Ors aktuell
- 1. Presentation for Hill Cooperation Almaty,Kazhazstan 09.10.2013 Plasma Tube Reactor PTR 20.000 From Benjamin Richters, Fluid Solutions – Norderstedt Head of Oil Recycling Department -1-
- 2. Content 1. 2. 3. 4. 5. 6. 7. Fluid Solutions –Oil Recycling Solutions Why Oil Recycling? Why Plasma Tube Reactor? The Oil Recycling Process Plasma Tube Reactor PTR 20.000 3D Plant Plot Plan Return of Investment Calculation -2-
- 3. Technology from theleading Recycler from Germany for a new leading Recycler in this world powered by Fluid Solutions -3-
- 4. Milestones of ORStoday In the year 1866, Z+G - Zeller & Gmelin Eislingen was founded They are in chemical, UV ink, lubricant and grease business in Germany in leading position The 100% daughter company from Z+G, Südöl started in 1932 the recycling refinery Today, Südöl re-refines more than 120.000 tons/year of waste oil (automotive and industrial) Since they installed the first Plasma Tube Reactor in 1999,Südöl is in leading position Quality, capacity and flexibility is brilliant and makes Südöl very profitable In 15 years of running this new plant ,now the status of process optimisation is very high The understanding of the potential of this technology was growing every year In 2008, Südöl and Fluid Solutions decided to go into the market with this technology ORS Oil Recycling Solutions Hamburg was founded together The Engineering R&D team has 4 engineers from Südöl and 4 from Fluid Solutions Rolf Schneider and Michael Krapalis are the General Managers of ORS Fluid Solutions handle successful lube oil, grease, resin, chemical project up to 20 Mio. € Since that time, 4 ORS projects are in process (Dubai, Abu Dhabi, Kuwait, Germany) The future and potential of ORS Technology worldwide is brilliant Result: the synergy of Südöl and Fluid Solutions provides our clients the most efficient oil recycling technology on the market -4-
- 5. Latest references ofFluid Solutions: • BASF turn key coating plant in China 2,0 Mio. $ • DuPont turn key paint plant in Germany 3,5 Mio. $ • Tesa turn key synthetic resin process plant 17,5 Mio. $ • Hüttenes Albertus turn key synthetic resin process plant 14,3 Mio. $ • Fuchs Russia turn key Lube oil blending plant 15,0 Mio.$ • Fuchs Brazil turn key Lube oil blending plant 12,0 Mio. $ • Fuchs Germany turn key grease plant 5,0 Mio. $ • DÖL turn key Lube oil blending plant 19,5 Mio. $ • BP turn key Lube oil blending plant 3,6 Mio. $ • Akzo Nobel turn key paint plant in Germany 3,4 Mio. $ • DSM turn key synthetic resin process plant 8,0 Mio. $ -5-
- 6. Perfect synergy ofpartners for your success JK Holding Mother Company Employee: 1.200 Founded: 1959 Turnover: 250 Mio. € Head office: Köln Z+G Holding Mother Company Employee: 2.500 Founded: 1866 Turnover: 185 Mio. € Head office: Eislingen Fluid Solutions General Contractor Engineering Company EPC Contractor GM: Michael Krapalis Südöl Recycling Waste Oil Recycling Refinery Plant Reference Plant R&D GM: Rolf Schneider 40% 60% ORS Oil Recycling Solutions Plasma Reactor Technology for Waste Oil Recycling Licence company GM: Rolf Schneider and Michael Krapalis -6-
- 7. Reference plant inGermany 100.000 to waste oil recycling per year -7-
- 8. Südöl Re-Refinig factoryfrom helicopter view -8-
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- 13. Scope of Services: • • • • • • • • • • • • Studyfor a preliminary concept Basic Engineering of a waste oil recycling plant Detailed Engineering of a waste oil recycling plant Complete engineering of a oil blending plant Adoption of engineering documents in accordance to local regulations Project management Procurement Construction of the plant with partner companies Installation and start up Optimization of the process Documentation Service contract including the laboratory work - 13 -
