feasibility study) Factory for recycling ,mixing,bottiling used oil and producing mineral grease and additives and chemicals

(primary feasibility study)

Factory

for

recycling ,mixing,bottiling used oil

and producing

mineral grease and additives and chemicals

in Egypt

technical introduction

Recycled Base Oil

The Recycled Base Oil is subjected to the highest level of mineral oil refining of the base oil groups.

Although Recycled Base Oil is not chemically engineered, still it offers good performance in a wide range of attributes as well as good molecular uniformity and stability.

Recycled Base Oil is commonly used to mix with additives and marketed as synthetic or semi-synthetic products.

Used waste mineral oils

: Principal Contaminants in Waste Oil

Metals and Inorganics

Aluminium

Antimony

Arsenic

Barium

Cadmium

Calcium

Chromium

Cobalt

Copper

Lead

Magnesium

Manganese

Mercury

Nickel

Phosphorus

Silicon

Sulphur

Zinc

Chlorinated hydrocarbons

Dichlorodifluoromethane

Trichlorodifluoromethane

-Trichloroethane

Trichloroethylene

Tetrachloroethylene

Total chlorine

Polychlorinated biphenyls

Other organics

Benzene

Toluene

Xylenes

Benza(a)anthracene

Benzo(a)pyrene

Naphthalene

Other PAHs

Water content

the First Schedule of the Environmental Quality (Scheduled Wastes) Regulations

, with the following codes and descriptions

(a) SW 305 – Spent lubricating oil

(b) SW 306 – Spent hydraulic oil

(c) SW 307 – Spent mineral oil-water emulsion

(d) SW 308 – Oil tanker sludges

(e) SW 309 – Oil-water mixture such as ballast water

(f) SW 310 – Sludge from mineral oil storage tank

(g) SW 311 – Waste oil or oily sludges

(h) SW 312 – Oily residue from automotive workshop, service station oil

or grease interceptor

(i) SW 314 – Oil or sludge from oil refinery or petrochemical plant

Typical analysis specifications of waste lub.oil

Test description Standard test method Range

Water contents (%in emulsion w/w ASTM D-95 5 to 10%

Flash point (ºC) ASTM D-92 100 to 190ºC

Viscosity at 40ºC (cSt) ASTM D-445 70 to 110

Sulphated Ash (% w/w) ASTM D-482 1.5 to 3.0%

Total acid no. (mg KOH/gm) ASTM D-664 1

Pentane insoluble (% w/w) ASTM D-893 1%

Specific gravity ASTM D-1298 0.850 to 0.900

The greatest problems in waste oil in egypt

Water content

Water will affect the oil’s base stock, encouraging oxidation, viscosity increase and foaming.

Water can also affect the additive package through Water washing and hydrolysis, leading to acids and additive depletion.

Water encourages rust and corrosion and will cause increased wear as a result of aeration, changes in viscosity resulting in film strength failure, hydrogen blistering and embrittlement, and vaporous cavitation.

Finally, Water is a generator of other contaminants in the oil such as waxes, suspensions, carbon and oxide insolubles and even micro-organisms.

The following technologies applied to remove Water from oil, in Egypt

Gravity Separation

As already mentioned, free Water in the system will settle to the bottom of the tank (assuming the specific gravity of Water is greater than the lubricant).

In basic systems, opening the drain valve and allowing the Water to drain off may be sufficient.

The effectiveness of this action, however, will depend upon how long the system was allowed to stand prior to draining the water, whether the temperature was low enough to lower the saturation point dramatically and the oil’s demulsibility characteristics. Lowering the saturation point helps ensure that as much of the Water as possible will exist in the free state. tank may be employed to allow the oil to cool

The major downside to this method is that it removes only free water, so elements of emulsified and dissolved Water will remain.

The upside is the low cost of Water removal.

Centrifuge - Spin Your Oil Clean

The principle of the centrifuge is to separate the oil’s heavier elements by spinning the oil to create high G-forces - often in the tens of thousands of Gs.

The greater the difference in specific gravity between the contaminant and the oil, the more effective the process.

For this reason, centrifuges often work better on low specific gravity and low viscosity oils, like turbine oils, rather than heavier gear type oils.

