U.S. patent application number 14/169126 was filed with the patent office on 2014-09-11 for method for producing base lubricating oil from oils recovered from combustion engine service.
This patent application is currently assigned to VeroLube, Inc.. The applicant listed for this patent is VeroLube, Inc.. Invention is credited to Martin R. MacDonald.
Application Number | 20140257000 14/169126 |
Document ID | / |
Family ID | 51486519 |
Filed Date | 2014-09-11 |
United States Patent
Application |
20140257000 |
Kind Code |
A1 |
MacDonald; Martin R. |
September 11, 2014 |
METHOD FOR PRODUCING BASE LUBRICATING OIL FROM OILS RECOVERED FROM
COMBUSTION ENGINE SERVICE
Abstract
A method for producing ILSAC GF5 or higher compatible oils from
used oil, comprising separating material having a boiling point
less than about 350.degree. F. from recovered oil to produce
de-volatized oil fraction and light oil fraction. Separating
material with a boiling point greater than about 350.degree. F. and
less than about 650.degree. F. from the de-volatized oil fraction
to produce fuel oil fraction and heavy oil fraction. Separating
material with a boiling point greater than about 1200.degree. F.
from the heavy oil fraction to produce partially purified oil
fraction and residual fraction. Treating the partially purified oil
fraction to separate it into purified oil fraction and contaminant
fraction. Hydrogenating the contaminant fraction to remove
predetermined compounds, further saturating the fraction and
thereby creating a saturated oil fraction. Fractionating the
saturated oil stream to produce one or more of naphtha fraction,
diesel oil fraction and base oil fraction.
Inventors: |
MacDonald; Martin R.;
(Plano, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
VeroLube, Inc. |
Calgary |
|
CA |
|
|
Assignee: |
VeroLube, Inc.
Calgary
CA
|
Family ID: |
51486519 |
Appl. No.: |
14/169126 |
Filed: |
January 30, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61774027 |
Mar 7, 2013 |
|
|
|
61774037 |
Mar 7, 2013 |
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Current U.S.
Class: |
585/264 |
Current CPC
Class: |
C10G 67/14 20130101;
C10G 7/00 20130101; C10G 53/04 20130101; C10G 21/20 20130101; C07C
7/005 20130101; C10G 21/18 20130101; C10G 2300/1007 20130101; C10G
7/003 20130101; C10G 21/16 20130101; C10G 2400/22 20130101; C10G
53/06 20130101; C10G 21/006 20130101; C10G 45/04 20130101; C10G
21/02 20130101; C10G 2300/44 20130101; C07C 5/02 20130101; C10G
7/006 20130101; C10G 21/24 20130101; C10G 67/04 20130101; C10G
53/08 20130101; C11B 3/006 20130101; C10G 2400/30 20130101 |
Class at
Publication: |
585/264 |
International
Class: |
C07C 5/02 20060101
C07C005/02 |
Claims
1. A method for efficiently producing a high yield of ILSAC GF5 or
higher compatible oils from the recovery and upgrade of oil derived
from modern electric, hybrid, turbocharged, and high efficiency
gasoline and diesel engines, the method comprising: a) separating
at least a portion of material having a boiling point less than
about 350.degree. F. from recovered oil to produce a de-volatized
oil fraction and a light oil fraction; b) separating at least a
portion of material with a boiling point greater than about
350.degree. F. and less than about 650.degree. F. from the
de-volatized oil fraction to produce a fuel oil fraction and a
heavy oil fraction; c) separating at least a portion of material
with a boiling point greater than about 1200.degree. F. from the
heavy oil fraction to produce a partially purified oil fraction and
a residual fraction; d) treating the partially purified oil
fraction to separate it into a purified oil fraction and a
contaminant fraction; e) hydrogenating the contaminant fraction to
remove predetermined compounds, further saturating the fraction and
thereby creating a saturated oil fraction; and g) fractionating the
saturated oil stream to produce one or more of a naphtha fraction,
a diesel oil fraction and a base oil fraction.
2. The method of claim 1 wherein the base oil faction consists of
oils that met at least one of American Petroleum Institute
standards SJ/SL/SM/SN or higher or CG-4/CH-4/CI-4/CJ-4 or higher
specifications when the base oil was first put into service.
3. The method of claim 1 wherein the light oil fraction is
separated from the de-volatized oil fraction by at least one of
distillation, vacuum distillation, evaporation, filtration,
ultrafiltration, extractant extraction, extraction, centrifugation,
absorption, and adsorption.
4. The method of claim 1 wherein the light oil fraction is
separated from the de-volatized oil fraction by at least one of
atmospheric or vacuum distillation.
5. The method of claim 1 wherein the fuel oil fraction is separated
from the heavy oil fraction by at least one of distillation, vacuum
distillation, evaporation, filtration, ultrafiltration, extractant
extraction, extraction, centrifugation, absorption, and
adsorption.
6. The method of claim 1 wherein the fuel oil fraction is separated
from the heavy oil fraction by atmospheric distillation.
7. The method of claim 1 wherein the partially purified fraction is
separated from the residual oil fraction by at least one of
distillation, vacuum distillation, evaporation, filtration,
ultrafiltration, extractant extraction, extraction, centrifugation,
absorption, and adsorption.
8. The method of claim 1 wherein the partially purified fraction is
separated from the residual oil fraction by vacuum distillation in
an unpacked column.
9. The method according to claim 1 whereby the feedstock is treated
with an alkali or base to condition the feedstock.
10. The method according to claim 9 whereby the alkali or base is
one of sodium carbonate, sodium hydroxide, and potassium
hydroxide.
11. The method according to claim 1 whereby the feedstock is
treated to remove water and light hydrocarbons.
12. The method of claim 1 wherein the purified oil fraction and the
contaminant fraction are separated by at least one of the
filtration, ultrafiltration, molecular sieves, extraction,
extractant extraction, absorption, and adsorption.
11. The method of claim 1 wherein the purified oil fraction and the
contaminant fraction are separated by liquid/liquid extraction.
12. The method of claim 1 wherein one or more liquids are used
including ethanol, diacetone-alcohol, ethylene-glycol-mono(low
alkyl) ether, di-ethylene-glycol, diethylene-glycolmono(low alkyl)
ether, o-chlorophenol furfural, acetone, formic acid,
4-butyrolacetone, low-alkyl-ester of low mono- and dicarbonic
acids, dimethylformamide, 2-pyrrolidone and N-(low
alkyl)2-pyrrolidone, N-methyl-2-pyrolodone, epi-chlorohydrin,
dioxane, morpholine, low-alkyl- and amino(low-alkyl)morpholine,
benzonitrile and di-(low-alkyl)sulfoxide and phosphonate.
13. The method of claim 1 wherein two or more liquids are used of
ethanol, diacetone-alcohol, ethylene-glycol-mono(low alkyl) ether,
di-ethylene-glycol, diethylene-glycolmono(low alkyl) ether,
o-chlorophenol furfural, acetone, formic acid, 4-butyrolacetone,
water, aqueous salts, low-alkyl-ester of low mono- and dicarbonic
acids, dimethylformamide, 2-pyrrolidone and N-(low
alkyl)2-pyrrolidone, N-methyl-2-pyrolodone, mono or poly protic
acids, mineral acids, carboxylic acids, hydroxide bases, carbonate
bases, mineral bases, epi-chlorohydrin, dioxane, morpholine,
low-alkyl- and amino(low-alkyl)morpholine, benzonitrile and
di-(low-alkyl)sulfoxide and phosphonate.
14. The method according to claim 12 wherein at least one of the
liquids is the extractant N-methyl 2 pyrolidone.
15. The method of claim 1 wherein the one or more of the oil
streams is suitable for use in ILSAC GF4 or higher
applications.
16. The method according to claim 1 wherein the contaminant
fraction consists of polars, aromatics, heteroatoms, unsaturates,
and olefines.
17. The method according to claim 1 wherein the liquid/liquid
extraction is under conditions wherein the extractant is at least
partially miscible in the oil.
