Membrane Fouling Reduction During Lubricant Re-Refining

Integrated plant for regeneration and recovery of waste industrial and engine oils, comprising a module for removing moisture and fuel fractions, a diagnostics and monitoring module, a quality control module, and an additive application module, all connected through high-pressure hydraulic circuits and reservoirs for oil, additives, and vapors. The plant features automated recirculation circuits with sensors and centrifuges for continuous oil purification and quality monitoring.

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Fouling of heat exchangers and refining equipment by crude oil deposits is a chronic operating problem. In general, many such deposits are narrowly defined as coke fouling, for which the prescribed cleaning has traditionally been high-pressure water blasting. The results for this type of cleaning are mixed at best. Heat exchangers are often returned to service at conditions less than 85% clean performance, driving the need for more efficient cleaning regimens. A detailed characterization of 62 field-based crude oil fouling deposits from hydrocarbon process units was presented by the authors in 2019. This paper demonstrated that such deposits are exceptionally complex, resulting in the introduction of the Coke Spectrum. Here, these deposits are revisited, and chemical cleaning methods are applied. Chemical cleaning encompasses a variety of applications. Circulation, ultrasonic immersion, and clean-in-place techniques were reviewed on laboratory-scale samples to determine what chemical cleaning agents are most effective toward the various categories of foulant making up the Coke Spectr... Read More

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AbstractHeat exchanger fouling is problematic in crude oil refining, impacting energy consumption, greenhouse gas emissions, plant capacity, and maintenance budget. As part of the digital transformation journey at TotalEnergies and with advances in research on hydrocarbon fouling, advanced fouling monitoring and prediction tool (HTRI SmartPMTM) was implemented throughout TotalEnergies to better manage fouling in heat exchangers. The SmartPM software performs advanced data reconciliation, including simulation of detailed exchanger operational data using proprietary HTRI shell-and-tube heat exchanger calculation methods. After deployment and adoption of the software for fouling monitoring and reporting, the predictive functionalities have been applied to several feasibility studies concerning energy efficiency and CO2 emissions reduction projects. The present work describes the predictive study of the cleaning schedule of a refinery. The result of this study is an industrial project proposal on the installation of new bypasses across selected exchangers, leading to an economically opti... Read More

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The results of studies to assess the influence of the operation of flushing the lubrication system of tractor engines on some technical characteristics of the machine and the service life of freshly filled oil are presented in the work. It has been established that during the operating process, contaminants accumulate in the oil, which gradually, despite the operation of oil purification devices, accumulate in the oil channels and on the bottom of the oil pan. The dependence of the change in the content of mechanical impurities, insoluble sediment and color over an operating period of more than 200 hours is presented. Contamination reduces the effectiveness of additives, increases the acid number of the oil, which intensifies wear of parts, increases operating and repair costs. It has been shown that over a period of 240 hours of oil running in a tractor engine, the alkaline number decreases from 8.5 mg KOH/g to 4.0 mg KOH/g, and the acid number increases from 2.0 mg KOH/g to 2.5 mg KOH /g for M10DM oil when the engine is running even without high loads. The chromatogram of the color... Read More

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Abstract Fouling of refinery reboilers is a major source of production loss, health, safety, and environment (HSE) issues, and increased carbon emissions. Reboilers can be especially difficult, as fouling is difficult to address without major cleaning operations, and anti-fouling solutions outside of design modifications are limited. Formulation development of a novel coating material for reboiler systems examined a wide variety of polymer and nanocomposite chemistries. An iterative development process was used to identify and synthesize a polymer nanocomposite surface treatment to protect against corrosion induced by the buildup of chloride and sulfide salts typically found within distillation reboilers. Application on carbon steel test panels was completed using industry standard spray application methods and subsequently characterized for adhesion strength, thermal stability, chemical compatibility, and corrosion mitigation. Data included in this study will demonstrate that the material has a durability comparable to existing state-of-the-art coating materials (following ASTM D335... Read More

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Engine oil (EO) is produced by mixing base oil derivatives from crude oil with chemical additives to the lubricity of moving parts and reduce the friction inside the engine. Used lubricating oil (ULO) is one of the hazardous materials that consists of pollution harmful to the environment, it needs to be managed properly. In this work, vacuum distillation technique is used to recycle used lubricating oil. Used lubricating oil samples from two different brands of diesel engine oil (20w-50) and gasoline engine oil (10W-30) are used in this study. Various properties of ULO and recycled oil were characterized such as kinematic viscosity, viscosity index, density, pour point, flash point, Sulphur content, and Fourier transform Infrared spectroscopy FTIR. The yield recycles for ULO of gasoline engines, diesel engines, and mix (gasoline and diesel) by vacuum process were 85%, 74%, and 75% respectively, it was discovered that the sulfur component decreased from 9792.3 ppm of ULO to 405 ppm of yield distillates. The pour point results show an increase from -30 C of used lubricating oil to -18... Read More

