Final year project

1. 1
2/7/2014

2. PROJECT TITLE
2

3. Group Members
Hafiz Mohammad Tahir
Ali Hassan
Hafiz Mohammad Zohaib
Waqar Younus
3

4.  Introduction
 Process Selection
 Capacity Selection
 Process Description
 Material Balance
 Energy Balance
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4

5. Base oil
consist of hydrocarbons with 20 to 50 carbon atoms and boiling point
range of 550-1050oF
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5

6. Base Oils Primary Sources
Natural
Chemical Synthesis
Crude Oil
2/7/2014
Non-Crude oil
6

7. GROUP
VISCOSITY INDEX
SATURATES
SULPHUR CONTENTS
I
80-120
upto 90%
Upto 0.03%
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7

8. What is Waste Lube Oil
 Water
 Dirt
 Broken down components
 Varnish
 Oil quality gradually decreases
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8

9. Waste lube oil
 Used as Fuel
- Direct
- Indirect
 Re-Refining
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9

10. Reasons of re-refining
 Environment pollution to a great extent
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10

11. 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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11

12. composition of feed is given below:
Feed
Mass (lb/hr)
Mass%
Water + light ends
Gasoil
Lube oil +S compound
Residue
Total
301.37
226.03
2637
602.74
3767.12
8
6
70
16
100
2/7/2014
12

13. 2/7/2014
13

14. 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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14

15. Quick comparison of different process
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
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15

16. Capacity Selection
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16

17.  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
2/7/2014
17

18. 2/7/2014
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19.  This deficit is met through
import of lube base oil
 Import of lube base oil in
year 2013 was
5,136,660US$
2/7/2014
19

20.  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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20

21. PROCESS STEPS
1. Dehydration
2. Gas oil removal
3. Lube oil separation
4. Hydro-treatment
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22. 2/7/2014
22

23. 2C8H6S
+
5H2
C8H10
+
C8H8
C9H8S
+
3H2
C9H12
+
H2S
C12H8S
+
5H2
C12H16 +
H2S
0.7
C13H10S +
2H2
C13H12 +
H2S
0.67
C14H12S +
2H2
C14H14 +
H2S
0.63
2/7/2014
+
2H2S
0.76
0.77
23

24. Basis
Processing of 3767 lb/hr of waste lube oil for the production of base
oil
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24

25. • It is very important for physical properties calculation of
petroleum fractions such as enthalpy and molecular weight.
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25

26. Two methods
 Mathematically
 Graphically

32. 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

33. 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

35. 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
2/7/2014
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36. Units
1
2
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
2/7/2014
444,860
steam in steam out
444,860
36

37. 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
0
0
43
Temperature
ᵒF
77
77
104
Q = ṁ ∆H
Btu/hr
2/7/2014
255.04
320
47832.75
47832.75
37

38. Balance Across Flash Drum:
Units
2
2
OUT
3
4
Mass Flow Rate
Weighted ∆H Values
Temperature
lb/hr
Btu/lb
ᵒF
3767.12
118.044
320
187.55
255.04
320
3579.75
110.85
320
Q = ṁ ∆H
Btu/hr
444,680 47832.75
3968,47.25
Total
Btu/hr
444,680
2/7/2014
444,680
38

39. 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
3579.57
3579.57
Grand Total
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40. Units
4
5
Hot
product
in
Mass Flow Rate
lb/hr
3579.74
3579.74
2379
Weighted
Enthalpy Values
Btu/lb
Temperature
Q = ṁ ∆H
ᵒF
Btu/hr
2/7/2014
188.34
320
2379
431
590
674,208
Cold
product
out
662
326
674,208
40

41. 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
Temperature
Q = ṁ ∆H
ᵒF
Btu/hr
2/7/2014
297
560
170
1108405
43
77
104
108,405
41

42. Units
20
9
Mass Flow Rate
lb/hr
40.208
40.208
Weighted
Enthalpy Values
Btu/lb
Temperature
ᵒF
Q = ṁ ∆H
Btu/hr
2/7/2014
Steam in Steam out
546.696
601.5
620
24,601
546.696
45.09
620
650
625
24,601
42