18. The method of claim 11 wherein the liquid/liquid extraction is
undertaken between 140.degree. F. and 200.degree. F.
19. The method of claim 11 wherein the liquid/liquid extraction is
undertaken with an extractant treat ratio in excess of 3:1.
20. The method of claim 11 wherein the liquid/liquid extraction is
undertaken in an extraction column designed to limit entrainment
and enable good separation of the oil and extractant phases.
21. The method of claim 11 wherein the liquid/liquid extraction is
undertaken in a packed column.
22. The method of claim 11 wherein the residence time is sufficient
to enable efficient extractant oil contact and good phase
disengagement.
23. The method according to claim 11 whereby a phase catalyst is
used to enhance extraction.
24. The method of claim 1 wherein the hydrogenation process
consists of one or more of hydrotreating, hydrofinishing,
alkylating, or molecular reforming.
25. The method of claim 24 wherein hydrogenation is undertaken
using hydrogen gas at a temperature from about 500 to about
1200.degree. F. and at a pressure from about 100 to about 2000 psig
in the presence of a catalyst containing group VB, BIB and VIII of
the periodic table, metal components and compounds thereof
supported on a suitable.
26. The method according to claim 1 wherein the purified oil
fraction and the saturated oil fraction are combined and then
fractionated into one or more of a light oil fraction, a diesel oil
fraction and lube oil fractions.
27. The method according to claim 1 whereby the residence time of
the non-volatized portion of the feed to each step has a residence
time within the vessels of the step of between 5 minutes and 5
hours.
Description
RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
patent application 61/774,027, filed Mar. 7, 2013 and U.S.
Provisional patent application 61/774,037, filed Mar. 7, 2013, and
is related to U.S. Pat. No. 8,366,912, issued Feb. 5, 2013, which
are hereby incorporated by reference for all purposes as if set
forth herein in their entirety.
TECHNICAL FIELD
[0002] The present disclosure relates to the recovery of synthetic
oils, and more specifically to the recovery of base lubricating
oils from oils removed from combustion engine service.
BACKGROUND OF THE INVENTION
[0003] Large volumes of engine oil is produced world-wide, but is
typically discarded after use.
SUMMARY OF THE INVENTION
[0004] A method for producing International Lubricant
Standardization and Approval Committee (ILSAC) GF5 or higher
compatible oils from used oil is disclosed. The method includes
separating material having a boiling point of less than about
350.degree. F. from recovered oil to produce a de-volatized oil
fraction and a light oil fraction. Separating material with a
boiling point of greater than about 350.degree. F. and less than
about 650.degree. F. from the de-volatized oil fraction to produce
a fuel oil fraction and a heavy oil fraction. Separating material
with a boiling point of greater than about 1200.degree. F. from the
heavy oil fraction to produce a partially purified oil fraction and
a residual fraction. Treating the partially purified oil fraction
to separate it into purified a oil fraction and a contaminant
fraction. Hydrogenating the contaminant fraction to remove
predetermined compounds, further saturating the fraction and
thereby creating a saturated oil fraction. Fractionating the
saturated oil stream to produce one or more of a naphtha fraction,
a diesel oil fraction and a base oil fraction.
[0005] Other systems, methods, features, and advantages of the
present disclosure will be or become apparent to one with skill in
the art upon examination of the following drawings and detailed
description. It is intended that all such additional systems,
methods, features, and advantages be included within this
description, be within the scope of the present disclosure, and be
protected by the accompanying claims.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0006] Aspects of the disclosure can be better understood with
reference to the following drawings. The components in the drawings
are not necessarily to scale, emphasis instead being placed upon
clearly illustrating the principles of the present disclosure.
Moreover, in the drawings, like reference numerals designate
corresponding parts throughout the several views, and in which:
[0007] FIG. 1 is a diagram of a system for processing waste oil in
accordance with an exemplary embodiment of the present
disclosure;
[0008] FIG. 2 is a diagram of a system for processing waste oil in
accordance with an exemplary embodiment of the present
disclosure;
[0009] FIG. 3 is a diagram of a controller for controlling waste
oil processing in accordance with an exemplary embodiment of the
present disclosure; and
[0010] FIG. 4 is a diagram of a distillation column in accordance
with an exemplary embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0011] In the description that follows, like parts are marked
throughout the specification and drawings with the same reference
numerals. The drawing figures might not be to scale and certain
components can be shown in generalized or schematic form and
identified by commercial designations in the interest of clarity
and conciseness.
[0012] The present disclosure relates to producing high quality
petroleum products suitable for modern environmentally friendly and
technologically enhanced engines from spent modern engine oils
consisting in part of synthetic oils. The disclosed process
includes separating the feedstock into a volatile fraction, a fuel
oil fraction, a residual fraction, and a partially purified oil
fraction, and thereafter treating the partially purified oil to
separate it into a purified oil fraction and a contaminant
fraction. The contaminant fraction is hydrogenated to upgrade this
fraction and produce a saturated oil fraction. The petroleum
products produced by this process are greater than the quantity and
higher in quality than those produced by previous processes.
[0013] In recent years, the demand for lubricating oils for
combusting engines has increased, such that conventional lubricants
are no longer suitable for use in today's modern combustion
engines. As a result, the need for synthetic quality and
specialized lubricants has increased to satisfy these demands. In
addition to being more robust and capable of handling modern
extreme service conditions, these new lubricants produce less
emissions and yield longer service lifetimes. As a result of the
characteristics of these improved oils, new processes are needed to
treat the spent oils once they have been recovered at the end of
their service life.
[0014] Historically, several treatment processes have been proposed
for treating conventional crude oil-based used oil, which produce
conventional products which heretofore have satisfied lower
lubricant standards. However, the new synthetic lubricants that are
being produced including poly aromatics and esters that were not
typically found in used oils until recently. Furthermore, the
increasingly stringent lubricant specification, such as ILSAC GF5,
has resulted in a change to many chemical additives that are
compounded with the base oils. As a result, these new lubricants,
when recovered after service, can pose processing challenges for
some of the traditional recovery technologies.
[0015] Conventional oils recovered from combustion engine services
can be re-refined utilizing a process known as hydrotreating or
hydrofinishing. This treatment method typically employs some form
of distillation to separate a gas oil fraction from other
contaminants, followed by treatment with hydrogen at elevated
temperatures and pressures over a catalyst. While this method has
been successful in saturating some aromatics and non-saturated
compounds, severe hydrotreating (such as characterized by higher
temperatures, higher pressures, greater hydrogen concentrations,
and longer residence time) is required to sufficiently saturate oil
molecules and achieve the physical and compositional properties of
higher quality base oils. Unfortunately, these severe processing
conditions can result in molecular cracking, which consequently
results in damage to synthetic oil molecules thereby lowering the
quality and amount of base oil produced. Furthermore, when higher
quality molecules, such as modern synthetic oils, are processed
through hydrotreating, the molecules are susceptible to being
fractured or changed, making them less desirable or unsuitable for
use in manufacturing GF5 lubricants.
[0016] Another method of re-refining oils recovered from combustion
engine service utilizes solvent extraction. These processes suffer
from a yield/quality trade-off. In solvent extraction, a portion of
the contaminated base oil molecules (polars, aromatics,
heteroatoms, unsaturates) are separated from the base oil fraction
using liquid/liquid extraction. This process creates a purified
base oil stream (raffinate) and an extract oil stream (extract)
wherein some of the contaminated molecules are concentrated. The
efficacy of separation of quality base oil from contaminated
molecules is determined by several variables including temperature,
treatment ratio, residence time, contact, and the presence of other
fluids added to the oil and solvent. In the extraction process,
there is continual trade-off between selectivity (the amount of
good base oil taken with the extract) and purity (percent of
contaminated base oil molecules left in the raffinate).
[0017] Typically, solvent extraction processes are effective at
removing some of the aromatics, polars and unsaturated compounds.