In a centrifuge, both free and emulsified Water will be removed; this will depend to some extent on the type of additive package, as some Water will be held in suspension in the oil.

Absorption Removal

Typically, most filter media will absorb a small amount of moisture from the oil, resulting in swelling of the media.

This is particularly true for cellulose-based media. In fact, examination of used filters will often indicate if the presence of Water is a concern.

Some filter cartridges with an additional wrap consisting of polymer and desiccants are available.

These filters are specifically designed to remove Water by absorption and remove both emulsified and free water, as well as solids.

However, the elements typically have a limited volume capacity and are best fitted to a portable filter cart for minor Water ingression problems.

Vacuum the Oil Dry

The vacuum dehydration process lowers the partial pressure, which assists in removing the Water from the oil.

Just like boiling Water on top of Mount Everest, lowering the pressure allows Water (and other volatile materials) to boil at a much lower pressure.

At the typical pressures used by most vacuum dehydrators (25" to 28" of mercury), Water boils at 120°F to 130°F.

By heating the oil, typically to 150°F to 160°F, Water is vaporized inside the dehydrator, without causing excessive oil degradation due to thermal and oxidative stress.

In most dehydrators, the air is warmed and dried prior to being passed over the oil, encouraging the Water to transfer from the oil into the air.

To maximize the process, the oil is thinned to obtain the greatest amount of surface area exposure possible.

This is achieved by allowing the oil to pass over a number of surfaces internally in the vacuum chamber, or by creating an umbrella spray within the chamber through which the dry air passes.

Dehydration by Air Stripping

An alternative technology to vacuum dehydration is dehydration by air stripping a process that removes Water as well as gaseous contaminants in the oil.

Not only does it remove free and emulsified water, but also dissolved Water down to less than 100 ppm.

Because of its ability to degas, it is also suitable for removing hydrocarbons in seal oil systems.

Air stripping works by drawing air or nitrogen gas into a stream of heated oil, which mixes in and absorbs the Water and gasses within the oil.

The oil/air is then expanded to release the air or nitrogen, which takes the impurities with it.

The exhaust air and gasses are also controlled to minimize the oil vapor released.

Heat the Oil Dry

Some applications are self-cleansing because they run at elevated temperatures and consequently, Water is evaporated.

The combustion engine is a perfect practice to deliberately heat the oil briefly to drive off moisture to maintain oil health is open to debate.

Allowing the Water to remain in the oil is usually far more damaging than briefly heating the oil.

And in static systems, like reservoirs, ensure that the power density of such elements remains below 5W/in2 to minimize thermal stress to the oil.

The downside to heating oil is that it must be controlled, particularly with mineral oils, to avoid harm. However, the relative cost is less than the centrifugal or vacuum separation technologies, making this an effective Water removing tool in certain circumstances.

the applied methods for Reclamation or re-recycling of used oils in Egypt

are classified into two main groups:

Physical Method

Physio-chemical method

- Physical Method

-1-Mechanical Filtration by vacuum dehydrating-cum-filtering unit

Mechanical Filtration is widely used method of re-cycling. Here contaminants are separated mechanically or by absorption or adsorption by passing through materials of controlled porosity.

Area or edge type strainer embody a purely mechanical process of forcing oil by pressure through a straining device which prevents the passage of solid contaminants above a certain size.

The filter elements are usually made with different porosity. Porous metallic or non-metallic filters are made in either cylindrical or disc form by compacting or sintering metal, ceramics, or glass powder of graded fineness.

Other strainers may be paper, fabric or other materials.

Depth Filter in turn, may be divided into two general classes

Absorbent –

A mechanical action that remove fine contaminants such as insoluble oxidised material and coarser particles from the oil.

Adsorbent –

a process in which one substance attracts another and retains the material to be removed from the oil on the surface and throughout the filter medium

Gravity Filter is actually a low head pressure filter, depending for its action on slight difference in head between the dirty and clean oil level.

Water and oil, for all practical purpose, are immiscible liquids. If not agitated, water introduced into lubricating oil separates readily by gravity.

However, any kind of agitation can break up the body of water into small droplets, which become dispersed in the oil and are then not readily separated by gravity.

The more intense and persistent the agitation, the finer these droplets will split into particles.