43. Balance Across stripper:
Units
Mass Flow Rate
lb/hr
Weighted
Enthalpy Values
Temperature
Q = ṁ ∆H
Total
Btu/lb
OUT
8
7
3579.57 3214.97
364.6
.
188.34 164.95
394.35
ᵒF
Btu/hr
Btu/hr
590
620
560
674,208 530,326
143,882
674,208
674,208
2/7/2014
In
5
43

44. 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
3214.71
3214.71
Grand Total
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44

45. Units
12
13
Mass Flow Rate
lb/hr
3214.71
3214.71
Weighted
Enthalpy Values
Temperature
Btu/lb
Q = ṁ ∆H
Btu/hr
2/7/2014
ᵒF
16.38
620
Steam
Steam
in
out
1221.63 1221.63
44.205
662
54007.20
752
671
54002.2
45

46. Units
21
10
Mass Flow Rate
lb/hr
828.26
828.26
Weighted
Enthalpy Values
Btu/lb
Temperature
Q = ṁ ∆H
ᵒF
Btu/hr
2/7/2014
343.9
662
Hot
water
6329
43
170
284,835
Cold
water
6329
77
104
284,835
46

47. 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
Temperature
ᵒF
Q = ṁ ∆H
Btu/hr
2/7/2014
568.106
620
45.09
620
1355,6119
77
104
1355,6119
47

48. Over All Balance Across Evaporator
In
9
12
10
lb/hr
3214.71
2386.65
828.06
Btu/lb
16.838
411.71
485.391
ᵒF
620
662
Q = ṁ ∆H
Btu/hr
73826245
660
2182,09
24
Total
Btu/hr
367870.04
Units
Mass Flow Rate
Weighted Enthalpy
Values
Temperature
2/7/2014
OUT
286,050,.3
367870.04
48

49. •
•
•
•
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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49

50. 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
50
2/7/2014

51. Converted
lb/hr
Stream 15
lb/hr
C8H6S
Stream 14 +20
(lb/hr)
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
Component
58.58
51

52. Component
Gasoil
Lube oil
Residue
1H2
CO
N2
Methane
Ethylene
Ethane
Propylene
Propane
Butadiene
Butylene
Iso and nbutane
C5+
H2S
2/7/2014
Total
Stream 14 +20
(lb/hr)
Stream 15
(lb/hr)
2.117
2367.378
17.155
2.074
0.021
0.249
1.327
0.498
0.747
0.166
0.166
0.003
0.012
2.120
2360.638
17.155
0.580
0.020
0.249
1.326
0.497
0.746
0.166
0.166
0.003
0.013
0.03
0.03
0.05
0
2392
0.05
8.23
2392

53. 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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54. ∆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
2/7/2014
54

55. Component
Stream 15
(lb/hr)
Stream 17
(lb/hr)
Stream 18
(lb/hr)
Gasoil
Lube oil
Residue
H2
CO
N2
Methane
Ethylene
Ethane
Propylene
Propane
Butadiene
Butylene
Iso and n-butane
C5+
H2S
Total
Grand Total
2.120
2360.638
17.155
0.580
0.020
0.249
1.326
0.497
0.746
0.166
0.166
0.003
0.013
0.03
0.05
8.23
2392
2392
0
0
0
0.580
0.020
0.249
1.326
0.497
0.746
0.166
0.166
0.003
0.013
0.03
0.05
8.23
12.08
2392
2.120
2360.638
17.155
0
0
0
0
0
0
0
0
0
0
0
0
0
2379.91
2/7/2014
55

56. Balance Across
Separation Vessel over all
Mass Flow Rate
Weighted Enthalpy
Values
Temperature
lb/hr
9
9
2392
Btu/lb
431
431
485.391
ᵒF
662
662
Q = ṁ ∆H
Btu/hr
662
102,534
9
Total
Btu/hr
Units
2/7/2014
106,9010
OUT
12
2379
10
12.08
4366.1
10690,10
56

57. In = Out + Losses
398,888,5.51 = 3988,0193.57 + 3691.14
398888,5.51 = 39888,85.51
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57

58. 9476.38 tone/year or 2379.91lb/hr of base oil is
produced
Recovery of base oil is 90%
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58

59.  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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60.  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
2/7/2014
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