Engi neer i ng & Cont r ac t or

STP - Studi Tecnologie Progetti Srl

Rome, Italy
USED LUBE OI L RE-REFI NI NG
A SUCCESSFUL I NVESTMENT
PRESENTATION
Oil recycling proves its worth
Re-refining of used lube oil is an economically attractive recycling method in terms of
resources conservation and environment protection. It allows processing of hazardous
material in a safe and effective way to recover an high quality base oil product.
This result in a strong economic incentive for re-refining considering lube oil price.
Re-refining can produce base oils or VGO distillate that is a suitable feedstock to FCC or
HDC Refinery Units.
USED LUBE OIL RE-REFINING
2 liters of Used Lube Oil
1,5 liters of Rerefined Oil
give
Used lube oil is generally a mixture of different types and grades of used lube oils, coming
frommotor crankcases and industry users.
Used lube oil is made up of a multitude of small individual batches collected at garages,
maintenance shops, transportation companies and industries and depends on local situation,
seasonal consumption, handling practice at the collection source and collecting system
organization.
LUBE OI L LI FE CYCLE
Lube oil Production
Lube oil marketing
Lube oil user
Used lube oil Collection
Used Oil Re-Refining
USED LUBE OIL RE-REFINING
used lube oil is collected and
re-refined
When refilling lubricant
on motor crank-case.
to give Re-refined Base Oil for
lubricant production
USED LUBE OIL CYCLE
USED LUBE OIL RE-REFINING
Ener gy c onsumpt i on
l ow er t han f or vi r gi n
base oi l pr oduc t i on
Re-r ef i ni ng i s a st r ong ec onomi c
i nc ent i ve f or envi r onment pr ot ec t i on
and ener gy savi ng
USED LUBE OIL RE-REFINING
ADVANTAGES
Hi gh qual i t y
pr oduc t s and
l ess dependenc e
on i mpor t ed oi l
Envi r onment
Pr ot ec t i on
USED LUBE OIL RE-REFINING
SUCCESS OF RE-REFINING
depends on the
COLLECTION SYSTEM
USED LUBE OIL COLLECTION
Collectionof usedlubeoil isthestarting point for a succesfull Re-refining.
Re-refiningdependsoncollectioneffectivenessandusedlubeoil availability.
Efficient collectionfacilitiesareanecessityfor Re-refininginrelationto:
Availability of used lube oil (quantity)
Composition of used lube oil (quality)
USED LUBE OIL RE-REFINING
USED LUBE OIL COLLECTION STRATEGY
Investigation on used lube oil providers
Division of the territory in Areas and Sectors
Storage capacity of collection centres
Transport network and drivers formation
Pre-selection laboratory
Segregation of contaminants
USED LUBE OIL RE-REFINING
Re-refiningremovesall thecontaminantsfromusedlubeoil torecover baselubeoil product.
During the last years many factors have obliged rerefiners to look for alternative Re-refining
process, suchas:
increased use of additive packages in the formulation of finished lube oil and by
consequencehigher level of contaminantsintheusedoil
increased amount of thermal degradation products due to longer mileage of the
lubricants
pollution problems related to the disposal of acid sludges and spent clay fromthe
traditional acid/clayre-refining
Among theavailabletoday processes, STP Re-refining offers a low energy high yield operation,
highqualityproductsandabsenceof noxiouswastesor byproducts.
USED LUBE OIL RE-REFINING
USED LUBE OIL RE-REFINING
STP is pioneer on Used Lube Oil Re-refining
since more than 20 years.
STP has implemented several Re-refining Plants worldwide
and is providing the last generation of Re-refining Process
based on unicum open art know-how.
USED LUBE OIL RE-REFINING
Advantages of STP Re-refining Process
High flexibility towards feedstock quality and composition
High process yield. The lube oil recovery is more than 95%
High separation selectivity, removal of contaminants and
production of high quality base oils
Lowenergy and lowutility consumption
High onstreamefficiency without corrosion, fouling, coking
Environment safeguarding operation
Management of all odorous compounds to eliminate malodorous
and toxic emissions
Capital investment and operating cost highly competitive
USED LUBE OIL RE-REFINING
STP Re-refining Process
STP Re-refining process removes all the contaminants from the
used lube oil and recovers a distillate product as VGO or high
quality base oil either API Group I by chemical finishing or API
Group II by hydrofinishing.