However, to reach the desired level of purification necessary for
higher quality standards using known processes, the selectivity of
the solvent must be reduced whereby both contaminated molecules as
well as good molecules are dissolved in the solvent, which
significantly reduces the yield of base oil. Therefore, there is an
inherent trade-off between quality and yield so that in order to
get high quality base oil, yield quantity is reduced.
[0018] As previously noted, known processes of this type are
capable of producing either quality or yield, but not both. This is
due to the nature of the oils recovered from combustion engine
service, which consists of a wide variety of types, qualities and
contaminants and the consequential trade-off between quality and
quantity that is typically inherent in these processes.
Furthermore, most known processes of this type typically can only
produce an API Group I base oil. An additional disadvantage of this
process is that the extract formed by solvent extraction of oils
recovered from combustion engine service is also prone to
reformation assumed to be polymerization. This polymerization is
believed to be catalyzed by acid, which can be reduced through
addition of base or blending with fuel oil or other anti-polymer
chemicals, thereby adding to the overall production cost.
Furthermore, the resulting product is low quality fuel oil, which
may be difficult to market.
[0019] The present disclosure provides a system and method for
producing high quality petroleum products suitable for modern
environmentally friendly and technology enhanced engines, such as
on-road diesel fuel and GF5 compatible base oils, from used engine
oils consisting in part of synthetic oils. The process includes
separating the feedstock into a volatile fraction, a fuel oil
fraction, a residual fraction, and a partially purified oil
fraction, and thereafter treating the partially purified oil to
separate it into a purified oil fraction and a contaminant
fraction, then hydrogenating the contaminant fraction to upgrade
this fraction and produce a saturated oil fraction. Finally, the
saturated oil fraction is fractionated to produce a naphtha stream,
a diesel fuel stream and one or more base oil streams. The
petroleum products produced by this process are greater in quantity
and higher in quality than those produced by previous
processes.
[0020] The present disclosure further relates to a method for
efficiently producing a high yield of ILSAC GF5 or higher
compatible oils and on-road diesel fuel from the recovery and
upgrade of oil (feedstock) derived from modern electric, hybrid,
turbocharged, and high efficiency gasoline and diesel engines. In
one exemplary embodiment, the method can include first separating
at least a portion of the feedstock with a boiling point less than
about 350.degree. F. from the recovered oil to produce a
de-volatized oil fraction and a light oil fraction. Second, at
least a portion of the feedstock is separated with a boiling point
greater than about 350.degree. F. and less than about 650.degree.
F. from the de-volatized oil fraction to produce a fuel oil
fraction and a heavy oil fraction. Third, at least a portion of the
feedstock is separated with a boiling point greater than about
1200.degree. F. from the heavy oil fraction creating a partially
purified oil fraction and a residual fraction. Fourth, the
partially purified oil fraction is treated to separate it into a
purified oil fraction and a contaminant fraction. Fifth, the
contaminant fraction is hydrogenated, or optionally the combined
contaminant fraction and fuel oil fraction is hydrogenated, to
improve or remove undesirable constituents further saturating the
fraction(s) and thereby creating a saturated oil fraction. Then the
saturated oil stream is fractionated to produce a naphtha fraction,
a diesel oil fraction and a base oil fraction. Optionally, the
purified oil stream can be fractionated to produce two or more
purified oil streams that are differentiated based on boiling point
profiles.
[0021] FIG. 1 is a diagram of a system 100 for processing waste oil
in accordance with an exemplary embodiment of the present
disclosure. In the embodiment shown, oil recovered from combustion
engine service, line 102, is first charged to separation zone 106
of step 1 where a light oil fraction, line 104, is separated from
the de-volatilized oil fraction, line 108. The materials recovered
through line 104 may be low molecular weight materials such as
light hydrocarbons, water, glycols, and the like, typically having
a boiling range generally below about 350.degree. F. The average
residence time through this section 3 is generally between about 5
minutes and 10 hours. In step 2, the de-volatilized oil, line 108,
is then charged to a second separation zone 110 where a fuel oil
fraction, line 112, is separated from a heavy oil fraction, line
114. The fuel oil fraction consists primarily of hydrocarbons with
a boiling point greater than 350.degree. F. and less than
650.degree. F. The average residence time through this section is
between about minutes and 10 hours. In a third step, the heavy oil
fraction, line 114, is then passed to a third separation zone 116
where a residual fraction, line 118, is separated from a partially
purified oil fraction, line 120. The residual fraction, line 118,
consists primarily of non-volatile material and material with a
boiling point in excess of 1200.degree. F. The partially purified
oil is recovered through a line 120 and typically consists of
hydrocarbon molecules with 18 to 60 carbon atoms and typically
having a boiling range (between) from about 650.degree. F. to about
1200.degree. F.
[0022] In a separation zone 122 of the fourth step, a portion of
the non-paraffinic or unsaturated molecules, such as the aromatics,
olefins, and heteroatoms (contaminant fraction), are separated from
the paraffinic oil through a line 126 and passed to a treatment
section 128 in the fifth step. The primarily paraffinic material is
recovered through line 124 and sold as a blend stock for the
production of ILSAC GF5 or higher quality oils. The contaminant
fraction recovered through line 126 is passed to a treatment zone
128 of step 5 where it is treated with hydrogen to more fully
saturate the molecules and produce a more saturated oil fraction,
line 130. The saturated oil fraction is then distilled to produce a
naphtha fraction, diesel oil fraction and one or more base oil
fractions.
[0023] In the first three steps, zones 106, 110 and 116, the
partially purified oil fraction is separated from various physical
and chemical contaminants. Typically, such contaminants include
water, light hydrocarbons, extractants, solids, polymers, high
molecular weight hydrocarbons, lubricating oil additives,
chemicals, salts, dirt, fines, debris, non-volatiles, and the like.
Several processes or combination of processes can be used to effect
these separations including various forms of extraction,
distillation, filtration, centrifugation, adsorption, and the like,
as known to those skilled in the art. Typically, the separation
will take place based upon differences in the physical or chemical
properties of the base oil fraction and the various contaminating
materials. In the fourth step, the partially purified oil fraction
is then fed to zone 122 of the process where a portion of the
non-paraffinic material is separated from the paraffinic material.
These molecules may comprise polars, aromatics, olefins,
unsaturates, heteroatoms, and the like, which are separated from
the higher quality base oil molecules, which are typically
saturated, paraffinic and non-aromatic. The purified oil fraction
line 124 is a high quality oil stream typically having a percent of
saturates greater than 90% and a sulfur content of less than about
0.3 weight percent. The stream in line 126 will typically have a
higher concentration of sulfur, oxygen, nitrogen, olefins,
aromatics, and the like. Various processes or combinations thereof
can be used to effect separation of these materials from the high
quality base oil. These processes include various forms of
extraction, ultrafiltration, absorption, molecular sieves, and the
like, as known to those skilled in the art. In the fifth step,
stream 126 is processed in zone 128 by hydrogenating, alkylating,
molecular reforming, molecular substituting, or the like, or a
combination thereof, as known to those skilled in the art, to
remove undesirable elements such as sulfur, nitrogen, oxygen, and
the like, and increase the percent saturation of at least a portion
of the hydrocarbon molecules. The resulting saturated oils produced
through line 130 are typically sold as a petroleum product suitable
for combustion or lubrication use.
