587.7 -826,989.64 + 1886,04782.6 Q load = -641,794.69 Btu/hr 2/7/2014 54

Component Stream 15 (lb/hr) Stream 17 (lb/hr) Stream 18 (lb/hr) Gasoil Lube oil Residue H2 CO N2 Methane Ethylene Ethane Propylene Propane Butadiene Butylene Iso and n-butane C5+ H2S Total Grand Total 2.120 2360.638 17.155 0.580 0.020 0.249 1.326 0.497 0.746 0.166 0.166 0.003 0.013 0.03 0.05 8.23 2392 2392 0 0 0 0.580 0.020 0.249 1.326 0.497 0.746 0.166 0.166 0.003 0.013 0.03 0.05 8.23 12.08 2392 2.120 2360.638 17.155 0 0 0 0 0 0 0 0 0 0 0 0 0 2379.91 2/7/2014 55

Balance Across Separation Vessel over all Mass Flow Rate Weighted Enthalpy Values Temperature lb/hr 9 9 2392 Btu/lb 431 431 485.391 ᵒF 662 662 Q = ṁ ∆H Btu/hr 662 102,534 9 Total Btu/hr Units 2/7/2014 106,9010 OUT 12 2379 10 12.08 4366.1 10690,10 56

In = Out + Losses 398,888,5.51 = 3988,0193.57 + 3691.14 398888,5.51 = 39888,85.51 2/7/2014 57

9476.38 tone/year or 2379.91lb/hr of base oil is produced Recovery of base oil is 90% 2/7/2014 58

 Technical Data Book-Petroleum Refining Refining Department Sixth edition, april 1997  “Basic principles and calculations in chemical engineering” by david m. Himmelblau University of texas  “Chemical Reaction Engineering”, 3rd Edition by O.Levenspile chapter 9  Re-refining of waste lube oil, I- by solvent extraction and vacuum distillation followed by hydrotreating Eman A. Emam, abeer M. Shoaib  International Journal of Scientific Engineering and Technology Volume No.2, Issue No.9, pp : 928-931  Economic Survey of Pakistan 2010-11 2/7/2014 59

 The feasibility studies on sonochemical processes for treating used oil: toxin reduction for eliminating recycle interference by chia-yu (iris) yang  “Thermal and catalytic processes in petroleum refining” by Serge Raseev  US Patent 3985642  US Patent 4101414  US Patent 4994168  www.fbr.gov.pk  www.arl.com.pk/group_profile.php        www.stle.org/assets/document/Lubricant_base_oils www.benzeneinternational.com/baseoil.html www.globalindustrialsolutions.net/base-oildefinition.php www.synmaxperformancelubricants.com www.base.shamrockoils.com www.vurup.sk/petroleum-coal www.stpitaly.eu 2/7/2014 60

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