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Crude oil is probably the most complex natural chemical mixture processed in various ways to make fuel and fine chemicals among a wide range of products in industrial processing. The conditions of those industrial processes often include high temperatures, which often cause undesired chemical reactions. One of those reaction sequences is crude oil fouling, which finally results in the formation of undesired solid deposits of carbon material, a calamity that costs millions of dollars worldwide each year and produces toxic waste. However, the compounds involved in fouling, let alone the underlying reaction mechanisms, are not understood to date. Here, in order to investigate chemical fouling, the process was simulated under laboratory conditions, focusing on hydrocarbons as the main constituents of crude oil. The results demonstrate large differences within the hydrocarbon class of compounds before and after thermal treatment, even for a very light crude oil fraction, which initially does not contain any bigger or heavier compounds. Here, the fouling reaction is simulated and studied o... Read More

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Contaminants are formed in diesel internal combustion engines of tractors during operation under the influence of high temperatures and loads on the parts of the cylinder-piston group, which then enter the engine oil, which affects the service life of the oil and the characteristics of the machine-tractor unit. An important measure that affects the contamination of parts and the service life of the oil is flushing the lubrication system during routine replacement of used oil. However, for a number of well-known objective and subjective reasons, this technological method is practically not carried out under real operating conditions. Resource-saving technology for flushing the lubrication system with motor oil running in the tractor engine was developed at TSTU. A number of technological methods for cleaning oil from contaminants and resins under the influence of chemical reagents added to the oil, followed by idling the engine, have been developed. The dependences of changes in contamination, base number, viscosity and color of the oil on the cleaning method, the concentration of the... Read More

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The article deals with the possibilities of regenerating operating fluids, assessing the composition of new, used, and regenerated oils by evaluating their toxicity and proposing the environmentally friendly regeneration method.The focus lies on two methods of regeneration of waste operating fluids: distillation and electrostatic cleaning.Oil samples, regenerated through these methods, were analyzed using gas chromatography with mass detection.The variance in composition among new, used, and regenerated oils depends on the method of regeneration.Properties of hydrocarbons exhibiting ecotoxic, mutagenic, teratogenic, carcinogenic, and other effects were identified using safety data sheets and databases like Pubchem, ChemicalBook.Analyzing HLP 46 oil (samples of new, unused, used and regenerated oil) revealed that the most toxic hydrocarbons (acetane, heptacosane, nonacosane) were absent after regeneration through electrostatic cleaning.Comparing the composition of operating fluids before and after regeneration, it was established that the most environmentally favorable regeneration me... Read More

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The results of studies assessing the properties of oils for removing contaminants from the lubrication system during routine replacement of motor oils in tractor engines are presented. It has been established that when used motor oil is drained, some of the contaminants remain in the lubrication system and negatively affect both engine operation and the service life of freshly filled motor oil. Dependences of changes in the content of mechanical impurities, tar deposits, alkaline and acid numbers on operating time were obtained. It has been established that the alkaline number of the oil during the engine operating period can decrease from 8.7 mg KOH/g to 2.0 mg KOH/g and reach the rejection value by 250 hours of oil operation in the engine. The influence of the operation of flushing the lubrication system with Lukoil mineral-based flushing oil in MTZ-1221 tractor engines is considered. The flushing operation made it possible to reduce the accumulation of impurities by 20...30% over the same operating period and to reduce the accumulation of tar deposits in the engine oil from 9.8% t... Read More

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Lubricants are used to reduce friction and wear in machines, saving billions of dollars worldwide in energy and breakdown costs and lowering CO2 emissions. Today, most lubricants are made using hydrocarbons derived from crude oil, which is a finite resource, although alternative bio-based lubricants are also being investigated, as is the re-refining of used lubricants to make new base oil. The machines. It is also shown that an effective way to make lubricants more sustainable is to extend lubricant oil drain intervals and collect used oil and re-refine it to make base oil for re-use. The role of bio-based lubricants, and their benefits and disadvantages are discussed. Other aspects in which lubricants can be made more sustainable are also briefly covered, such as lubricant packaging, the removal of toxic additives via improved regulatory chemistry, and the use of renewable electricity in blending plants.

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The present work, on an experimental basis, consists of an analysis and treatment of used motor oil (used oil collected by NAFTAL stored at the port of Algiers). For this, we carried out tests in the laboratory in order to develop an adequate re-refining process. First we made a comparative analysis between the sample taken from a storage tank and a new engine oil produced in the Arzew refinery. The results of these analysis allowed us to identify the different stages of the process of regeneration (Pre-treatment, metal removal by a chemical agent, a finishing treatment by passage through the bentonite and filtration). This process has enabled us to eliminate most of the impurities and the optimization of different parameters, the engine oil obtained at the end of the process is a basic oil ready to be used again.