[0024] FIG. 2 is a diagram of a system 200 for processing waste oil
in accordance with an exemplary embodiment of the present
disclosure. In step 1, the feedstock is heated and charged into a
distillation system 206. In distillation system 206, a light oil
fraction, namely materials that have a boiling point less than
approximately 350.degree. F., line 204, is separated from the oil
feedstock, line 202, thereby producing a de-volatized oil fraction,
line 208. The distillation system 206 consists of one or more
vessels which may be operated under vacuum, at atmospheric
conditions or at pressure and can be single or multiple staged, as
known to those skilled in the art. One or more of the vessels may
be designed to enable an average residence time for the
de-volatized oil of between 5 minutes and 5 hours and generally
around 1 hour. The light oil fraction, line 204, generally consists
of one or more low boiling point contaminants such as water, light
hydrocarbons, glycols, solvents and other volatile materials such
as might be found to have been combined with the oil feedstock. The
low boiling point contaminants may also contain breakdown products
from service. In certain rigorous applications, it is possible for
the oil molecules, or, if present, performance enhancing chemicals
to split into two or more smaller molecules. One or more of these
may be volatile below 350.degree. F. and would end up in the light
oil fraction, line 204. In the instances where the feedstock has
not split or been contaminated with volatile materials, the flow of
the light oil fraction, line 204, may be minimal or zero.
[0025] The de-volatized fraction, line 208, consists of the
material that generally has a boiling point greater than
350.degree. F. This stream discharges from the bottom of
distillation system 206 and is optionally heated and charged into a
second distillation system 210. The second distillation system 210
consists of one or more distillation devices such as columns,
evaporators or the like known to those skilled in the art, for
fractionating streams based on boil point. The distillation devices
may be operated under vacuum, at atmospheric conditions or at
pressure and can be single or multiple staged as known to those
skilled in the art. One or more of the vessels may be designed to
enable an average residence time for the de-volatized oil of
between 5 minutes and 5 hours and generally around 1 hour. In
distillation system 210, at least a portion of the molecules having
a boiling point between approximately 350 and 650.degree. F., the
fuel oil fraction, are separated from the balance of the
de-volatized stream, line 208, to form a heavy oil fraction. The
fuel oil fraction, line 212, passes from the distillation devices
whereon it is condensed and fed to the hydration system feed
accumulator, device 268. The heavy oil fraction consisting of
material with a boiling point greater than 650.degree. F. is passed
via line 214 to the third step. Optionally, this stage of the
process can be broken up into two or more steps which further
separate the oil into two or more fractions. For example, two
distillation steps each consisting of one or more vessels can be
used to separate the oil into a first 350 to 500.degree. F.
fraction, a second 500 to 650.degree. F. fraction and a heavy oil
fraction. One or both of the first 350 to 500.degree. F. fraction
or the second 500 to 650.degree. F. fraction can then be fed via
line 212 to hydration system feed accumulator 268.
[0026] In the third step, the heavy oil, line 214, is further
heated and passed to distillation system 216 wherein oil with a
boiling point of approximately 650 and 1,200.degree. F. is
separated from the balance of the heavy oil stream creating a
partially purified oil stream, line 220, and a residual stream,
line 218. The third distillation system 216 consists of one or more
columns, evaporators or other suitable distillation devices for
fractionating streams based on boil point. Third distillation
system 216 has a design that optimizes the distillation at lower
temperatures, to avoid the cracking and fouling of the oil, by
utilizing the inverse relationship between vacuum and temperature.
In general, as you lower the amount of vacuum, the temperature
required to produce the same distillation profile also decreases,
and as pressure increases, higher temperatures are required to get
the same distillate. With no vacuum or increased pressure, the
boiling temperature is high, whereas with vacuum, the boiling
temperature will drop. The columns of third distillation system 216
are designed to facilitate a low vacuum, such as one having 20 mm
of mercury or less. This design can utilize an unpacked column, a
single stage with little bits of grit to limit entrainment, and a
horizontal section a series of chevrons on a series of circles, to
provide a steeper vacuum at the flash zone. The distillation
devices may be single or multiples staged and operated under
vacuum, at atmospheric conditions or at pressure and can be single
or multiple staged, or other suitable systems or devices. One or
more of the vessels may be designed to enable an average residence
time for the de-volatized oil in excess of 5 minutes. The material
having a boiling point less than 1200.degree. F. (partially
purified oil) passes from the distillation device 216, whereon it
is condensed, collected and passed through line 220 to step 4 of
the process. The residual is cooled to 350.degree. F. and passed to
storage where it will be sold as a petroleum product.
[0027] The fourth step of the process consists of liquid/liquid
extraction and recovery. The partially purified oil, line 220, is
generally passed through a cooler where it is cooled to between 100
and 300.degree. F. and into a liquid/liquid extraction system 270.
In the liquid extraction system, an extractant is used to
preferentially remove certain molecular types from the partially
purified oil. The liquid/liquid extraction system may consist of
one or more contacting vessels 234 which may be single or multiple
staged and are designed to induce contact between the partially
purified oil and the extractant. The contacting vessel(s) 234 is
shown with a top and a bottom. A contact section is shown
schematically in the center portion of the vessel 234. A liquid
extractant accumulation and storage vessel is shown at 230 and
supplies the liquid extractant to an upper portion of vessel 234
near its top via a line 232. The extractant moves downwardly,
counter-current to the flow of the partially purified oil stream
via a line 220, which is introduced near the bottom of the contact
section. Upon contact, the extractant attracts, and weakly bonds
to, the molecules that are polar, aromatic, olefinic or unsaturated
in nature, drawing them downward to the bottom of the column (the
extract), thereby extracting them from the partially purified oil,
creating a more purified, saturated, paraffinic oil stream (the
raffinate).
[0028] The raffinate stream consisting of purified oil fraction
with a portion of the extractant is recovered from the top of
vessel 234 and passed via a line 236 to an extract recovery system.
The extractant recovery system consists of one or more vessels
designed to recover and purify the extractant. In one embodiment,
the purified oil/extractant stream 236 is heated to between
350.degree. F. and 650.degree. F. and passed to two or more
distillation vessels 238 having a top and a bottom, whereby the
extractant is separated from the purified oil molecules with
cross-current heat exchangers or other suitable energy recovery
being employed to increase extractant recovery without significant
increase in energy cost. The recovered extractant is provided to
extractant accumulation vessel 230 and the purified oil, line 242,
sent to storage. One or more of the vessels 238 can also be
configured to fractionate the purified oil into different viscosity
cuts. Optionally, a separate fractionation column 276 can be used
whereby the purified oil is fractionated by distillation into
different viscosity cuts. The distillation vessels 238 can be
operated under vacuum, at atmospheric conditions or under pressure
and may have single or multiple stages. Additionally, steam or
other gaseous streams can be used to influence partial pressure and
help separate the extractant from the purified oil. The extractant
is recovered through a line 240, and is typically treated to remove
water, low boiling point contaminants and the like, and neutralize
organic acids, as known to those skilled in the art, and returned
to extractant accumulator 230.
[0029] A bottom extract stream 222 is also recovered from vessel
234 and passed to a second extractant separation system 224 having
a plurality of columns, each having a top and a bottom. The use of
multiple columns increases the efficiency of extractant separation,
with a small increase in energy costs through the use of energy
recovery, such as cross-current heat exchangers. In the second
extractant separation system 224, the extractant is separated from
the extracted molecules (contaminant fraction) and passed via a
line 228 to the extractant accumulator 230. The contaminant
fraction is recovered from the bottom of vessel 224 and is passed
via a line 226 to the feed accumulator for the hydrogenation system
268. The second extractant recovery system consists of two or more
vessels designed to recover and purify the extractant from the
extract (contaminant) oil. In one embodiment, the purified
oil/extractant stream 222 is heated to between 350.degree. F. and
650.degree. F. and passed to one or more distillation vessels 224,
each having a top and a bottom, whereby the extractant is separated
from the contaminant oil molecules with the extractant being
distilled, condensed and then recovered in a first line 278 back to
vessel 234 and in a second line 228 to the extractant accumulation
vessel 230. The use of the first line 278 increases process
efficiency by providing additional solvent to vessel 234 that has
not been subjected to additional processing. The distillation
vessels 224 can be operated under vacuum, at atmospheric conditions
or under pressure and may have single or multiple stages.
Additionally, steam or other gaseous streams can be used to
influence partial pressure and help separate the extractant from
the contaminant oil. The extractant is recovered through a line
228, and is typically treated to remove water, low boiling point
contaminants and the like, and neutralize organic acids, as known
to those skilled in the art, and returned to extractant accumulator
230.
