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Introduction
1.1 Background
Lubricating oils or lube oil, as they are commonly called, are viscous liquids used
in lubricating moving parts of machineries. Lube oils are mainly a blend of base oil
and a number of chemical additives, giving products that last longer and allow the
machinery to work better under severe operating conditions. Lube oils are used to
protect rubbing surfaces from friction, wear and excessive heating. They also
providing a tight sealing of spaces and engine cleanliness. A typical blend of lube
During usage the performance of lube oil deteriorates over time. This is due to the
contamination of the lube oil with various foreign matters and the degradation of
after about 5,000 kilometers of engine use, the oil can no longer provide desired
pg. 1
functions expected of it. Hence, it is discarded as used engine oil or waste engine
oil.
Used engine oil is known to have adverse impacts on both human health and
contaminants and by-products of degradation render waste oils more toxic and
harmful to human health and the environment than virgin base oils (Irwin 1978)
The used oil from one oil change can contaminate 1 million gallons of fresh
water—a years’ supply for 50 people (US EPA, Used Oil Management Program).
For mammals and birds, harmful impacts include toxic contamination, destruction
of food resources and habitats and impaired reproductive capability. Report has
shown that used oils contain more metals and heavy polycyclic aromatic
as compared with the fresh oil. Lead (Pb) and Cadmium (Cd) are pollutants
associated with high blood levels in Children, anthralgia, colic and other human
The main sources of used oils in Nigeria was categorized as; transportation,
industry and private electricity generation (Bamiro & Osibanjo, 2004). In Nigeria
the estimated used crankcase oil was 150 million liters per annum and industry-
based used oil was estimated at 50 million liters, leading to a total national oil
generating capacity of 200 million liters per annum (Bamiro & Osibanjo, 2004).
pg. 2
With this figure, efficient technology options for handling, treating and disposing
2004). Common disposal methods of used oil by auto technician and allied artesian
include disposal into gutters, and indiscriminate dumping on land and waterways.
Some generators store it in plastic containers like kegs, jerry cans and drums,
where they are left until use was found for them or they were eventually sold to
dealers or direct users. Uses include direct reuse as; lubricants in old and worn
engines, weed killer to control weeds, dust control, wood preservation, rust
furnaces to generate heat for boilers, cement kilns, bakery oven, etc. These
primitive methods give rise to toxic air emissions that exacerbate air pollution
problems.
Used engine oil re-refining is a process that uses conventional refining steps to
recover new oil from the used oil by removing water, dirt, heavy metal, and
and chemical treatment aimed at recovering the properties of the base oil. The
properties of re-refined used lube oils are similar to the fresh ones. Therefore, re-
refining of the used oil leads to production of valuable base oils with quality
comparable with virgin base oils. The principle of refining waste oils utilizes the
pg. 3
following four steps: dewatering and defueling, de-asphalting, fractionation and
in Fig.1.
The American Petroleum Institute (API) categorized base oils by composition (API
pg. 4
allow to produce premium quality base oils belonging to at least Group I according
to the API base oils classification. Under more severe or solvent finishing
In Nigeria, there has been several studies on used engine oil and the need to set up
an organized re-refining plant. Key to the success of any re-refining project is the
technological backup of the processes. Hence, this paper gives an overview of the
1.2 Significance
This paper will contribute towards the analysis of technology choices regarding
used engine oil recycling while proffering possible solutions that will assist both
the public and private sector in making policies regarding the management of
pg. 5
1.3 Scope
This technical paper covers the applicability of five currently used technologies in
pg. 6
CHAPTER TWO
Literature Review
Introduction: The acid-clay re-refining process was the first regeneration process
amounts of sulfuric acid and clay were used to treat the waste oils. Acid-clay re-
separation of water and light hydrocarbons. Concentrated sulfuric acid (10–15 wt.
%) is added into dehydrated waste oil, wherein the foreign substances (e.g.
additives and sulfides) will form sludge, enabling deposition within 16–48 h which
is thereafter separated from the waste oil. The impurities such as colloids, organic
acids and waxy substances are removed by clays (porcelain clay or aluminum
silicate). Filtered oil is distilled to produce base oils with various characteristics
pg. 7
Figure 2.1: Block flow diagram of acid-clay process.