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Abstract: Continuous use and disposal of lubricating oil causes land, water and air pollution and also increases dependence on crude oil. This is the reason for the spread of disease, which affects every living being. Reuse of waste oil is the easiest option to avoid such pollution and dependence on crude oil. Another benefit of reusing waste oil is converting waste into money. Recycling waste lubricating oil has become an increasingly important aspect of sustainable waste management and resource conservation. Lubricant oil is made with 90% of base oil and rest of additives. In the lubricant oil, Base oil is never spoiled but after continues use of lubricating oil, it loses their properties because of continues friction, heavy load, and dirt metals absorbed hence its become waste oil. Here, we review the methods available to recycle the waste oil with the help of various treatment including acid treatment, clay treatment, adsorption, and solvents. The viscosity modifiers and additives used to make the SAE (Society of Automotive Engineers) grade recycled oil have also reviewed.

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The need for virgin base oil is reduced and other resources are conserved during the refining of used, spent, or waste oils to make new lubricating oil. It is important to collect and recycle spent lubricating oil in order to protect the environment and natural resources. Although the lubricating oil itself remains unchanged after use, it becomes contaminated with combustion byproducts, deteriorated additives, water, and various dust particles during its time in the engine. The purpose of re-cycling is to eliminate degraded additives and impurities while restoring the oil's qualities to those specified by the Society of Automotive Engineers. Therefore, this study focuses on the extraction of engine oils utilizing a single solvent approach for re-cycling. The N-methyl-2-pyrrolidone was used as the solvent. The used oil was gathered from vehicle repair stations. After being allowed for settling to removing large suspended particles, the oil was subjected to a sequence of physical treatment processes. The solvent recovery process was carried out by using rotary evaporator equipment with... Read More

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Investigating important challenges to eliminate crude oil fouling in pipelines needs to be studied thoroughly. According to environmental and economic issues, fouling in pipelines increases the price of crude oil. According to chemical and environmental experts, the loss in heat required additional energy to compensate which meant higher fuel consumption and more carbon emissions into the atmosphere. The increase in fluid flow rate combined with a constant drop in pressure is dangerous for pipelines. In addition, the Iraqi crude oils block refinery preheat trains because they contain very little asphaltene. The fouling of a variety of these crude oils and their blends is examined in this paper. Fouling may be caused by four major processes: solid particles, corrosion, sedimentation, and chemical reaction.

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Quality of process flows and commercial oil products deteriorates due to developing the deposits, which reduces the efficiency of heat and mass transfer and, accordingly, the clarity of rectification, resulting in changes in the component and fractional composition of the processed raw materials. There has been studied the influence of different chemical reagents introduced at the stages of production, treatment and processing of gas condensate and oil on the change in the physicochemical properties of the resulting dark oil products, which are responsible for deposit formation in the field and plant equipment during further processing or storage. The results of experimental studies are presented. Physicochemical properties of fuel oil are shown to be affected not only by the properties of the hydrocarbon feedstock, but also by the composition and concentration of chemical reagents introduced at different stages of production, field preparation and transportation. In the course of the experiment it has been stated that, depending on the concentration of the reagent and its main activ... Read More

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The article considers the balance of the engine oil aging components in the diesel engine lubrication system with the refinement of oil composition caused by the oil product loss. The motor oil aging process has been identified under continuous and periodic oil refill in order to replenish the lubrication system with fresh oil which would compensate the burnt off oil products. There were derived and solved the differential equations of the oil product balance for such aspects of aging as contamination by insoluble impurities and multifunctional additives impact, which helped understand the general regularities and kinetics of the studied process. Novelty of the approach to theoretical description of the process consisted in the fact of filtering the insoluble and colloidal components of mechanical impurities and additives by the purification and burnout means. Cyclic picture of aging allows to analyze the state of the oil aging before and after refill with its periodic refreshment. The dependence is transformed and presented in a form where it is possible to determine the state of th... Read More

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Western Canadian refineries process a wide range of conventional light, extra-heavy and synthetic crude oils. The chemical and physical properties of these oils determine their potential to initiate fouling in process units. A survey of the refineries identified common and unique foulants. Foulant control and removal was accomplished by standard industrial mitigation practices.

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This paper presents the causes and recommended solutions for three examples of fouling in heat exchangers in oil industry. The studied cases include fouling and underneath corrosion in heavy diesel oil (HOD) heat exchangers, fouling in glycol heat exchangers and fouling in vertical thermosyphon heat reboilers.

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Crude oil fouling is a complex process caused by multiple mechanisms. This study examined fouling's environmental impact on a distillation unit's heating tubes and heat exchangers, proposing optimal pollution levels to reduce emissions and achieve sustainability goals. The study evaluated five crude oil blends in terms of API, sulphur, salt content, and other physical properties. Contaminated water was analyzed through biological and chemical means, while CO2, NOx, and SOx emissions were calculated from actual fuel and power consumption. Solid and sludge sediments were observed throughout all plate heat exchangers, consisting primarily of iron hydroxides and manganese oxides. Rationalizing energy use reduced the burden on the environment and fuel consumption by 7 %, with a 2 % reduction in energy needed to refine crude oil feeding units when fouling is removed after maintenance. By optimizing pollution levels and reducing energy consumption, the environmental impact of fouling can be mitigated.

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