[0030] In the hydrogenation section 272, the material in the
hydrogenation feed accumulator is heated and passed to the first
treatment zone 252 in the hydrogenation system 272. Hydrogen is
heated and added to stream 250. The stream is then passed through a
third heater and into zone 252. Zone 252 consists of one or more
guard beds designed to remove catalyst poisons in the oil that
might otherwise poison the hydrotreating catalyst. These vessels
have a top and bottom and include a contact zone containing a
catalyst, spent catalyst, activated clay, or the like, as known to
those skilled in the art. It will be understood that hydrogen could
be injected into line 250 at a plurality of points or into vessels
in zone 252 at a plurality of points. The product from the vessels
in zone 252 is recovered through a line 254 and passed to a
hydrogenation reactor zone 256.
[0031] Generally, the vessels in zone 256 have a top and a bottom
and include a catalytic bed. Hydrogen may be added at various
points along line 254 or at various points along the length of the
vessels in zone 256. To some extent, unsaturates including olefins,
aromatics and molecules containing contaminants such as sulfur,
nitrogen, oxygen, heteroatoms, and the like, are hydrogenated in
zone 256. In one exemplary embodiment, zone 256 can include a
reactor with catalyst, where hydrogen and oil ager generated. Line
258 can include hydrogen separation and recovery system 270 to
remove this hydrogen. In addition, zone 256 can be implemented as
two or more vessels, which can be run in series or parallel. A
series combination can be used to obtain a better quality product,
such as by using intermediate separation in different vessels, such
as to treat for sulphur removal, napthenics removal, or removal of
other compounds. Zone 256 can also be used to form more saturated
hydrocarbon molecules and volatile compounds of hydrogen. The
contaminated oil, which has now been upgraded through hydrogen
saturation forming a saturated oil product, is recovered through a
line 258 and passed to a fractionation column 260. In the
fractionation column 260, the saturated oil is fractionated in one
or more of naphtha, diesel oil and base oil.
[0032] In the embodiment described above in steps 1, 2 and 3, one
distillation column is typically used for each step. Steps 1 and 2
are preferably undertaken at atmospheric pressure, whereas step 3
is undertaken at a vacuum generally between 2 to 200 mmHg.
Furthermore, in general, the residence time is increased by
designing the vessels with an enlarged lower column section in
which the non-volatile fraction is held before being passed to the
next step. Alternatively, a second holding vessel which is closely
associated with the distillation column of each step could be used.
In the practice of this invention, it may be desirable to use as
few as one or as many six distillation systems to undertake steps 1
through 3.
[0033] In all of the steps described in the embodiment above where
a distillation system is envisioned, vessels are used to separate
various constituents from each other. These vessels include any
suitable vessel or system that effects a single or multiple stages
of separation including simple evaporators, thin or wiped film
evaporators, columns, packed columns, vessels, tanks, pipes or
other suitable systems or devices. These vessels may be operated
under vacuum, at atmospheric pressure or elevated pressure.
[0034] In the embodiment described above, prior to the first vessel
of step 1, an optional treatment vessel can be used to chemically
treat the composite stream prior to entry into distillation system
206 to facilitate treatment. This chemical treatment can be an
alkali or base material such as sodium carbonate, sodium
bicarbonate, sodium hydroxide, potassium hydroxide, or an acid such
as sulfuric acid or other chemicals known to reduce the tendency to
foul, enhance separation, processability, equipment availability,
or the like, or to enhance the quality of the synthetic oil or
other products, as known to those skilled in the art.
[0035] In the practice of the present invention, it may be
desirable in some instances for the boiling point of stream 212 to
be generally between 350.degree. F. and 500.degree. F., thereby
enriching line 214 with material with a boiling point between
around 500.degree. F. and 650.degree. F.
[0036] In some instances, it may be preferable to create more than
one partially purified oil stream from distillation system 216,
whereby the partially purified oil streams are distinguished in
terms of distillation profile. In this instance, one or more
storage vessels can be used between step 3 and step 4 to
temporarily store partially purified fractions and one partially
purified fraction at a time can be passed to step 4 on a blocked
out basis. Thus, step 4 would be used to purify each of the
partially purified oil fractions individually. While one first
partially purified synthetic oil stream is being processed through
step 4, the other stream(s) are accumulated in intermediate storage
tanks. When the first stream intermediate storage tank is close to
being emptied, the feed to step 4 can be switched to process the
content of a second intermediate storage tank containing a second
partially purified oil stream.
[0037] In the embodiment shown above, the extractant recovered from
the oil stream 240 and the contaminant stream 228 are consolidated
in an extractant accumulator vessel 230. Either prior to vessel 234
or post vessel 238, the extractant can be treated to remove any
contaminants such as water or similar boiling point materials that
may have contaminated the extractant. Such treatments include
distillation, extraction, absorption, adsorption, osmosis, chemical
treatment or other suitable processes.
[0038] In the fourth step of the embodiment shown above, the
extraction process used in vessel 234 may be a suitable process,
such as extractant extraction, with materials such as ethanol,
diacetone-alcohol, ethylene-glycol-mono(low alkyl) ether,
di-ethylene-glycol, diethylene-glycolmono(low alkyl) ether,
o-chlorophenol furfural, acetone, formic acid, 4-butyrolacetone,
low-alkyl-ester of low mono- and dicarbonic acids,
dimethylformamide, 2-pyrrolidone and N-(low alkyl)2-pyrrolidone,
N-methyl-2-pyrolodone, epi-chlorohydrin, dioxane, morpholine,
low-alkyl- and amino(low-alkyl)morpholine, benzonitrile and
di-(low-alkyl)sulfoxide, and phosphonate, or other suitable
processes.
[0039] N-methyl-2-pyrolodone is a preferred extractant for step 4
of the process of the present invention. In one exemplary
embodiment, extraction is undertaken at a temperature between about
100 and about 250.degree. F. and preferably between about 130 and
about 190.degree. F. Typically, both the extractant and partially
purified oil are fed into the extraction column within this
temperature range although not necessarily at the same temperature.
The extractant dosage (percent of extractant relative to feed) fed
to the extraction column is typically between 50 and 1000% by
volume and preferably between 100 and 400%. Typically, extraction
is undertaken in a packed or trayed column whereby the extractant
is fed into the top of the column and partially purified synthetic
oil is fed into the bottom. The packed column can contain
structured packing, random packing or other suitable packing. Water
may be injected into the extractant or extraction column as desired
to control extractant selectivity. Similarly, temperature gradients
or regional heating or cooling can be used at various points along
or across the extraction column to affect performance and
selectivity. Recycles of both raffinate and extract at similar or
different temperatures can also be employed. In some instances, it
may be beneficial to remove a side stream from the extraction
column, raffinate or extract streams cool, and separate a portion
of the extractant from the oil and return the oil to the column.
The extractant may be recovered from the raffinate stream in line
and the extract stream in line using distillation. The distillation
can be undertaken atmospherically or by using vacuum. Flash
separators or multi-stage columns can be used or combinations
thereof can be used in order to separate the extractant from the
synthetic oil or the extracted contaminants.
[0040] In the exemplary embodiment described above, additional
processing may be undertaken on the distillate stream, line 204,
from system 206 such as further separating the constituents of this
stream such as water, glycols, extractants, light hydrocarbons and
the like, thereby creating separate products which may be used or
further upgraded to higher quality products. In the disclosed
embodiment, only one distillate cut is taken from distillation
system 206.
[0041] A phase transfer catalyst or the like can also or
alternatively be used to enhance the operation of the fourth step
of the process, whereby the efficiency, selectivity and the like of
the process are enhanced, thereby providing for better separation
of the high quality base oil molecules from the lower quality
molecules.