In the vacuum dehydrating-cum-filtering unit, the oil to be treated is heated to comparatively lower temperature in vacuum, thus obviating the necessity of using high temperatures with possible resulting in oxidation of the oil.

It employs fuller's earth to remove suspended solids and oil oxidation products.

Vacuum vaporisation removes moisture, diluent fuel, low molecular weight organic acids and other impurities, which have a boiling point lower than that of the oil.

Before the oil passes to the clean oil storage tank, small filter press and then a secondary filter using a fabric as a filtering medium filter it.

The product of this purification process is straight mineral oil, which can be blended with additives, as desired.

-2-Centrifugal Separation

It is efficiently used in some commercial oil purifying equipment to separate solids and free water from the oil.

The method involves whirling the dirty oil to separate it into layer of insoluble contaminants, water and clean oil.

Water and some of solids will be expelled near the periphery of the bowl, and clean oil through or near the center.

Two types of centrifugal separators are much in use:

One is known as disc type centrifuge.

It can be used as a purifier to eliminate the solids only.

In the second, known as a tubular type centrifuge.

the oil enters near the bottom of the vertical bowl and is expelled at the top.

Both types of centrifugal purifiers can be used either alone or in combination with pressure filter.

-3-Magnetic Separation

Several types of magnetic filters are used principally for the removable of ferrous metal contaminants from low viscosity oils and water-soluble oil coolants.

There are two typical devices much in use viz:

First type has no moving parts and consists of a stack of soft steel grids placed between and magnetised by two powerful permanent magnets.

This enuregrid stack is enclosed in a cylindrical case through which the liquids flow.

This filter is not of the self-cleaning type and must be taken out of use for cleaning at varying intervals depending upon the service.

Second type known as rotating-drum design of magnetic filter consists of a rotating drum from which the ferrous particles are scrapped off and discharged.

Physio-Chemical Method (the ACID/CLAY refining)

These Methods for oils, which are heavily contaminated and re-refining is not possible only by physical methods.

With the ever-increasing awareness towards the cleaner environment, following new ECO friendly process producing higher yields of re-refining oils have been developed which totally eliminates ACID SLUDGE.

The process combines unique & proprietary chemical demetalization followed with hydro treating to produce high yield of base oil.

Acid - Clay Process
Acid-Clay Process for used oil recycling/reprocessing is Old and popular
it be set-up for very small capacity
Low Capital investment. Makes it most cost effective for small and tiny scale plants
Non sophisticated, Very simple process. Simple to operate, No advanced instruments
No skilled operators required
Drawbacks
Causes Environmental pollution due to generation of acid sludge and acid gas emission
Disposal of acid sludge is a problem
Causes corrosion of equipments reducing its life
Gives Lower yield, Due to loss of oil in sludge as well as clay since higher dosage of clay is required
Acid Activated Clay Process
No acid is required
It is simple process
Suitable for small capacity plant
Drawbacks
Very high clay consumption, low yield, inconsistent quality
Disposal of large quantity of spent clay is a environmental problem
Suitable only for very small capacity plants
Process is dependent on a particular type of clay which may not be available from all the sources
Recycled base oils using the acid-clay and the clay filtration processes are not the same as rerefined base oils
„ Typical concerns
-Do not get typical base oil viscosity fractions/grades
-Recycled base oils may not have the same performance and oxidation stability
-Quality may be very variable depending on feedstock

Vacuum Distillation
Thin/Wiped Film Evaporator
Suitable for high capacity plants
Thin film evaporator is capable of Operating at high vacuum and normally used for high value and heat sensitive products
Does not cause pollution
Sophisticated Equipments & Process
Produces good quality Base Oils
Drawbacks
Operates at high temperature & very high Vacuum.
Require special /expensive thermic fluids & heating system
High cost of heating fluid and High operational costs
Requires high capital investment
Plant has to be of a higher capacity to make it economically viable
Require highly skilled & Operational maintenance Staff.
As it has very sophisticated equipments
Higher Fuel Cost
Due to multiple stage of distillation involving heating & cooling

Oil Recycling Process in Egypt

Pretreatment

Used oil undergoes a pretreatment step in the overall recycling process.

The recycled oil is dewatered to get rid of its water content.

The main tool used to dewater oil is gravity.

