Regeneration of used oils
Modular units for filtration, dehydration and removal of volatile components, with recovery of an oil fraction for potential reuse
Integrated used-oil regeneration
Used oils may contain water, mechanical impurities, oxidation products, fuel residues, solvents and other components accumulated during operation. The feasibility and process design depend on the oil's origin, composition and level of contamination.
The installation may include pre-filtration, controlled heating, dehydration, removal of volatile components, distillation separation, condensation of the separated fractions and final purification. The process steps are selected after testing an oil sample.
Source oil streams
Oil regeneration objectives
Removing mechanical impurities
Removal of solids before thermal treatment and distillation
Dehydration
Removal of free, emulsified and dissolved water to the level specified by the process design
Removing light components
Separation of fuel residues, solvents and other volatile impurities
Separation of oil fractions
Obtaining the main oil fraction and separated light components
Product clarification
Reduction of color-forming components where a clarification stage is included
Reducing waste
Return of a suitable oil fraction to service or reuse in production after its properties have been assessed
Preparing for further use
Preparation of oil for reuse, further processing or blending
Separate collection of by-products
Separate collection of water, light fractions and solids in the systems defined by the process design
Advantages of the process solution
Selection of a process for a specific oil
The equipment package is determined by the results of analysis and laboratory tests of the feedstock
Multi-stage processing
Pre-cleaning, dewatering, separation and final polishing are performed in an appropriate sequence
Controlled heat exposure
Operating temperatures are selected for the oil composition and required separation
Closed circulation of working gas
Inert gas can be used to transfer vapors of volatile components, followed by cooling and return to the process
Collection of separated components
Water, light fractions and other condensable substances are collected in separate streams
Modular design
The installation can be formed from separate functional blocks and expanded step by step
Integration into an existing plant
Individual modules can be used to upgrade an existing oil treatment system
Automated control
Monitoring of temperature, pressure, levels and equipment status is integrated into a control system
Process configurations
The plant is configured for the oil type, water and contaminant content, required throughput and target product properties.
Main process stages
- Feed oil receipt and storage
- Sampling and composition analysis
- Preliminary removal of large mechanical impurities
- Filtration and preparation of the feed stream
- Controlled oil heating
- Removing water
- Removal of solvents and volatile components
- Distillation separation if necessary
- Cooling and condensation of separated vapors
- Collection of regenerated oil fraction
- Final filtration or clarification if necessary
- Testing the treated product
- Separate collection of by-products
The sequence of operations and operating conditions are determined after analyzing the source oil. Individual stages are only included when necessary.
Oil pretreatment
Before thermal treatment or distillation, large contaminants and mechanical impurities that can impair the operation of pumping, heat transfer and separation equipment are removed from the oil.
Depending on the state of the feedstock, settling, mesh or filter-media filtration, agitation and preheating are used.
Dehydration and devolatilization
Water, fuel residues and solvents can degrade the oil and prevent its further use. Their removal is carried out by controlled heating and removal of the resulting vapors.
In inert gas circulation technology, the gas passes through the heated product, carries away vapors of volatile components and is sent to the cooling and condensation system. After separation of the liquid phase, the gas can be returned to the process cycle.
Distillation regeneration
Distillation separates oil components by volatility. The selected components are vaporized, routed to the condensation system and collected as specified by the process design.
The recovered oil product, light fractions and residues are collected according to the selected process configuration. Feedstock composition and target product specifications determine the separation stages and operating conditions.
Final purification and clarification
After removing water and volatile components, the product can be sent for additional filtration or clarification. The need for this stage is determined by the composition of the oil and the requirements for further use.
The type of filter or sorption materials is selected based on the results of laboratory tests. Final polishing alone cannot restore every property of the feed oil.
Process line equipment
The actual equipment package is determined by the selected process flowsheet. Individual items are used only when necessary.
Modular design of equipment
The plant can combine separate modules for feed reception, filtration, heating, dehydration, distillation, condensation and final polishing. The module package is selected for the oil and its intended use.
The scope may be a laboratory, pilot or industrial unit, individual process modules, or equipment for upgrading an existing line.
Resulting process streams
Regenerated oil fraction
Oil fraction treated to remove water, volatile components and solids as specified in the process design
Aqueous phase
Water separated during dehydration and routed for further treatment as specified by the project
Light hydrocarbon fraction
Condensable components separated from the feed oil by heat and distillation processes
Solid residue and contaminated materials
Mechanical impurities, sediment and waste filter materials requiring separate handling
Options and configurations
Pre-cleaning module
Equipment for receiving, settling and removing mechanical impurities
Dehydration module
Equipment for removing water from used oil
Light component removal module
Heating, condensing and recovery equipment for the separation of solvents and fuel residues
Distillation module
Equipment for separating the oil flow and condensing the separated fractions
Integrated oil regeneration plant
Sequential combination of pretreatment, dehydration, distillation and final purification
Modernization of an existing installation
Integration of additional filtration, heating, condensing and automation modules
How a process flowsheet is selected
- Review of project data
- Oil sampling and testing
- Determination of water content
- Determination of mechanical impurities
- Determination of volatile components
- Evaluation of viscosity and temperature characteristics
- Definition of target product specifications
- Laboratory tests
- Pilot tests if necessary
- Selection of process stages
- Definition of operating conditions
- Selection of equipment and automation
- Preparation of technical proposal
Whether the oil can be regenerated, and to what quality, depends on its composition. Specific performance properties cannot be guaranteed before testing.
Delivery and implementation
Available equipment configurations
We will select a regeneration process for your oil
To prepare a technical proposal, we need the oil's origin and volume, water and contaminant content, details of existing equipment and target product specifications.