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PROJECT TITLE

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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