[0042] In the embodiment described above, flash vessels are used to
separate various constituents in steps 1, 2 and 3. These vessels
include any vessel or system that effects a single stage of
separation including simple evaporators, thin or wiped film
evaporators, columns, vessels, tanks, pipes, and the like, as known
to those skilled in the art. The flash vessels are also designed to
provide for a residence time from 5 minutes to 5 hours and
generally around 60 minutes. This residence time is generally
enabled through the use of a liquid well either at the bottom of or
otherwise associated with the vessel.
[0043] In the embodiment described above, stage four is used to
separate the contaminant from the purified oil molecules, thereby
creating a first purified oil stream wherein the concentration of
aromatics, polars, unsaturates, heteroatoms, and the like, is lower
than the second stream and thereby consists of higher quality base
oil. It is also possible to further upgrade this purified oil
stream using processes similar to those described in step 5 by
converting a portion of any remaining aromatic, polar, unsaturated,
heteroatom molecules and the like, to higher quality molecules,
thereby further purifying it, increasing the degree of saturation
and thereby producing an highly purified oil. This oil may be
suitable for use as a white oil in the medicinal or food processing
industries as well as a lubricating oil in the industrial
lubrication markets.
[0044] In the embodiment shown above, the extractant recovered from
lines 228 and 240 of step 4 is combined in the extractant
accumulation unit 230. In the extractant accumulation unit 230, the
extractant may be purified by removing water and other low boiling
point contaminants prior to re-use. The extractant can also be
treated at this stage with bases and the like, as known to those
skilled in the art, to neutralize organic acids that may have built
up in the extractant.
[0045] In the embodiment described above, distillation systems 206
and 210 are operated at atmospheric pressure. These vessels could
also be operated at pressure or under vacuum by varying
temperature, as known to those skilled in the art, to effect
similar separation of the oil fractions from the feedstock.
[0046] The product stream recovered through line 218 typically
comprises asphalt flux range materials and includes heavy oils,
polymer, salts, solids, other high boiling range materials and the
like, which are constituents of the feedstock stream 202. The
residual stream recovered from this system 216 is generally cooled
to approximately 350.degree. F. and passed to heated storage.
[0047] In the preferred embodiment of the present invention as
discussed above, hydrofinishing is used to purify and saturate the
contaminant and/or fuel fractions (lines 226 and 212, respectively,
collectively the unsaturated oil stream) as a final step. The
unsaturated oil stream is mixed with 50 to 2000 scf of hydrogen per
barrel of base oil feed, preferably between 70 and 150 scf of
hydrogen per barrel of base oil feed, heated to between about 500
and about 1200.degree. F., preferably between about 650 and about
850.degree. F. and pressurized to between about 100 and about 3000
psig and preferably between about 500 and about 1500 psig. The
mixture is passed through a guard bed consisting of activated clay
or spent catalyst and then through a reactor containing one or more
hydrogenation catalysts with metal components from Groups V(b),
VI(b) and VIII of the Periodic Table or other suitable materials.
Preferable compounds are nickel, molybdenum, vanadium, tungsten or
cobalt metal supported on carriers such as activated carbon,
kieselguhr, silica, alumina, and the like, such as a
cobalt-molybdenum on alumina, nickel-molybdenum on alumina or
nickel-tungsten on silica/alumina. Typically, the hydrogenation is
undertaken at a space velocity of about 0.1 to about 10 and
preferably between 0.5 and 2 volumes of liquid feed per volume of
catalyst per hour. Typically, only one reactor stage is used.
However, several stages can be used if desired by using multiple
reactors in a series. After the hydrogenation treatment, the base
oil fraction is separated from the hydrogen gas and volatile
reaction products in a flash vessel, which may be operated at
reduced pressure. Typically, the pressure is between a full vacuum
and about 100 psig, although wide variations in the suitable
pressure are possible.
[0048] In the fifth stage of the process presented in this
embodiment, it may be advantageous to have multiple guard beds, run
reactors in parallel or series to utilize phase or separation or
the like between reactors or between guard beds and reactors.
Furthermore, in some instances it may be advantageous to strip the
saturated oil of light contaminants or further fractionate it into
different cuts. Although the system described herein does not
specify a hydrogen recovery system, one could be employed to
recover and purify un-reacted hydrogen and reaction products after
recovery separation from the product base oil.
[0049] The disclosed embodiment shows continuous flow between the
steps of the operations. It may be desirable in certain instances
to have intermediate storage vessels between the steps to allow for
process surges, contain off specification material, smooth
operations, quality control, allow for more than one cut of base
oil distillate, and the like. Many variations and schemes are
possible to incorporate regenerative or recuperative heat
exchangers to recover heat from process streams and optimize the
thermal efficiency of the process.
[0050] By the process of the present invention, the oil feedstock
is separated into a number of fractions in the first three steps.
In the fourth step, the one fraction produced in step 3 is further
refined using liquid/liquid extraction to produce a base oil
fraction suitable for the manufacture of ILSAC GF5. The extract
from the fourth step is combined with the fuel oil fraction from
step 2 and purified through hydrogenation to produce a saturated
fraction which is subsequently fractionated to produce a high
quality base oil and one or more fuel fractions at least one of
which is suitable for use as an on-road low sulfur fuel in diesel
engines. The combination of these steps has produced a surprisingly
superior process that yields a surprisingly high yield of base oil
suitable for use in the manufacture of lubricants for modern high
tech, environmentally friendly engines, high quantity fuel products
and the full recovery of all petroleum fractions found in the
feedstock.
[0051] The use of this five step process provides several
significant advantages over existing process methodologies. The
present invention enables both objectives of manufacturing products
that meet the demands of the market for higher quality,
environmentally friendly products and the desire to maximize the
amount of base oil produced from feedstock. Existing processes can
only produce lower quality base oils and fuels and are not able to
produce the same yield or product slate as the method of this
invention.
[0052] The total base oil produced through lines 262, 264 and 266
is more than has been produced by previous processes and is of
higher overall quality. Stream 242 is capable of being used in the
production of lubricants that meet GF5 standards that are thought
to be as well positioned to meet new standards as they arise. When
previous extraction processes are used to separate the base oil
from other undesirable components, the extraction treatment is
required to be relatively severe in order to produce high quality
base oil and consequently results in a base oil yield loss due to
over extraction. Similarly, when previous hydrotreating processes
are used, relatively severe treatment is again required in order to
produce high quality base oil. This severe treatment results in
cracking of some of the base oil molecules into smaller non-base
oil molecules, resulting in yield loss. Thus, neither of these
processes alone is capable of producing a high yield and high
quality base oil.
[0053] According to the present invention, heavy oil material
charged to extraction and severe extraction can be used to separate
the polar, aromatic and unsaturated oil molecules from the
paraffinic, saturated high quality molecules since the extracted
oil is recovered and upgraded in the next stage without concern for
yield loss. The base oil is recovered in relatively high yield
quantities, typically from about 75 to about 95% of the oil content
of the feedstock to the extraction system 234, depending on the
desired quality of base oil. Further, the contaminated oil removed
in the extraction process, which includes contaminants of various
types, is recovered through line 226 and passed to upgrading where
it is upgraded to on-road diesel fuel and saturated base oil.
Typically, from about 10 to about 30% of the base oil contained in
the feedstock stream 202 is recovered through line 258, again
depending on quality.
[0054] The combination of these steps results in a much larger
recovery than is typically achieved by any known process. For
instance, the use of hydrogenation to upgrade the entire base oil
stream results in cracking a large number of molecules which would
otherwise be suitable as base oil. Others may be isomerized or
otherwise modified over the cracking catalyst. The process enables
the recovery of over 90% of the base oil available in the feedstock
202.
[0055] Another unexpected advantage of the current disclosure over
existing technologies is its ability to process oils recovered from
combustion engine services of varying specification and quality and
still produce high quality products. Existing processes are highly
influenced by feedstock quality and their product quality and/or
yield are highly influenced by feedstock quality. The present
disclosure is capable of processing a wide variety of feedstocks
and still manufacture high quality products and maintain a high
yield of total base oil product.