STP Re-refining process does not release harmful or pollutant
wastes to be disposed and is therefore environment friend.
Effluents are oily drains / low BOD/CODoily process water sent to
treatment before disposal and process off gas sent to thermal
oxidizer for combustion and destruction according to environmental
lawand regulations.
USED LUBE OIL RE-REFINING
API Definitions for Base Oils
For the purpose of guidelines on Base Oil Quality Assurance and Base
Oil Interchange, base stocks are divided into six base stock groups
according to defined physical and chemical characteristics as follows:
Group I Base stocks containing less than 90 mass percent
saturates and/or greater than 0.03 mass percent sulphur
and having a viscosity index greater than or equal to 80 and
less than 120.
Group II Base stocks containing greater than or equal to 90 mass
percent saturates and less than or equal to 0.03 mass
percent sulphur and having a viscosity idnex greater than
or equal to 80 and less than 120.
USED LUBE OIL RE-REFINING
API Definitions for Base Oils (contd)
Group III Base stocks containing greater than or equal to 90 mass
percent saturates and less than or equal to 0.03 mass
percent sulphur and having a viscosity index of greater than
or equal to 120.
Group IV Base stocks are polyalphaolefins (PAO)
Group V All base stocks not included in Groups I, II, III, IV or VI.
Group VI Base stocks are polyinternalolefins (PIO)
The analytical methods to be used in the definition of the above base
stock groups are:
PROPERTY TEST METHOD
Saturate content ASTM D 2007
Viscosity index ASTM D 2270
Sulphur content ASTM D 2622
ASTM D 4294
ASTM D 4927
ASTM D 3120
USED LUBE OIL RE-REFINING
STP Re-refining Process
Unit Operations
Dehydration
Gas oil removal
Vacuum distillation
Finishing and final fractionation
USED LUBE OIL RE-REFINING
PROCESS DESCRIPTION
Dehydration: used oil is partly vaporized at atmospherique pressure and
160C to remove water, gasoline, light contaminants (solvents, glycols,
lighter organic). Water andlightsarecondensedandrecovered.
Gasoil removal: dehydrated oil is stripped under vacuumfor light gasoil
removal andflashpoint adjustment of lubeoil.
Vacuum distillation: oil fromgasoil stripper is sent to vacuumdistillation
torecover VGOoil fractionfromheavier than contaminants.
Vacuum distillation is carried out under high vacuum conditions, high
temperatureandbythinfilmevaporator.
Thin film evaporator achieves high selectivity and oil purification from
metals, heavypolymers, carbon, dust.
USED LUBE OIL RE-REFINING
Thinfilmevaporator isavertical cylindrical shell enclosedinanheatingjacket with
an internal rotor distributing a thin layer of oil on the heated wall, by means of
rotatingblades.
Bytheactionof rotor (electricallydriven) highturbulenceandback mixingoccur in
thethinlayer of theoil filmandproduct degradationat hightemperatureisavoided.
PROCESS DESCRIPTION (contd)
Mainfeaturesof thinfilmevaporator are:
short residence time (in order of magnitude of 10 seconds) by mechanical
agitationof oil ontheheat transfer surface;
highheat transfer ratethroughthefilm;
efficient andregenerativecleaningof thecontact surface
Cracking and fouling problems are avoided by keeping low residence time, low
wall temperatureandhighflowturbulence.
Lubeoil is recovered as distillatewhileheavy components, additives, metals and
degradationproductsareconcentratedinthebottomresidue.
USED LUBE OIL RE-REFINING
THI N FI LM EVAPORATOR
OPERATING PRINCIPLE
A ThinFilmEvaporator consistsof acylindrical shell with
internal rotor andexternal heatingjacket
FEED
The feed is distributed by the rotor blades and spread on
theheatedwall toformanhighlyturbulent thinlayer.