The process involves allowing the natural separation of the oil from the water over time.

When the two have separated into an upper layer of oil and a bottom layer of water.

the water is then drained from the oil and undergoes a treatment process to make it safe for disposal into the environment.

Heat is also used in the dewatering process to speed it up by causing the water to evaporate.

Once the water is separated out of the oil, it is then ready for the next step.

Filtering

Debris and additives are filtered out of the recycled oil.

Some of the additives extracted by filtering are also recycled for reuse.

The used oil is placed in a reaction tank, where it is mixed with sulfuric acid and then heated.

Demineralization

A surfactant is added to the mixture, which is then left to separate into oil and a water-based, soap-like phase.

This water-based part collects debris and contaminants, such as oil additives and metals, and then it is drained off at the bottom of the tank.

The water is then evaporated off, and the waste is disposed of as solid matter.

The oil is filtered again to remove finer particles of debris.

The oil is then ready to be used as fuel, and can undergo further refining to produce different grades of fuel oils, from heavy fuels to lighter fuels for specialized burners.

Distillation

Recycled oil can also undergo distillation to remove water, gases, petrol and solvents.

The first type of distillation is atmospheric distillation, a process that separates these components from the oil based on their respective boiling points.

As the recycled oil is heated in the distillation process up to 300 degrees Celsius, each component boils off and is collected for reuse.

Another type of distillation is vacuum distillation, which further refines the oil to control its flash point, viscosity and carbon residue.

The recycled oil undergoes heating at temperatures higher than 300 degrees Celsius, as the vacuum system works to reduce pressure build-up that, in turn, prevents destruction of the oil components.

The oil is heated and distilled off into trays, as different grades of oil.

The lightest is gas oil, which is distilled off at the highest level of the system.

This is followed by light oil, medium oil and heavy oil.

This process separates out the remaining components, called vacuum tower bottoms (VTB), the heaviest components in the oil, that were unaffected by the distillation process.

Uses marketing for recycled oil in Egypt and africa

Used oil, or 'sump oil' as it is sometimes called, should not be thrown away

Although it gets dirty, used oil can be cleaned of contaminants so it can be recycled again and again

There are many uses for recycled used oil

These include

Industrial burner oil, where the used oil is dewatered, filtered and demineralised for use in industrial burners

Mould oil to help release products from their moulds (e.g. pressed metal products, concrete)

Hydraulic oil

Bitumen based products

An additive in manufactured products

Re-refined base oil for use as a lubricant, hydraulic or transformer oil

the series of recycled engine/motor oil

purification plant

Application

New series waste oil regeneration treatment, can effectively remove the debris, sand, impurities, moisture, acid quality, an organic acid and an inorganic acid in the waste oil, it capable of removing the carbon particles dispersed in the engine oil ,and deep oxides and other mini impurities, colloid, asphalt and other undesirable substances, it can demulsification and improve oil color reach to new oil color.

restore the performance index of the oil and improve the performance of the engine oil, Ensure that the engine lubrication system normal operation, to extend the life of the internal combustion engine and oil.

Working Principles

Sucking oil into the distillation tank by pump, when the oil is separated vaporized in the distillation tank, cooled by the cooling system, to enter the water seperation apparatus, and then through decolorization, deacidification, dealkalizing and desulfuration system processing, the harmful gases in the waste oil processing through decomposition, cooling, purification treatment.

The oil of after reaction through a high-precision filter, the recycled oil can reach new oil color and discharge into oil collectors .

when the oil to the specified location, new oil pump automatically starts working and pump the oil into the clean oil tanks.

The exhaust gas passes through the activated carbon absorption and through the water treatment, discharged after by exhausters fan.