Performance: The base oil obtained has low quality with a lubricating yield of
62–63% on dry basis. The product oils are dark in colour and tend to have a
noticeable odour. Moreover, the products have from 4 to 17 times higher content of
polycyclic aromatic hydrocarbon (PAH) than virgin oils. While the technology has
tar, oil saturated clay, and other hazardous waste by-products. Under increasing
including many developing countries. Several plants with low capacity in Italy,
pg. 8
2.1.2 Hylube process
Universal Oil Products (UOP) for the catalytic processing of used lube oils into re-
refined lube base stocks for re-blending into saleable lube base oils. This is the first
particulate matter such as iron and spent additive contaminants such as zinc,
Process description: The first part of the process involves separation of the lube
range and lighter components of the feed from the non-distillable residue portion.
After the separation step the light feed is flowed through the so-called ‘guard’
in the large pore size catalyst. A simplified block diagram of the process is shown
pg. 9
Figure 2.2: Block flow diagram of the Hylube process.
The treated feed is hydrogenated in the main reactor before the second separation
step. The Hylube unit operates with reactor section pressures of 60–80 bar and
hydrofinishing reactors, contaminants are removed and the quality of the lube base
sulfur and nitrogen, the catalyst is able to increase the viscosity index via
are stripped and separated in the fractionation tower to gasoline, petroleum, gas oil
and base oil fractions. Light ends from the high temperature separator are blended
pg. 10
with sodium carbonate and flowed to the low temperature separator, where the
waste water is settled and separated. The hydrogen rich vapor from the cold
hydrocarbon liquids collected in the separators are sent to the product fractionation
section where the products are separated into various cuts to meet the desired lube
oil viscosity grades. The processed feedstock is converted into a wide boiling range
products are the same as the properties of fresh Group II base oils (Table 3) The
Hylube process achieves more than 85% lube oil recovery from the lube boiling
Base oils
S/N Properties Light Medium Heavy
grade grade grade
1 Density @ 150C, kgm-3 850 855 860
2 Flash point, 0C 190 215 228
3 Pour point, 0C -12 -12 -12
4 Kinetic viscosity@ 400C, mm2s-1 13.5 29.5 58
5 Kinetic viscosity@ 1000C, mm2s-1 3.19 5.2 8.4
6 Viscosity index 100 115 116
7 Sulfur content, ppm 100 100 100
8 Saturates, % wt. >>90 >>90 >>90
pg. 11
2.1.3 CEP process
(CEP), a process technology company offering a range of products and services for
re-refining waste lubricating oils. The CEP process is located in Hamina, Finland
and has a capacity of 60 000 tons/year with base oil production of 42000tons/year.
Process description: The process combines thin film evaporation and hydro-
processing (Fig. 2.3). The used oil is chemically pretreated to avoid precipitation of
contaminants which can cause corrosion and fouling of the equipment. The
amount to give a pH about 6.5 or higher. The pre-treated used oil is first distilled
for separation of water and light hydrocarbons. Water is treated and sent to a waste
water treatment facility. Light hydrocarbons are used at the plant as fuel or sold as
a product. Thereafter, free-of-water oil is distilled under high vacuum in a thin film
evaporator for separation of diesel fuel, which can be used at the plant or sold as
fuel.
pg. 12
Figure 2.3: Block flow diagram of the CEP process.
Heavy materials such as residues, metals, additive degradation products, etc. are
temperature (315◦C) and pressure (90 bar) in a catalytic fixed bed reactor. This
the final stage of the process, three hydrotreating (Hydrofinishing) reactors are
used in series to reduce sulfur to less than 300 ppm and to increase the amount of
saturated compounds to over 95%, in order to meet the key specifications for API
Group II base oil (Table 4). The final step is vacuum distillation to separate the
pg. 13
Performance: Hydroprocessing technology is one of the most widely used
Introduction: This technology has been processing and recycling used oil and oily
liquids since 1955. The applied oil re-refining process is based on a patent held by
AVISTA OIL. The ‘Enhanced Selective Refining’ process uses solvent N-methyl-
NMP is a powerful, aprotic solvent with low volatility, which shows selective
affinity for unsaturated hydrocarbons, aromatics, and sulfur compounds. Due to its
aromatic extraction solvent in lube oil re-refining. The advantages of NMP over
pg. 14
other solvents are the non-toxic nature and high solvent power, absence of
azeotropes formation with hydrocarbons, the ease of recovery from solutes and its
high selectivity for aromatic hydrocarbons. Being a selective solvent for aromatic
hydrocarbons and PAH, NMP can be used for the re-refining of waste oils with
Process description: The MRD solvent extraction process uses the liquid–liquid
extraction principle. Figure 6 provides the flow chart of the process. Vacuum
distillates from the flash distillation are used as feed. These distillates are processed
the distillate enters the extraction column, any residues of dissolved oxygen in the
pg. 15
Figure 2.4: Block flow diagram of the MRD extraction process.