- 14. Content 1. 2. 3. 4. 5. 6. 7. Fluid Solutions –Oil Recycling Solutions Why Oil Recycling? Why Plasma Tube Reactor? The Oil Recycling Process Plasma Tube Reactor PTR 15.000 3D Plant Plot Plan Return of Investment Calculation - 14 -
- 15. Why Oil Recycling? Re-refiningoffers an improved envi-ronmental profile than the original refining process in terms of • • • • • resource con-sumption, global warming, acidification, nitrification, carcinogenic risk and fine particulates production - 15 -
- 16. Why Oil Recycling? RecourceConservating Hierarchy - 16 -
- 17. State of theArt Oil Quality • Sulfuric Acid Pro/Contra Bad Simple Procedure Many Plants, mainly China Dangerous Material •Thin Layer Evaporation Some Plants, mostly Germany Medium Danger of scab formation After treatment required •Precipitation by Propane Some Plants, mainly Italy Medium High Explosion Risk Investment high •Hydration Growing Number, mainly USA very light Very Expensive in Operation and Investment expensive additives are lost High Explosion Risk •Evaporation Procedures Some Plants, mainly Spain Moderate Sensitive Against Variations in Composition •Plasma Tube Reactor 2 Plants in Germany + Saudi-Arabia Good Low Operating Costs Reliable robust construction Low investment cost
- 18. Content 1. 2. 3. 4. 5. 6. 7. Fluid Solutions –Oil Recycling Solutions Why Oil Recycling? Why Plasma Tube Reactor? The Oil Recycling Process Plasma Tube Reactor PTR 15.000 3D Plant Plot Plan Return of Investment Calculation - 18 -
- 19. Why Plasma TubeReactor Technology Reactor Tubular tubes of structural steel of 10 to 2000 m length with a diameter of 5 to 500 mm, heated up to 340 to 420 °C to reach kinetic plasma conditions in a rapidly flowing gaseous petroleum product Safety Due to small reactor volume of 20 to 50 liters and continuous operation very low risk for fire or explosion Flexibility Very short time for changing conditions in case of varying product properties Operating Fully automated process control system, to ensure simple operating and repetitious accuracy Energy Current consumption for 1 ton dry oil: 43 kWh Heating oil demand for 1 ton dry oil: 50 kg - 19 -
- 20. Content 1. 2. 3. 4. 5. 6. 7. Fluid Solutions –Oil Recycling Solutions Why Oil Recycling? Why Plasma Tube Reactor? The Oil Recycling Process Plasma Tube Reactor PTR 20.000 3D Plant Plot Plan Return of Investment Calculation - 20 -
- 21. ORS Oil RecyclingProcess What is the key of the process? • • • • • • • • The Plasma-Tube-Reactor creates the best possible and fast evaporation 380 grad Celsius plus10 mbar vacuum and speed of sound Highest reactivity in the atmosphere of the reactor with extreme high friction Na+ and K+ as reacting catalytic for finishing the cleaning process This process is absolute robust and stabile in daily operation Relative low investment budget for this type of plant Outcome of base oil is very high Process cost are very low Material balance on the next pages: - 21 -
- 22. Total Process „Basestock“with Plasma Tube Reactor 100 % Feed Used Oil ca. 90 % Used Oil + ca. 5 % Water + ca. 1 % Light Oil (Fuels) + ca. 2 % Gasoil + ca. 1 % Esters + ca. 1 % Unvaporables Dehydration Prevaporization Alkaline Base + ca. 1,7% Plasma Tube Reactor 5 % Water 1 % Light Oil (Fumes) 2 % Gasoil ca. 51,0 % Lubeoil 1 ca. 37,9 % Lubeoil 2 Bleaching Clay ca. +2,08 % 4,8 % Residue +0,7% Sulfuric Acid 96% Settler Acid Tar ca. 1,4% Agitator Vaporisator Rectification Spindleoil 2 ca. 5,64% Spindleoil 1 ca. 24% Bleaching Clay Niagarafilter Used Clay ca. 3,94% Agitator Oil Fumes + Water Filterpress Used Clay Blow Vessel Base Stock ca. 56,7% Air - 22 -
- 23. ORS Oil RecyclingProcess Functional Process Diagram PTR 20.000 - 23 -
- 24. Used Oil RecyclingPlant P&I-Diagram Top View - 24 -
- 25. ORS Oil RecyclingProcess Process Flow Diagram PTR 2000 - 25 -