Components

（1）electronic control system

（2）heating system

（3）distillation system

（4）fractionating system

（5）heat exchanger system

（6）Dehydration system

（7）Decolorizing system

（8）oil storage system

（9）waste gas treatment system

（10）waste gas treatment cooling system

（11）recycling system of Decolorizing material

(12)deodorization unit

(13) final oil

Technical index of good machine for recycling in egypt

Treatment Capacity L/8 -10hrs = 10000 l/10 hrs

Regeneration Rate % 70-90%

Working Pressure MPa -0.095-0.4

Temperature ℃ 60℃-200℃

Working Noise dB(A) ≤90

Treated recycle base oil specifications in Egypt

Standard and Specification of Recovered Waste Oil

Parameters / Constituents Allowable Level

Arsenic 5 ppm maximum

Cadmium 2 ppm maximum

Chromium 10 ppm maximum

Lead 100 ppm maximum

Total Halogen (as chlorine) 1000 ppm maximum

Flash point 37.7 C or higher

Appearance The recovered waste oil must have a clear and bright appearance

Poly-aromatic hydrocarbons

Benzo(a)pyrene 10 mg / 1 kg oil (10 ppm) maximum

Dibenz(ah)anthracene 10 mg / 1 kg oil (10 ppm) maximum

Benz(a)anthracene 100 mg / 1 kg oil (100 ppm) maximum

Benzo(b)fluoranthene 100 mg / 1 kg oil (100 ppm) maximum

Benzo(k)fluoranthene 100 mg / 1 kg oil (100 ppm) maximum

Chrysene 100 mg / 1 kg oil (100 ppm) maximum

Indeno(123-cd)pyrene 100 mg / 1 kg oil (100 ppm) maximum

General Data sheet for treated recycled base oil in egypt

Item Unit Theory index Treated oil index

flow viscosity 100℃ mm2/s 12.5-16.3 11.6

Flash point （open） ≥ 220 232

Acid mgkoH/g ≤ 2.0 0.04

Impurity % ≤ 0.01 0.006

Water-solubility acid or alkali / / no

viscosity index ≥ 80 91

Pour point ℃ ≤ -10 -26

Sulfate ash / / 0.172

The most treated recycled base oil in egypt

RECYCLED BASE OIL – SN 500

PROPERTY VALUE TEST METHOD

Color 2.5 to 3.5 ASTM D98 / 1500

Specific Gravity 0.87 to 0.89 ASTM D96 / 4052

Viscosity @100 Deg C 9.5 to 11.5 ASTM D96 / 445

Viscosity Index Min 95 ASTM D93 / 2270

Pour Point 0 ASTM D97

Flash Point Min 205 ASTM D92

Specification of Recycled Base Oil SN150

Recycled Base Oil SN150 is a highly refined base oil stock using vacuum distillation / thin film recycling processes.

SN-150 is defined as a light grade base oil at the lower end of the specifications for Grade I light base oils.

They are mainly used in lubricant and lubricant additives production.

Typical Specsifications

PROPERTY TEST METHOD UNIT RESULT

Appearance D4176 0 B&C

Color D1500 - 1.5-2

Density @ 15°C D4052 Kg/lt 0.84-0.86

Kinematic Viscosity @ 100°C D445 cSt 3-4 Cst

Viscosity Index D22 70 - 90 min

Flash Point COC D92 °C 170-190

APPLICATIONS of treated recycled base oil in egypt

 General purpose oils

 Mould oil

 Transmission fluids

 Gear oils

 Metal working fluids

 Additives

The project requirements

[ltr]-          The proposed site for the factory = industrial area licensed[/ltr]
[ltr]-          The licensed sector in the industrial zone =chemical sector [/ltr]
[ltr]-          The proposed factory area =1500-7500 square meters [/ltr]
[ltr]-          The factory productivity recommended daily = 15-80 tons / day[/ltr]
[ltr]-          Quality oils involved in the production of oils = oilchanging for cars shops / factories / Oils petroleum companies / gas stations / transformer oil/ Agricultural machinery oil / diesel oils / Hydraulic oils[/ltr]
[ltr]-          The amount of used oil tons to produce ton of base oil = 3 tons / 1 ton basis[/ltr]
[ltr]-          The price of used oil ton = 1500-2500 LE[/ltr]
[ltr]Licenses required to operate the plant of the factory in Egypt[/ltr]
[ltr]- Investment Authority approved after the submission of the commercial register and tax card and a technical and economic feasibility study to taken initial industrial approval for the project and the allocation of land for the factory[/ltr]
[ltr]-Approval of the General Authority for Petroleum after the submission of consent Investment Authority and the allocation of land for the factory and provide a technical feasibility study inputs and outputs and plant products to be approved[/ltr]
[ltr]-The approval of the Ministry of the Environment on the environmental feasibility study and environmental impact assessment submitted according to the egyptain standard environmental specifications of the project[/ltr]
[ltr]- final industrial approval and record industrial document and operating license after the installation of the production line and construction of the factory and operating the production line[/ltr]
[ltr]- according the all of these licences can marketing in mineral oils by selling, buying and collecting with brand name of the factory to private and governmental coustmers[/ltr]

