waste lube oil re refining
DESCRIPTION
Final year projectTRANSCRIPT
2/7/2014
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PROJECT TITLE
3
Hafiz Mohammad Tahir
Ali Hassan
Hafiz Mohammad Zohaib
Waqar Younus
Group Members
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Introduction
Process Selection
Capacity Selection
Process Description
Material Balance
Energy Balance
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Base oil
consist of hydrocarbons with 20 to 50 carbon atoms and boiling point
range of 550-1050oF
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Base Oils Primary Sources
Crude Oil
Chemical Synthesis
Non-Crude oil
Natural
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GROUP VISCOSITY INDEX SATURATES SULPHUR CONTENTS
I 80-120 upto 90% Upto 0.03%
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Oil quality gradually decreases
What is Waste Lube Oil
Water
Dirt
Broken down components
Varnish
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Waste lube oil
Used as Fuel
- Direct
- Indirect
Re-Refining
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Environment pollution to a great extent
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
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Reasons of re-refining
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composition of feed is given below:
Feed Mass (lb/hr) Mass%
Water + light ends 301.37 8
Gasoil 226.03 6
Lube oil +S compound 2637 70
Residue 602.74 16
Total 3767.12 100
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1) Acid - Clay Process
3) Vacuum Distillation
2) Solvent Extraction Process
i) Thin/Wiped Film Evaporator
Methods of waste lube oil refining
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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
Quick comparison of different process
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Capacity Selection
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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
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This deficit is met through
import of lube base oil
Import of lube base oil in
year 2013 was
5,136,660US$
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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%
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PROCESS STEPS
1. Dehydration
2. Gas oil removal
3. Lube oil separation
4. Hydro-treatment
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2C8H6S + 5H2 C8H10 + C8H8 + 2H2S
C9H8S + 3H2 C9H12 + H2S
C12H8S + 5H2 C12H16 + H2S
C13H10S + 2H2 C13H12 + H2S
C14H12S + 2H2 C14H14 + H2S
0.76
0.77
0.7
0.67
0.63
Basis
Processing of 3767 lb/hr of waste lube oil for the production of base
oil
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• It is very important for physical properties calculation of
petroleum fractions such as enthalpy and molecular weight.
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
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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
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Units 1 2 steam in steam out
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 444,860 444,860
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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
255.04
0 0 43
Temperature ᵒF 320 77 77 104
Q = ṁ ∆H Btu/hr 47832.75 47832.75
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Balance Across Flash Drum:
Units 2 OUT
2 4 3
Mass Flow Rate lb/hr 3767.12 187.55 3579.75
Weighted ∆H Values Btu/lb 118.044 255.04 110.85
Temperature ᵒF 320 320 320
Q = ṁ ∆H Btu/hr 444,680 47832.75 3968,47.25
Total Btu/hr 444,680 444,680
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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
Grand Total 3579.57
3579.57
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Units 4 5
Hot
product
in
Cold
product
out
Mass Flow Rate lb/hr 3579.74 3579.74 2379 2379
Weighted
Enthalpy Values Btu/lb 188.34 431
Temperature ᵒF 320 590 662 326
Q = ṁ ∆H Btu/hr 674,208 674,208
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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 297 43
Temperature ᵒF 560 170 77 104
Q = ṁ ∆H Btu/hr 1108405 108,405
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Units 20 9 Steam in Steam out
Mass Flow Rate lb/hr 40.208 40.208 546.696 546.696
Weighted
Enthalpy Values Btu/lb 601.5 45.09
Temperature ᵒF 620 620 650 625
Q = ṁ ∆H Btu/hr
24,601 24,601
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Balance Across stripper:
Units In OUT
5 8 7
Mass Flow Rate lb/hr 3579.57 3214.97
.
364.6
Weighted
Enthalpy Values
Btu/lb 188.34 164.95 394.35
Temperature ᵒF 590 620 560
Q = ṁ ∆H Btu/hr 674,208 530,326 143,882
Total Btu/hr 674,208 674,208
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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
Grand Total 3214.71
3214.71
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Units 12 13 Steam
in
Steam
out
Mass Flow Rate lb/hr 3214.71 3214.71 1221.63 1221.63
Weighted
Enthalpy Values
Btu/lb 16.38 44.205
Temperature ᵒF 620 662 752 671
Q = ṁ ∆H Btu/hr 54007.20 54002.2
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Units 21 10 Cold
water
Hot
water
Mass Flow Rate lb/hr 828.26 828.26 6329 6329
Weighted
Enthalpy Values
Btu/lb 343.9 43
Temperature ᵒF 662 170 77 104
Q = ṁ ∆H Btu/hr 284,835 284,835
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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 568.106 45.09
Temperature ᵒF 620 620 77 104
Q = ṁ ∆H Btu/hr 1355,6119 1355,6119
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Over All Balance Across Evaporator
Units In OUT
9 12 10
Mass Flow Rate lb/hr 3214.71 2386.65 828.06
Weighted Enthalpy
Values Btu/lb 16.838 411.71 485.391
Temperature ᵒF 620 660 662
Q = ṁ ∆H Btu/hr 73826245 2182,09
24 286,050,.3
Total Btu/hr 367870.04 367870.04
• 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
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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
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Component Stream 14 +20
(lb/hr)
Converted
lb/hr
Stream 15
lb/hr
C8H6S 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 58.58
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Component Stream 14 +20
(lb/hr)
Stream 15
(lb/hr)
Gasoil 2.117 2.120
Lube oil 2367.378 2360.638
Residue 17.155 17.155
1H2 2.074 0.580
CO 0.021 0.020
N2 0.249 0.249
Methane 1.327 1.326
Ethylene 0.498 0.497
Ethane 0.747 0.746
Propylene 0.166 0.166
Propane 0.166 0.166
Butadiene 0.003 0.003
Butylene 0.012 0.013
Iso and n-
butane 0.03 0.03
C5+ 0.05 0.05
H2S 0 8.23
Total 2392 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
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∆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
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Component Stream 15
(lb/hr)
Stream 17
(lb/hr)
Stream 18
(lb/hr)
Gasoil 2.120 0 2.120
Lube oil 2360.638 0 2360.638
Residue 17.155 0 17.155
H2 0.580 0.580 0
CO 0.020 0.020 0
N2 0.249 0.249 0
Methane 1.326 1.326 0
Ethylene 0.497 0.497 0
Ethane 0.746 0.746 0
Propylene 0.166 0.166 0
Propane 0.166 0.166 0
Butadiene 0.003 0.003 0
Butylene 0.013 0.013 0
Iso and n-butane 0.03 0.03 0
C5+ 0.05 0.05 0
H2S 8.23 8.23 0
Total 2392 12.08 2379.91
Grand Total 2392 2392
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Balance Across
Separation Vessel over all
Units 9 OUT
9 12 10
Mass Flow Rate lb/hr 2392 2379 12.08
Weighted Enthalpy
Values Btu/lb 431 431 485.391
Temperature ᵒF 662 662 662
Q = ṁ ∆H Btu/hr 102,534
9 4366.1
Total Btu/hr
106,9010 10690,10
In = Out + Losses
398,888,5.51 = 3988,0193.57 + 3691.14
398888,5.51 = 39888,85.51
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9476.38 tone/year or 2379.91lb/hr of base oil is
produced
Recovery of base oil is 90%
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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
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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