[0056] The present disclosure also has the unexpected benefit of
reducing capital expenditures. In most processes, the good base oil
molecules are treated with the contaminated base oil molecules even
though upgrading of the good base oil molecules may not be
necessary. Because of this, the process must be sized larger to
process all of the base oil molecules together. In the current
disclosure, the good base oil molecules are separated from the
contaminated base oil molecules prior to upgrading the contaminated
molecules. By doing so, the processing equipment can be sized to
treat a much smaller stream thereby saving capital cost for
expensive high pressure and high temperature upgrading equipment.
The cost of upgrading is also reduced due to the lower operating
cost associated with processing the stream wherein the contaminates
have been concentrated.
[0057] The use of the type of distillation system outlined herein
is considered to provide substantial advantages over previous
systems. The process provides additional efficiency and economic
benefits since it uses simple distillation vessels enabling more
effective separation with less complicated equipment at each step.
Similarly, it enables excellent separation of the physical
contaminants typically found in oils recovered from combustion
engine service yielding distillates suitable for further processing
and upgrading. The sequential removal of physical contaminants also
enables good control over product streams and unit operations
availability. Columns that do not have mechanical means, such as
those found in film evaporators and the like, result in lower
capital and operating costs. Similarly, simple distillation columns
avoid the typical problem packing fouling, which can be experienced
when processing used oil.
[0058] A surprising benefit of the process is its ability to avoid
the problem of heat exchanger and equipment fouling typically
experienced in processing oils recovered from combustion engine
service. The design of the vessels with increased residence time
enables certain contaminants in the feedstock sufficient time to
decompose, thereby stabilizing the oil streams and reducing
fouling. Finally, the present disclosure enables the production of
both high quality base oils and one-road diesel fuel. No other
re-refining technology heretofore has been able to do this. While
the present invention has been described by reference to certain of
its preferred embodiments, it is pointed out that the embodiments
described are illustrative rather than limiting in nature and that
many variations and modifications are possible within the scope of
the present invention. Many such variations and modifications may
be considered obvious and desirable by those skilled in the art
based upon a review of the foregoing description of preferred
embodiments.
[0059] FIG. 3 is a diagram of a controller 300 for controlling
waste oil processing in accordance with an exemplary embodiment of
the present disclosure. Controller 300 can be implemented in
hardware or a suitable combination of hardware and software, and
can include one or more software systems operating on a processor.
Controller 300 can also be used to implement offsite monitoring,
for archiving of operations data (temperatures, pressures,
recovered compounds) and subsequent statistical analysis of the
archived operations data, to develop trends, to notify operators of
maintenance requirements, to avoid shutdowns, to improve online
reliability, to provide operator notices (e.g. trend of dropping
temperatures, trend of increasing pressures) or for other suitable
purposes.
[0060] As used herein, "hardware" can include a combination of
discrete components, an integrated circuit, an application-specific
integrated circuit, a field programmable gate array, or other
suitable hardware. As used herein, "software" can include one or
more objects, agents, threads, lines of code, subroutines, separate
software applications, two or more lines of code or other suitable
software structures operating in two or more software applications,
on one or more processors (where a processor includes a
microcomputer or other suitable controller, memory devices,
input-output devices, displays, data input devices such as
keyboards or mice, peripherals such as printers and speakers,
associated drivers, control cards, power sources, network devices,
docking station devices, or other suitable devices operating under
control of software systems in conjunction with the processor or
other devices), or other suitable software structures. In one
exemplary embodiment, software can include one or more lines of
code or other suitable software structures operating in a general
purpose software application, such as an operating system, and one
or more lines of code or other suitable software structures
operating in a specific purpose software application. As used
herein, the term "couple" and its cognate terms, such as "couples"
and "coupled," can include a physical connection (such as a copper
conductor), a virtual connection (such as through randomly assigned
memory locations of a data memory device), a logical connection
(such as through logical gates of a semiconducting device), other
suitable connections, or a suitable combination of such
connections.
[0061] System 300 includes waste oil processing controller 302,
which includes low temperature distillation monitor 304, mid
temperature distillation monitor 308, high temperature distillation
monitor 312, solvent treatment monitor 316, hydrogenator monitor
320, low temperature distillation heater controller 306, mid
temperature distillation heater controller 310, high temperature
distillation heater controller 314, solvent treatment heater
controller 318, hydrogenator heater controller 322, low temperature
distillation pump controller 324, mid temperature pump control 326,
high temperature distillation pump controller 328, solvent
treatment pump controller 330 and hydrogenator pump controller 332
each of which can be implemented as one or more objects having
associated graphical and functional characteristics. Consolidation
of these monitors and controls in a single location, display panel
or set of display panels allows process variables to be readily
monitored and coordinated, unlike separate systems in different
locations that have to be monitored and adjusted over time. Such
separate systems can have process variations that are not observed
by a single operator, which can result in lower quality, lower
efficiency or other problems. These problems are more pronounced
and significant when processing waste oil with high amounts of
synthetic oil compounds, because the quality of the waste oil and
the composite compounds of the waste oil can be highly variable,
which can make it difficult to adjust process variables over
time.
[0062] Low temperature distillation monitor 304 generates one or
more low temperature distillation metrics, such as temperature,
pump speed, pressure, flow rate or other suitable metrics. In one
exemplary embodiment, low temperature distillation monitor 304 can
include one or more user-selectable controls that allow a user to
display or hide a metric, to increase the size of a display for a
metric, to add an audible alarm for a metric, or other suitable
functions.
[0063] Mid temperature distillation monitor 308 generates one or
more mid temperature distillation metrics, such as temperature,
pump speed, pressure, flow rate or other suitable metrics. In one
exemplary embodiment, mid temperature distillation monitor 308 can
include one or more user-selectable controls that allow a user to
display or hide a metric, to increase the size of a display for a
metric, to add an audible alarm for a metric, or other suitable
functions.
[0064] High temperature distillation monitor 312 generates one or
more high temperature distillation metrics, such as temperature,
pump speed, pressure, flow rate or other suitable metrics. In one
exemplary embodiment, high temperature distillation monitor 312 can
include one or more user-selectable controls that allow a user to
display or hide a metric, to increase the size of a display for a
metric, to add an audible alarm for a metric, or other suitable
functions.
[0065] Solvent treatment monitor 316 generates one or more solvent
treatment system metrics, such as pump speed, pressure, flow rate
or other suitable metrics. In one exemplary embodiment, solvent
treatment monitor 316 can include one or more user-selectable
controls that allow a user to display or hide a metric, to increase
the size of a display for a metric, to add an audible alarm for a
metric, or other suitable functions.
[0066] Hydrogenator monitor 320 generates one or more hydrogenator
metrics, such as temperature, pump speed, pressure, flow rate or
other suitable metrics. In one exemplary embodiment, hydrogenator
monitor 320 can include one or more user-selectable controls that
allow a user to display or hide a metric, to increase the size of a
display for a metric, to add an audible alarm for a metric, or
other suitable functions.
[0067] Low temperature distillation heater controller 306 generates
one or more user-selectable controls for low temperature
distillation heater and pump 334, such as an increase temperature
control, a decrease temperature control or other suitable controls.
In one exemplary embodiment, low temperature distillation heater
controller 306 can interface with low temperature distillation
monitor 304 to perform a suitable function in response to an alarm
or setting, such as to increase a temperature in response to a low
temperature alarm or setting, to decrease a temperature in response
to a high temperature alarm or setting, or to perform other
suitable functions.
[0068] Mid temperature distillation heater controller 310 generates
one or more user-selectable controls for mid temperature
distillation heater and pump 336, such as an increase temperature
control, a decrease temperature control or other suitable controls.
In one exemplary embodiment, mid temperature distillation heater
controller 310 can interface with mid temperature distillation
monitor 308 to perform a suitable function in response to an alarm
or setting, such as to increase a temperature in response to a low
temperature alarm or setting, to decrease a temperature in response
to a high temperature alarm or setting, or to perform other
suitable functions.