- the no. of recycling factories in Egypt= 12 licenses factories had (3 foreign investors+9 egyptain investors) with production capacity (15-50 tons output daily)

- the concern industrial cities for recycling factories ( badr city/portsaid city/borg el-arab city/gamasa city/shebin el-kom city /pelbise city)

- the no. of unlicenses factories in Egypt = 35 factories

- the no. of biggest petroleum companies in Egypt= 9 companies ( misr petroleum / co-operation petroleum / mobil/exxon mobile/ shell/total/casterol/kaltex/petromin) for refining ,production,mixing,bottling and recycling all types of virgin,refined and recycling mineral oils

- the private marketing companies importing virgin mineral oils from Europe,turkey,emarate,kuite and india= 50 companies

The primary econimecal fesability study

The capital cost:-

The price of factory land= 1-5 million eg.p/ 1500-7500 m²

The approved licenses = 1.0 million eg.p

The fesability study cost = 250000 eg.p / 4 fes.study

The construction cost = 3.0 million eg.p

The production line cost = 5.0 million eg.p

The cost for management offices,labs,labtops,etc =1.0 million eg.p

The cost of transporting cars,trucks,buses= 3.75 million eg.p

The liquid money for 3 monthes production = 12.0 million eg.p

The total capital cost= 31 million eg.p= 1.5 million usd

The predict prices for buying and selling waste used oil and treated recycling base oil in egypt

The good quality waste used oil ton price = 2500 eg.p = 125 usd / ton

the treated recycling base oil (sn 150) ton price= 14000 eg.p = 700 usd/ton

the treated recycling base oil (sn 500) ton price= 16000 eg.p = 800 usd/ton

the additives cost = 2000 eg.p = 100 usd/ton

the bottling cost = 5000 eg.p =250 usd/ton

the final product of motor engine oil(sf/sj/sl/sm/sn/cd/cf)= 1200-1600 usd/ton

COMMERCIAL CERTIFICATE NO.62543/EGYPT

TAXES CERTIFICATE NO. 381-972-143/EGYPT

LAB.CERTIFICTE.NO.1415/1999/2809/EGYPT

EGYPTAIN SYNDICATE OF SCIENTIFIC CONSULTANTS CERTIFICATE NO. 167/32599/1988

ISO 9001:2008 CERTIFICATE NO. 04-0130002-08

ISO 14001 : 2004 CERTIFICATE NO.04-0130004-08

ISO 22000 : 2005 CERTIFICATE NO. 04130001-08

OHSAS 18001:2007 CERTIFICATE NO. 04-0130003-08

INTERNATIONAL ARBITRATION ORG.CERTIFICATE NO.

8162 EGYPT/0002854 ENGLAND/0000666 BELGIUM

UNITED NATION ADVISORS CERTIFICATE NO. UN-387-2007

WFUNF CERTIFICATE NO. 07235751 UK

CAIRO-EGYPT

MOBILE NO. 002(01063793775/01117156569/01229834104)

TELEFAX NO. 002 (33920988)

E-MAIL : (TECHNOLABELBAHAAGP@GMAIL.COM)

WEB.SITE (WWW.TECHNOLABELBAHAAGP.GOOGOOLZ.COM)

» صيانة الغلايات محطة كهرباء ابى قير لتوليد الكهرباء
» mineral water production line photos from our factory/صور لتصنيع وتجميع خطوط انتاج مياه معدنية فى مصانعنا
» /الكلور/الزيوت والشحوم/المعادن/السيانيدCHLORINE/OIL&GREASE/METALS/CYANIDE
» مصنع الجمل لإنتاج الكربون النشط المحبب والبودره من قشر الرز وإنتاج سيليكون الصوديوم اول مصنع فى مصر والوطن العربى وافريقيا يحصل على الترخيص البيئى والصناعى
» ro-unites chemicals