PRODUCTS
Light fractionsareevaporatedandflowout uptowardsthe
top
Heavy components flow in a spiral path down to the
bottom
USED LUBE OIL RE-REFINING
THI N FI LM EVAPORATOR
Short residencetimeand high turbulencein thefilmgive
high heat transfer coefficient and avoid overheating,
crackingandfouling
FEATURES
Highevaporationrateisobtainedbyasimplepass
High oil yield is achieved without degradation or
polymerizationof heat sensitivematerial
Highonstreamfactor andeasymaintenance
USED LUBE OIL RE-REFINING
PROCESS DESCRIPTION (contd)
Finishing and final fractionaction : vacuumdistillate is further finished to improve product
quality.
FinishingisdonebyChemical Reactor or Hydrofinishing(Baseoil API GroupII production).
Hydrofinishing provides deep removal of further contaminants such as chlorinated, sulfurous,
andoxygenatedorganiccompoundsandpolyaromatic hydrocarbons.
Finishedoil isthenfractionatedtoproducelight oil (SN-150) andheavyoil (SN-500).
USED LUBE OIL RE-REFINING
STP Re-refining Process
Advanced vacuum system for high vacuum level stability, based on the
combineduseof steamejectorsandindividual tubular condensers.
Highefficiency/lowpressuredrops special packinginlieuof normal packing
(pall rings +grids), to reduce pressure drops and increase oil yield and
productseparation.
Special typeof pumpsandinstrumentationfor critical services.
Useof antifoulingtoreducefoulingandmaintenance/cleaningoperation.
ProprietarydesignChemical Reactor
TwoStagehydrofinishing(demetallization+hydrogenation) andhighactivity
catalyst, to upgrade the product quality in accordance with Api Group II
specification.
USED LUBE OIL RE-REFINING
USED LUBE OIL CHARACTERISTICS
(TYPICAL)
Specific gravity 0.915
Viscosity, cst
at 40C 130
at 100C 15
Composition, wt%
Min. Norm. Max
Water 2 5 10
Light ends 1 2 4
Gasoil 2 5 8
Lube oil fraction 65 75 80
Asphaltic residue 10 13 15
ASTM D-1160 Vacuum distillation of dry oil (corrected at atm pressure)
Vol % Temperature (C)
IBP 150
5 270
10 325
20 395
30 420
40 430
50 440
60 450
70 470
80 505
90 570
FBP 590
USED LUBE OIL RE-REFINING
USED LUBE OIL RE-REFINING
USED LUBE OIL PRESELECTION TEST
PCB / PCT, wt ppm 25 max
Cl, wt % 0.5 max
S, wt % 1.5 max
Saponification N, mgKOH/g 20 max
Heavy fuel oil (drop test) pass
Fatty acids (lux test) pass
PRODUCTS CHARACTERISTICS
Gasoil can be used as substitution fuel in the
Plant or as light fuel oil in industrial fired
heatersand/or boilers.