- 26. The ORS OilRecycling Process Used oil is processed using a combination of different procedures of thermal process engineering: • Dehydration • Evaporation • Total Distillation (Plasma Tube Reactor) • Decoloration • Rectification • Filtration • Oil blending to final products - 26 -
- 27. Dehydration 100 % FeedUsed Oil ca. 90 % Used Oil + ca. 5 % Water + ca. 1 % Light Oil (Fuels) + ca. 2 % Gasoil + ca. 1 % Esters + ca. 1% Unvaporables Dehydration 5 % Water 1 % Light Oil (Fumes) 90 % Used Oil 2 % Gasoil 1 % Esters 1% Unvaporables - 27 -
- 28. The ORS OilRecycling Process Used oil is processed using a combination of different procedures of thermal process engineering: • Dehydration • Evaporation • Total Distillation (Plasma Tube Reactor) • Decoloration • Rectification • Filtration • Oil blending to final products - 28 -
- 29. Evaporation Feed 90 % UsedOil + ca. 2 % Gasoil + ca. 1 % Esters + ca. 1% Unvaporables Prevaporization 2 % Gasoil 90 % Dryoil 1 % Ester 1% Unvaporables - 29 -
- 30. The ORS OilRecycling Process Used oil is processed using a combination of different procedures of thermal process engineering: • Dehydration • Evaporation • Plasma Tube Reactor • Decoloration • Rectification • Filtration • Oil blending to final products - 30 -
- 31. Plasma Tube Reactor TotalEvaporation / Distillation Feed 90 % Dryoil + ca. 1 % Esters + ca. 1 % Unvaporables Alkaline Base 1,7% Plasma Tube Reactor ca. 51,0 % Lubeoil 1 ca. 37,9 % Lubeoil 2 4,8 % Residue (Bottom Product) - 31 -
- 32. Plasma Tube Reactor P&IDPlasma Tube Reactor - 32 -
- 33. Plasma Tube Reactor P&IDSeperator - 33 -
- 34. Plasma Tube Reactor P&IDDistillation - 34 -
- 35. The ORS OilRecycling Process Used oil is processed using a combination of different procedures of thermal process engineering: • Dehydration • Evaporation • Plasma Tube Reactor • Decoloration • Rectification • Filtration • Oil blending to final products - 35 -
- 36. Decolorization and Rectification Feed Lubeoil1 and 2 in Mixture + 0,7% Sulfuric Acid 96% Settler Bleaching Clay +2,08% Agitator Acid Tar ca.1,4% Vaporisator Rectification Basestock-Clay-Mix ca. 58,78% Spindleoil 2 ca. 5,64% Spindleoil 1 ca. 24% - 36 -
- 37. The ORS OilRecycling Process Used oil is processed using a combination of different procedures of thermal process engineering: • Dehydration • Evaporation • Plasma Tube Reactor • Decoloration • Rectification • Filtration • Oil blending to final products - 37 -
- 38. Filtration and Finishing Feed Basestock-Clay-Mix Niagarafilter UsedClay ca. 3,94% Bleaching Clay Agitator Oil Fumes + Water Filterpress Used Clay Blow Vessel Air Base Stock ca. 56,7% - 38 -
- 39. Summary of Raffinate Thefollowing components are separated • Base oil • Gas oil • Spindle oil • Gasoline • Waste water • Asphalt - 39 -
- 40. Content 1. 2. 3. 4. 5. 6. 7. Fluid Solutions –Oil Recycling Solutions Why Oil Recycling? Why Plasma Tube Reactor? The Oil Recycling Process Plasma Tube Reactor PTR 20.000 3D Plant Plot Plan Return of Investment Calculation - 40 -
- 41. Fluid Solutions PlasmaTube Reactor Fluid Solutions Plasma Tube Reactor • • • Fitted for ISO 668 container High grade of pre-fabrication and testing Cost effective transportation and installation - 41 -
- 42. Fluid Solutions PlasmaTube Reactor All tubes are equiped with high performance pipe fins, to ensure • • optimal heat transfer characteristic longer operation lifetime - 42 -
- 43. Content 1. 2. 3. 4. 5. 6. 7. Fluid Solutions –Oil Recycling Solutions Why Oil Recycling? Why Plasma Tube Reactor? The Oil Recycling Process Plasma Tube Reactor PTR 20.000 3D Plant Plot Plan Return of Investment Calculation - 43 -
- 44. 3D-Plot Plan of typicalOil Recycling Plant Landscape 13.000 m² example with 130x100m - 44 -
- 45. 3D-Plot Plan of typicalOil Recycling Plant ISO View - 45 -
- 46. 3D-Plot Plan of typicalOil Recycling Plant Top View - 46 -
- 47. 3D-Plot Plan of typicalOil Recycling Plant - 47 -