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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

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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

Chemical Synthesis Natural

Crude Oil Non-Crude oil

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GROUP VISCOSITY INDEX SATURATES SULPHUR CONTENTS

I 80-120 upto 90% Upto 0.03%

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What is Waste Lube Oil

 Water

 Dirt

 Broken down components

 Varnish

 Oil quality gradually decreases

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Waste lube oil

 Used as Fuel

- Direct
- Indirect

 Re-Refining

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Reasons of re-refining

 Environment pollution to a great extent

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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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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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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

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Quick comparison of different process

Acid-clay process Corrosion of equipment Pollution Lowe yield

Solvent extraction Involves operational solvent Explosion hazard High yield

process losses

Vacuum distillation No corrosion and solvent No pollution High yield

loses

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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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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$

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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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2/7/2014 22
2C8H6S + 5H2 C8H10 + C8H8 + 2H2S 0.76

C9H8S + 3H2 C9H12 + H2S 0.77

C12H8S + 5H2 C12H16 + H2S 0.7

C13H10S + 2H2 C13H12 + H2S 0.67

C14H12S + 2H2 C14H14 + H2S 0.63

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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.

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Two methods
 Mathematically
 Graphically
 ∆H (Btu/lb) ∆H (Btu/lb) ∆H (Btu/lb) ∆H (Btu/lb) ∆H (Btu/lb)
Compound
at 77oF at 320oF at 590oF at 620oF at 662oF

Water +
80 190 344 370 385
light

Gas oil 98 222 405 429 450

Bas oil 95 218 400 426 445

Residue 70.5 168.9 395 401 412

 ∆H (Btu/lb) ∆H (Btu/lb) ∆H (Btu/lb) ∆H (Btu/lb)
Compound
at 320oF at 560oF at 590oF 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
 Stream 2 Stream 3 Stream 4
Component
(lb/hr) (lb/hr) (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
Btu/lb 0 118.044 0 1187.72
Values
Temperature ᵒF 77 320 320 320
Q = ṁ ∆H Btu/hr 444,860 444,860

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 Cold Hot
Units 3 21
water in water out

Mass Flow Rate lb/hr 187.55 187.55 1112.38 1112.38

Weighted Enthalpy 255.04

Btu/lb 0 0 43
Values
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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 Stream 4 Stream 7 Stream 8
Component
(lb/hr) (lb/hr) (lb/hr)

Water + light
122.33 122.33 0.00
ends

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

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 Hot Cold
Units 4 5 product product
in out
Mass Flow Rate lb/hr 3579.74 3579.74 2379 2379

Weighted
Btu/lb 188.34 431
Enthalpy Values
Temperature ᵒF 320 590 662 326
Q = ṁ ∆H Btu/hr 674,208 674,208

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 Cold water Hot water
Units 6 7
in out

Mass Flow Rate lb/hr 364.86 364.86 25,21 25,21

Weighted
Btu/lb 297 43
Enthalpy Values

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
Btu/lb 601.5 45.09
Enthalpy Values

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 Btu/lb 188.34 164.95 394.35
Enthalpy Values
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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 Stream 8 Stream 10 Stream 12
Component
(lb/hr) (lb/hr) (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

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 Units 12 13 Steam Steam
in out
Mass Flow Rate lb/hr 3214.71 3214.71 1221.63 1221.63

Weighted Btu/lb 16.38 44.205

Enthalpy Values
Temperature ᵒF 620 662 752 671
Q = ṁ ∆H Btu/hr 54007.20 54002.2

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 Units 21 10 Cold Hot
water water
Mass Flow Rate lb/hr 828.26 828.26 6329 6329

Weighted Btu/lb 343.9 43

Enthalpy Values

Temperature ᵒF 662 170 77 104

Q = ṁ ∆H Btu/hr 284,835 284,835

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 Cold Cold
Units 20 9
water in water out
Mass Flow Rate lb/hr 2386.654 2386.65 31,52.45 31,52.45

Weighted
Btu/lb 568.106 45.09
Enthalpy Values
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
Btu/lb 16.838 411.71 485.391
Values
Temperature ᵒF 620 660 662
2182,09
Q = ṁ ∆H Btu/hr 73826245 286,050,.3
24
Total Btu/hr 367870.04 367870.04

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• 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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 Stream 14 +20 Converted Stream 15
Component
(lb/hr) lb/hr 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 51
 Stream 15
Stream 14 +20
Component (lb/hr)
(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-
0.03 0.03
butane
C5+ 0.05 0.05
H2S 0 8.23
Total
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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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 Stream 15 Stream 17 Stream 18
Component
(lb/hr) (lb/hr) (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
Btu/lb 431 431 485.391
Values
Temperature ᵒF 662 662 662
102,534
Q = ṁ ∆H Btu/hr 4366.1
9
Total Btu/hr 10690,10
106,9010

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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

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