LIGHT GASOIL
Specific gravity at 15 C 0.850
End point, C 360
Viscosity, cst at 40 C 3-5
Sulfur, wt% 0.1
Cetane Index 50-55
Colour L 1.0
Flash point, C 55
USED LUBE OIL RE-REFINING
PRODUCTS CHARACTERISTICS
VGOisusedasfeedstock toFCC or HDC RefineryUnits
VGO
Distillation range, C 370 - 550
Specific gravity at 15C 0.875
Viscosity, cst @ 40C 27 - 35
cst @ 100C 4 - 5
Flash point, C 210 min
Sulfur, wt% 0.25
CCR, wt% 0.1 max
TAN, mgKOH/g 0.1 max
Ashes, wt% 0.2
Metals content, wt ppm 10 max
USED LUBE OIL RE-REFINING
PRODUCTS CHARACTERISTICS
Characteristics Base Oil Base Oil
SN-150 SN-450
Specific gravity at 15 C 0.870 0.885
Viscosity, cst at 40 C 25-32 85-95
Sulfur, wt% <0.03 <0.03
Saturates, wt% 90 90
CCR, wt% <0.01 <0.01
Colour L 1.0 1.5
TAN, mg KOH/g <0.01 <0.01
Flash point, C 220 260
Pour point, C -3 -6
Metals, ppm absent absent
RE-REFINED BASE OILS
API GROUP II
USED LUBE OIL RE-REFINING
USED LUBE OIL RE-REFINING
PRODUCTS CHARACTERISTICS
REREFINED BASE OILS
API GROUP II
Characteristics Base Oil Base Oil
SN-150 SN-450
VI 100 100
PCB, wt ppm <1 <1
PCT, wt ppm <5 <5
PNA, wt ppm <1000 <1000
Cl, wt ppm <1 <1
Cu corrosion 1a 1a
Noack evaporation loss 15.0 2.5
Saponification N <0.5 <0.5
Demulsification N 10 10
Oxydation stability
CCR increase, % 0.10 0.15
Viscosity ratio @ 40C 1.09 1.1
Color stability 1.0 1.0
PRODUCTS CHARACTERISTICS
Characteristics Base Oil Base Oil
SN-150 SN-500
Specific gravity at 15 C 0.870 0.885
Viscosity, cst at 40 C 25-32 90-100
Sulfur, wt% 0.20 0.25
CCR, wt% 0.05 0.07
Colour 2.0 2.5
TAN, mg KOH/g 0.03 0.05
Flash point, C 220 260
Pour point, C -3 -6
Metals, ppm L 10 L 10
RE-REFINED BASE OILS
API GROUP I
USED LUBE OIL RE-REFINING
PRODUCTS CHARACTERISTICS
Residuecontains highquantity of polymers andmetals andcanbe
used for asphalt blending, production of paving asphalt, bitumen
protectivecoveringor asfuel inthecement factories.
ASPHALTIC RESIDUE
Specific gravity at 15 C 0.950 - 1.050
Viscosity, cst
at 40 C 10,000
at 100 C 80
Sulfated ash, wt% 3-4
Sulfur, wt% 1-2
Penetration, mm/10 at 25 C 200-400
Softening point, C 15-20
USED LUBE OIL RE-REFINING
OVERALL MATERIALBALANCE
__________________________________
Used Lube Oil 100
___________________________________
PRODUCTS
Water and Light Ends 7
Light Gasoil 5
Lube Oil 75
Asphaltic Residue 13
USED LUBE OIL RE-REFINING
OPERATING REQUIREMENT
Utilities Consumption (per MT of Used Lube Oil)
VGO or Base oil API Group I
production
Base oil API Group II
production
Electric power, Kwhr 50 60
Cooling water, m
3
60 70
Steam, Kg/hr (Note 1) 2,000 2,000
Fuel, 10
3
Kcal 350 570
Chemical, Kg 7.5 -
Hydrogen, Nm
3
- 35
Note:
1 Steam consumption for vacuum systems does not depend on used lube oil capacity.
USED LUBE OIL RE-REFINING
OPERATION STAFF
Plant Manager 1
Plant Operation:
Supervisor/Board person (1 per shift)
Operators (2 per shift)
4
8
Maintenance/Workshop
Supervisors
Workers
1
4
Laboratory 2
_________
Total 20
USED LUBE OIL RE-REFINING
Operating labour requirements will depend on factors such as Plant operating philosophy, geographical
location, whether or not thePlantispart of anexistingcomplex.
BasedonSTP experiencewithsimilar Plant, theestimatedtypical labor andtechnical staff requirement isas
follows:
Thestaffingestimateisprovidedasaguidelineandisintendedfor preliminaryassessment.
USED LUBE OIL RE-REFINING
Utilities Systems & Offsite facilities
at the service of the Re-refining Unit
Electric power system
Steam system
Cooling water system
Compressed air system
Fire fighting system
Sewage and WWT
Flare system (in case of Hydrofinishing)
Used oil and Products storage and loading system
ISBL Re-refining Unit includes DCS system, Thermal oil system,
Thermal oxidizer, Process water stripper and post treatment (chemox)
LAND AREA REQUIREMENT
USED LUBE OIL RE-REFINING
TheUsedOil Re-refiningUnit isaverycompact facility.