Thereafter the distillate is sent to the bottom part of the extraction column. As the
is fed in at the top of the extraction column. The solvent containing raffinate phase
leaves the extraction column at the top and is routed to the downstream raffinate
solvent is removed. The extract phase is continuously withdrawn from the bottom
separation drum from the separated secondary raffinate. The latter is returned to the
pg. 16
extraction column in order to optimize the process yield. The extract phase from
the secondary separation drum is sent to the extract recovery section where the
solvent is removed. The extract recovery section also consists of a distillation and a
stripping column. The resulting extract is routed to the off plot intermediate storage
tank and used within the refinery as an energy carrier or mixing component for
heavy oil. The dry solvent separated in the distillation columns of the raffinate and
extract recovery sections is returned to the solvent tank. The moist solvent
separated in the stripping columns of the raffinate and extract recovery sections is
Performance: The average base oil yield within the process is about 91%.29 The
base oils produced have high quality (Table 6).30 The process is characterized by
compounds from the re-refined base oil and preservation of the synthetic base oils
used oils.
pg. 17
Table 2.3: Properties of base oil products of MRD solvent extraction process.
Introduction:
This re-refining process was based on vacuum distillation and acid-clay treatment
steps until the end of 2000. Clay adsorption was banned on 1 January 2001 and the
plant was modified and upgraded to the Sotulub process. Moreover, the addition of
hydroxide) has been provided and has allowed solving the following basic
problems:
cracking section;
pg. 18
• high losses of base oil in the oily clay due to the high consumption of clay.
Currently this technology is applied to recycle 125000 tons of used oil annually on
the Lillebonne site, recycling 45% of the used motor oils collected in France. The
Process description: The Sotulub proces is based on treatment of the used oil with
an alkali additive called Antipoll and high vacuum distillation (Fig. 7). The used
oil is pre-heated to about 160◦C and mixed with a small amount of Antipoll-
additive, which decreases equipment fouling. In the next step, oil is drawn into the
flash-drum where water and light hydrocarbons are separated from the lubricating
base.
The dehydrated oil is additionally heated to 280◦C and stripped under vacuum to
remove the gas-oil fraction. Thereafter oil is distilled under high vacuum in a thin-
additives, polymers and degraded products, is separated from the bottom of the
column.
Distilled oil is condensed and treated again with a small amount of Antipoll to
obtained with acceptable quality without any additional finishing stage. Oil is
pg. 19
Figure 2.5: Block flow diagram of the Sotolube process adapted from ref 1.
Performance: The process provides base oils with a yield of 82–92%. The
pg. 20
2.1.6 Revivoil process
thermal de-asphalting and hydrofinishing (Fig. 8). The filtered used oil from
storage tanks is heated to 140◦C and then distilled in a preflash column where the
(TDA), where the oil is separated from substances that can enhance fouling in an
pg. 21
intermediate tank. The asphaltic and bituminous products remain at the bottom and
three side cuts of different viscosities are obtained at the same time. Intermediate
For improvement of the product quality, oil cuts after TDA are treated with
hydrogen over the catalyst. The hydrofinishing process starts in a fired heater
where the oil and hydrogen are heated to 300◦C. They are then sent to a reactor
well as Sulfur and nitrogen containing compounds. The reactor effluent is then
separated into two phases, the vapor phase and the liquid phase; the first one is
washed with water to remove the chlorine and Sulfur compounds, the second one
is stripped with steam to eliminate the most volatile compounds and restore the
flash point. The water contained in the oil after stripping is then removed in a
vacuum dryer.