[0069] High temperature distillation heater controller 314
generates one or more user-selectable controls for high temperature
distillation heater and pump 338, such as an increase temperature
control, a decrease temperature control or other suitable controls.
In one exemplary embodiment, high temperature distillation heater
controller 314 can interface with high temperature distillation
monitor 312 to perform a suitable function in response to an alarm
or setting, such as to increase a temperature in response to a low
temperature alarm or setting, to decrease a temperature in response
to a high temperature alarm or setting, or to perform other
suitable functions.
[0070] Solvent treatment heater controller 318 generates one or
more user-selectable controls for solvent treatment valve and pump
340, such as an increase temperature control, a decrease
temperature control or other suitable controls. In one exemplary
embodiment, solvent treatment heater controller 318 can interface
with solvent treatment monitor 316 to perform a suitable function
in response to an alarm or setting, such as to increase a
temperature in response to a low temperature alarm or setting, to
decrease a temperature in response to a high temperature alarm or
setting, or to perform other suitable functions.
[0071] Hydrogenator heater controller 322 generates one or more
user-selectable controls for hydrogenator heater and pump 342, such
as an increase temperature control, a decrease temperature control
or other suitable controls. In one exemplary embodiment,
hydrogenator heater controller 322 can interface with hydrogenator
monitor 320 to perform a suitable function in response to an alarm
or setting, such as to increase a temperature in response to a low
temperature alarm or setting, to decrease a temperature in response
to a high temperature alarm or setting, or to perform other
suitable functions.
[0072] Low temperature distillation pump controller 324 generates
one or more user-selectable controls for low temperature
distillation heater and pump 334, such as an increase pump speed
control, a decrease pump speed control or other suitable controls.
In one exemplary embodiment, low temperature distillation pump
controller 324 can interface with low temperature distillation
monitor 304 to perform a suitable function in response to an alarm
or setting, such as to increase a pump speed and change associated
valve settings in response to a low pressure alarm or setting, to
decrease a pump speed and change associated valve settings in
response to a high pressure alarm or setting, or to perform other
suitable functions.
[0073] Mid temperature distillation pump controller 326 generates
one or more user-selectable controls for mid temperature
distillation heater and pump 336, such as an increase pump speed
control, a decrease pump speed control or other suitable controls.
In one exemplary embodiment, mid temperature distillation pump
controller 326 can interface with mid temperature distillation
monitor 308 to perform a suitable function in response to an alarm
or setting, such as to increase a pump speed and change associated
valve settings in response to a low pressure alarm or setting, to
decrease a pump speed and change associated valve settings in
response to a high pressure alarm or setting, or to perform other
suitable functions.
[0074] High temperature distillation pump controller 328 generates
one or more user-selectable controls for high temperature
distillation heater and pump 338, such as an increase pump speed
control, a decrease pump speed control or other suitable controls.
In one exemplary embodiment, high temperature distillation pump
controller 328 can interface with high temperature distillation
monitor 312 to perform a suitable function in response to an alarm
or setting, such as to increase a pump speed and change associated
valve settings in response to a low pressure alarm or setting, to
decrease a pump speed and change associated valve settings in
response to a high pressure alarm or setting, or to perform other
suitable functions.
[0075] Solvent treatment pump controller 330 generates one or more
user-selectable controls for solvent treatment heater and pump 340,
such as an increase pump speed control, a decrease pump speed
control or other suitable controls. In one exemplary embodiment,
solvent treatment pump controller 330 can interface with solvent
treatment monitor 316 to perform a suitable function in response to
an alarm or setting, such as to increase a pump speed and change
associated valve settings in response to a low pressure alarm or
setting, to decrease a pump speed and change associated valve
settings in response to a high pressure alarm or setting, or to
perform other suitable functions.
[0076] Hydrogenator pump controller 332 generates one or more
user-selectable controls for hydrogenator heater and pump 342, such
as an increase pump speed control, a decrease pump speed control or
other suitable controls. In one exemplary embodiment, hydrogenator
pump controller 332 can interface with hydrogenator monitor 320 to
perform a suitable function in response to an alarm or setting,
such as to increase a pump speed and change associated valve
settings in response to a low pressure alarm or setting, to
decrease a pump speed and change associated valve settings in
response to a high pressure alarm or setting, or to perform other
suitable functions.
[0077] Low temperature distillation heater and pump 334 can include
one or more heaters, pumps, valves, chillers, compressors and other
associated components of a low temperature distillation apparatus
such as distillation 206. Although exemplary systems for heater and
pump control are described herein, additional systems for
individual or group control of valves, chillers, compressors or
other components can also or alternatively be provided.
[0078] Mid temperature distillation heater and pump 336 can include
one or more heaters, pumps, valves, chillers, compressors and other
associated components of a low temperature distillation apparatus
such as distillation 210. Although exemplary systems for heater and
pump control are described herein, additional systems for
individual or group control of valves, chillers, compressors or
other components can also or alternatively be provided.
[0079] High temperature distillation heater and pump 338 can
include one or more heaters, pumps, valves, chillers, compressors
and other associated components of a high temperature distillation
apparatus such as distillation 216. Although exemplary systems for
heater and pump control are described herein, additional systems
for individual or group control of valves, chillers, compressors or
other components can also or alternatively be provided.
[0080] Solvent treatment heater and pump 340 can include one or
more heaters, pumps, valves, chillers, compressors and other
associated components of a solvent treatment apparatus such as 234.
Although exemplary systems for heater and pump control are
described herein, additional systems for individual or group
control of valves, chillers, compressors or other components can
also or alternatively be provided.
[0081] Hydrogenator heater and pump 342 can include one or more
heaters, pumps, valves, chillers, compressors and other associated
components of a synthetic separator apparatus such as hydrogenator
272. Although exemplary systems for heater and pump control are
described herein, additional systems for individual or group
control of valves, chillers, compressors or other components can
also or alternatively be provided.
[0082] FIG. 4 is a diagram of a distillation column 400 in
accordance with an exemplary embodiment of the present disclosure.
Distillation column 400 can be used for separation of components
with a boiling point of greater than 1200.degree. F. at atmospheric
pressure, such as in step 3 of systems 100 or 200, or for other
suitable purposes.
[0083] Distillation column 400 includes feed in 420, which provides
a suitable feedstock to vessel 424. Distillation occurs in vessel
424 for components having a normal boiling point of 1200.degree. F.
or greater at atmospheric pressure, but the operating temperature
of vessel 424 can be reduced by vacuum 422, which decreases the
ambient pressure within vessel 424 to reduce the effective boiling
point, and to prevent cracking and fouling of the feedstock and for
other suitable purposes. In order to remove asphalt and other
remnants from the residue in this stage of the process, pump 404
can be used to extract the residue, and asphalt flux 418 is
extracted from the residue before the liquid portion of the residue
is circulated through heater 402 by pump 404 and inserted back into
feed input 420 or alternate input 426.
[0084] As the distillate rises through the first vertical section
of vessel 424, it is sprayed with condensed distillate through
sprayer 424 and condenses on chevrons 416 in a horizontal section
of vessel 424. A second sprayer 414 is used to further recover
distillate, which collects at the bottom of the second vertical
section of vessel 424, where it is pumped out by pump 406, cooled
through cooler 408 and removed through distillate out line 410. A
portion of the cooled distillate is fed back into vessel 424
through sprayers 412 and 414, as described above.
[0085] In operation, distillation column 400 allows components
having a boiling point of 1200.degree. F. or greater at atmospheric
pressure to be removed without cracking or fouling at a lower
absolute temperature, by drawing a vacuum and using additional
processing to reduce the operating pressure within vessel 424.
[0086] It should be emphasized that the above-described embodiments
are merely examples of possible implementations. Many variations
and modifications may be made to the above-described embodiments
without departing from the principles of the present disclosure.
All such modifications and variations are intended to be included
herein within the scope of this disclosure and protected by the
following claims.
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