The plot size required for the Unit will depend upon the particular circumstances of the
proposedlocation.
Theestimatedlandarearequiredfor a50,000MTPY Re-refiningUnit onabattery limitsbasis
isasfollows:
Productionof BaseOil API GroupI or VGO(without Hydrofinishing) 1,400sq.mt
Productionof BaseOil API GroupII (withHydrofinishing) 2,400sq.mt
Used Lube Oil Re-refining
FLOW SCHEMES
USED LUBE OIL RE-REFINING
Used Lube Oil Re-refining
Block Scheme
USED LUBE OIL RE-REFINING
Used Lube Oil Re-refining
VGO production
Flow Scheme
USED LUBE OIL RE-REFINING
Used Lube Oil Re-refining
Base oil API Group I production
Flow Scheme
USED LUBE OIL RE-REFINING
Used Lube Oil Re-refining
Base oil API Group II production
Flow Scheme
Hydrofinishing & Fractionation
USED LUBE OIL RE-REFINING
Used Lube Oil Re-refining
Base oil API Group II production
Flow Scheme
Distillation
USED LUBE OIL RE-REFINING
Used Lube Oil Re-refining
PLANT VIEW AND ELEVATION
USED LUBE OIL RE-REFINING
Used Lube Oil Re-refining
PLANT VIEW AND ELEVATION
USED LUBE OIL RE-REFINING
Used Lube Oil Re-refining
VACUUM DISTILLATION MODELLING
USED LUBE OIL RE-REFINING
STP REFERENCES
USED LUBE OIL RE-REFINING
Client: VEOLIA ES CANADA
Location: St. Hyacinthe, Quebec
Capacity: 60,000 Ton/year
Type of Facility: Used Lube Oil Rerefining for production of VGO
Year: in progress. Completion 2012
USED LUBE OIL RE-REFINING
Client: ECOIL
Location: Ferrandina, Italy
Capacity: 65,000 Ton/year
Type of Facility: Used Lube Oil Rerefining for Base Oils production and Blending
Year: in progress. Completion 2012
Client: TOTAL / VEOLIA - OSILUB
Location: Gonfreville lOrcher, France
Capacity: 120,000 Ton/year
Type of Facility: Used Lube Oil Rerefining for production of VGO
Year: in progress. Completion 2011
USED LUBE OIL RE-REFINING
Client: SIRAL S.p.A.
Location: Nola, Italy
Capacity: 30,000 Ton/year
Type of Facility: Used Lube Oil Rerefinig for Base Oils production and Blending
Year: 2005-2007
USED LUBE OIL RE-REFINING
Client: KLOC- KUWAIT LUBE OIL COMPANY
Location: Ahmadi, Kuwait
Capacity: 27.000 Ton/year
Type of Facility: Used Lube Oil Rerefining for Base Oils Production
Year: 1998-2000
USED LUBE OIL RE-REFINING
Client: SOTULUB Socit Tunisienne de Lubrifiants
Location: Bizerte, Tunisia
Capacity: 20.000 Ton/year (Revamping)
Type of Facility: Used Lube Oil Rerefining for Base Oils production
Year: 1997-1999
USED LUBE OIL RE-REFINING
Client: GROUPO LWART
Location: Lencois Paulista, Brazil
Capacity: 60.000 Ton/year
Type of Facility: Used Lube Oil Rerefining for Base Oils production
Year: 1996-1998
USED LUBE OIL RE-REFINING
Client: RAMOIL
Location: Naples, Italy
Capcity: 30,000 Ton/year
Type of Facility: Used Lube Oil Rerefining for Base Oils production and Blending
Year: 1994-1996
USED LUBE OIL RE-REFINING
Client: KONKAT
Location: Armavir, Russia
Capacity: 50.000 Ton/year
Type of Facility: Used Lube Oil Rerefining for Base Oils production and Blending
Year: 1991-1993
USED LUBE OIL RE-REFINING
Client: SOTULUB- Socit Tunisienne de Lubrifiants
Location: Bizerte, Tunisia
Capacity: 16.000 Ton/year
Type of Facility: Used Lube Oil Rerefining for Base Oils production
Year: 1987-1989
USED LUBE OIL RE-REFINING
Client: EKVE/LPC
Location: Aspropyrgos, Greece
Capacity: 25,000 Ton/year
Type of Facility: Used LUBE Oil Rerefining for Base Oils production and Blending
Year: 1983-1985
USED LUBE OIL RE-REFINING
APPROVAL CERTIFICATES and TEST REPORT
The Re-refined Lube OilS produced by STP process have been approved by
USA Department of Army, USA Lubricants Research Institute, Grandi Motori
Trieste (Italy), FIAT (Italy), ANSALDO Motori (Italy) and Mercedes Daimler
Benz (Germany).