Performance: The yield of base oils from the Revivoil process is about 72%.
According to the operating parameters of hydrofinishing, the final base oil quality
can be upgraded until the amounts of sulfur and saturated compounds fulfil the API
pg. 22
Table 2.5: Properties of base oil products of Revivoil process.
Base Oils
S/N Properties Light grade Medium grade Heavy grade
1 Density @ 150C, kgm-3 852 853 858
4 Kinetic viscosity@ 16.5 30.6 55.2
400C, mm2s-1
5 Kinetic viscosity@ 3.6 5.3 7.8
1000C, mm2s-1
6 Viscosity index 101 106 107
7 Sulfur content, wt. ppm <300 <300 <300
pg. 23
CHAPTER THREE
Discussion of Result
pg. 24
The drawback of solvent extraction technology is the dependence of the product oil
quality on the quality of the feedstock, since this process is a physical one and does
not involve any chemical reactions with formation of the desired hydrocarbon
hydrocarbons, which were formed during the oil use. Thereby the solvent
extraction technology allows the production of the re-refined oil bases of the same
EcoHuile (Sotulub) process is based on the vacuum distillation of oil cuts in thin
film evaporators, which reduce coking caused by cracking of the hydrocarbons and
oil impurities at high temperatures. The process apply alkaline pretreatment of the
used oils, which requires the elimination of synthetic and vegetable oils in the
feedstock. Nevertheless, the quality of products is worse than in the above solvent
extraction processes. In order to produce high quality base oils finishing steps
operating and capital costs and the process could become less financially attractive.
pg. 25
However, the hydroprocessing technologies have the following drawbacks:
base oil products, in which viscosity index is higher than 110 and sulfur content is
less than 100 ppm. The process feedstock is oils from different sources, however, a
inorganic contaminants level in the reactor feed. Thus, careful monitoring of the
used oil for known catalyst poisons such as arsenic and silicon is needed. The high
produces high quality product oils comparable with Hylube-products. Since this
process applies caustic pretreatment of the used oil, the amount of vegetable oils
pg. 26
and some types of synthetic oils should be eliminated. Off-site catalyst
The Revivoil process accepts all type of used oils. Thermal deasphalting combined
about 72%. The advantage of this technology is regeneration of the used catalysts.
pg. 27
CHAPTER FOUR
Conclusions
first oil regeneration process used, was substituted in the majority of advanced
hydroprocessing.
3. The technologies applying hydroprocessing obtain product oils with the highest
Hylube, CEP, and Revivoil, produce high-quality base oils, which fulfill the
compounds in lubricants, the use of alkali agents can cause problems during re-
pg. 28
refining some types of synthetic oils (based on esters for instance) which tend to
5. Thus, currently the most attractive method for re-refining used oil could be a
of the hydrofinishing step gives product oils of high quality independent of the
poisoning without any alkaline treatment of the used oil. Absence of a need to
could be optimized to increase catalyst stability and achieve the highest oil
pg. 29
References
http://institute.unido.org/documents/M8_LearningResources/ICS/
95.%20Compendium%20of%20Used%20Oil%20Regeneration%20
Technologies.pdf
2. Bamiro, OA, & Osibanjo, O. (2004). Pilot study of used oils in Nigeria. Paper
Convention.
4. Dang GS, Garg MO, Disposal and rerefining of used lubricating oil. Indian
http://www.docstoc.com/docs/126372228/DISPOSAL-OF-
USEDLUBRICATING-OIL-AND-REREFINING-OF-USED.
transboundarymovementsonhazardouswastesandtheirdisposal.
Switzerland(2002).ISBN92-1-158605-4.
pg. 30
6. Antonina Kupareva, Paivi Maki-Arvela and Dmitry Yu.Murzin, Technology
Exform
http://www.pops.int/documents/meetings/bat_bep/2nd_session/egb2_followup/
draftguide/6MWasteoilrefineries DRAFT.doc.
Recyclingpossibilitiesandpotentialusesofusedoils.RegionalActivity
org/docs/olis_eng.pdf.
Elsevier,Netherlands(2006).
19(2010).
pg. 31