TheApproval CertificatesandTest Report areavailableonrequest.
Certificates and Test Report clearly show that the base oils product are top
qualityandsuitablefor motor andindustrial application.
Re-refined baseoils characteristics and performancearefully equivalent to the
virginLubeOils.
USED LUBE OIL RE-REFINING
Carlo G. Lombardi
Carlo G. Lombardi is the Chief Executive Officer and Managing Director of STP,
Studi TecnologieProgetti S.r.l..
Hehas morethan 20 years experiencein design and implementation of Used Lube
Oil Re-refining Plants and is a recognized worldwide leading expert of Used Lube
Oil Re-refining and oneof thepioneer of theRe-refining technology based on thin
filmevaporator andhydrofinishingprocess.
Mr. Lombardi is author of presentations on Used Lube oil Re-refining and former
lecturer at the Industrial Chemistry Institute of Chemical Engineering College at
RomeUniversity.
./..
USED LUBE OIL RE-REFINING
Carlo G. Lombardi
HisexperienceinLubeOil TechnologyandMarketingincludes:
Technology:
Processtechnologydevelopment
Pilot testingfor theapplicationof thinfilmevaporator toUsedLubeOil Re-refininginthe
year 1980at HABERLANDCo., Dollbergen, Germany
Designof thefirst industrial Re-refiningplant inGreecefor theformer EKVE Industries, at
Aspropyrgos, Greece
Marketing and Sales Strategy:
Cooperation with the Italian Obligatory Consortium of Used Lube Oil to set up the
proceduresandregulationfor thecollectionof theUsedLubeOil inItaly
Participation with SOTULUB and other Tunisian LubeOil distribution Companies to the
assessment of regulation and quality specification of re-refined lube oil in Tunisia, years
1983-84
Cooperation with REDOIL Italy, partner of Chall-Oils USA, for finished lubricant
formulation, Motor Oil, TransmissionFluids, WhiteOils, Industrial Oils
CooperationwithAGIPPETROLI, Italy, onlubricant production, marketingandselling.
USED LUBE OIL RE-REFINING
Carlo G. Lombardi
Publications and Conferences:
Modification of existing re-refining units and realization of new modular
units, November 11
th
13
th
, 1999.
The hidden asset, speach at Fifth Conference on Spent Lube Oil Re-
refining, LasVegas, USA, September 1982.
The used lube oil: a resource not to underevaluate, in Chemical
IndustriesMagazine, Italy, February1982.
Report on STP process at NORA National Oil Recyclers
Associations 1999 Conference and Trade Show, PalmSprings, USA,
November 1999.
USED LUBE OIL RE-REFINING
STP attendance to NORA Conference
at Palm Springs (USA)
USED LUBE OIL RE-REFINING
STP attendance to NORAConference
at Palm Springs (USA)
USED LUBE OIL RE-REFINING
STP Studi Tecnologie Progetti S.r.l.
Piazzale Ezio Tarantelli, 97
00144 Rome, Italy
Tel. ++39-06-52201070 (PBX 5 Lines)
Fax. ++39-06-52201078
E-mail: [email protected]
Web Site: www.stpitaly.eu
CONTACT US
USED LUBE OIL RE-REFINING