1. Presentation for
Hill Cooperation
Almaty, Kazhazstan
09.10.2013
Plasma Tube Reactor PTR 20.000
From Benjamin Richters, Fluid Solutions – Norderstedt
Head of Oil Recycling Department
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2. Content
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Fluid Solutions – Oil Recycling Solutions
Why Oil Recycling?
Why Plasma Tube Reactor?
The Oil Recycling Process
Plasma Tube Reactor PTR 20.000
3D Plant Plot Plan
Return of Investment Calculation
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3. Technology from the leading Recycler from Germany
for a new leading Recycler in this world
powered by Fluid Solutions
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4. Milestones of ORS today
In the year 1866, Z+G - Zeller & Gmelin Eislingen was founded
They are in chemical, UV ink, lubricant and grease business in Germany in leading position
The 100% daughter company from Z+G, Südöl started in 1932 the recycling refinery
Today, Südöl re-refines more than 120.000 tons/year of waste oil (automotive and industrial)
Since they installed the first Plasma Tube Reactor in 1999,Südöl is in leading position
Quality, capacity and flexibility is brilliant and makes Südöl very profitable
In 15 years of running this new plant ,now the status of process optimisation is very high
The understanding of the potential of this technology was growing every year
In 2008, Südöl and Fluid Solutions decided to go into the market with this technology
ORS Oil Recycling Solutions Hamburg was founded together
The Engineering R&D team has 4 engineers from Südöl and 4 from Fluid Solutions
Rolf Schneider and Michael Krapalis are the General Managers of ORS
Fluid Solutions handle successful lube oil, grease, resin, chemical project up to 20 Mio. €
Since that time, 4 ORS projects are in process (Dubai, Abu Dhabi, Kuwait, Germany)
The future and potential of ORS Technology worldwide is brilliant
Result: the synergy of Südöl and Fluid Solutions provides our clients the most efficient oil
recycling technology on the market
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5. Latest references of Fluid Solutions:
• BASF turn key coating plant in China
2,0 Mio. $
• DuPont turn key paint plant in Germany
3,5 Mio. $
• Tesa turn key synthetic resin process plant
17,5 Mio. $
• Hüttenes Albertus turn key synthetic resin process plant
14,3 Mio. $
• Fuchs Russia turn key Lube oil blending plant
15,0 Mio.$
• Fuchs Brazil turn key Lube oil blending plant
12,0 Mio. $
• Fuchs Germany turn key grease plant
5,0 Mio. $
• DÖL turn key Lube oil blending plant
19,5 Mio. $
• BP turn key Lube oil blending plant
3,6 Mio. $
• Akzo Nobel turn key paint plant in Germany
3,4 Mio. $
• DSM turn key synthetic resin process plant
8,0 Mio. $
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6. Perfect synergy of partners for your success
JK Holding
Mother Company
Employee: 1.200
Founded: 1959
Turnover: 250 Mio. €
Head office: Köln
Z+G Holding
Mother Company
Employee: 2.500
Founded: 1866
Turnover: 185 Mio. €
Head office: Eislingen
Fluid Solutions
General Contractor
Engineering Company
EPC Contractor
GM: Michael Krapalis
Südöl Recycling
Waste Oil Recycling
Refinery Plant
Reference Plant R&D
GM: Rolf Schneider
40%
60%
ORS Oil Recycling Solutions
Plasma Reactor Technology for
Waste Oil Recycling
Licence company
GM: Rolf Schneider
and Michael Krapalis
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7. Reference plant in Germany
100.000 to waste oil recycling per year
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8. Südöl Re-Refinig factory from helicopter view
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13. Scope of Services:
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Study for a preliminary concept
Basic Engineering of a waste oil recycling plant
Detailed Engineering of a waste oil recycling plant
Complete engineering of a oil blending plant
Adoption of engineering documents in accordance to local
regulations
Project management
Procurement
Construction of the plant with partner companies
Installation and start up
Optimization of the process
Documentation
Service contract including the laboratory work
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14. Content
1.
2.
3.
4.
5.
6.
7.
Fluid Solutions – Oil Recycling Solutions
Why Oil Recycling?
Why Plasma Tube Reactor?
The Oil Recycling Process
Plasma Tube Reactor PTR 15.000
3D Plant Plot Plan
Return of Investment Calculation
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15. Why Oil Recycling?
Re-refining offers an improved envi-ronmental profile
than the original refining process in terms of
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resource con-sumption,
global warming,
acidification,
nitrification,
carcinogenic risk and fine particulates production
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16. Why Oil Recycling?
Recource Conservating Hierarchy
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17. State of the Art
Oil Quality
• Sulfuric Acid
Pro/Contra
Bad
Simple Procedure
Many Plants, mainly China
Dangerous Material
•Thin Layer Evaporation
Some Plants, mostly Germany
Medium
Danger of scab formation
After treatment required
•Precipitation by Propane
Some Plants, mainly Italy
Medium
High Explosion Risk
Investment high
•Hydration
Growing Number, mainly USA
very light
Very Expensive in Operation
and Investment
expensive additives are lost
High Explosion Risk
•Evaporation Procedures
Some Plants, mainly Spain
Moderate
Sensitive Against Variations
in Composition
•Plasma Tube Reactor
2 Plants in Germany + Saudi-Arabia
Good
Low Operating Costs
Reliable robust construction
Low investment cost

18. Content
1.
2.
3.
4.
5.
6.
7.
Fluid Solutions – Oil Recycling Solutions
Why Oil Recycling?
Why Plasma Tube Reactor?
The Oil Recycling Process
Plasma Tube Reactor PTR 15.000
3D Plant Plot Plan
Return of Investment Calculation
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19. Why Plasma Tube Reactor Technology
Reactor
Tubular tubes of structural steel of 10 to 2000 m
length with a diameter of 5 to 500 mm,
heated up to 340 to 420 °C to reach kinetic
plasma conditions in a rapidly flowing
gaseous petroleum product
Safety
Due to small reactor volume of 20 to 50 liters
and continuous operation very low risk for fire
or explosion
Flexibility
Very short time for changing conditions in
case of varying product properties
Operating
Fully automated process control system, to
ensure simple operating and repetitious
accuracy
Energy
Current consumption for 1 ton dry oil: 43 kWh
Heating oil demand for 1 ton dry oil: 50 kg
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20. Content
1.
2.
3.
4.
5.
6.
7.
Fluid Solutions – Oil Recycling Solutions
Why Oil Recycling?
Why Plasma Tube Reactor?
The Oil Recycling Process
Plasma Tube Reactor PTR 20.000
3D Plant Plot Plan
Return of Investment Calculation
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21. ORS Oil Recycling Process
What is the key of the process?
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The Plasma-Tube-Reactor creates the best possible and fast evaporation
380 grad Celsius plus10 mbar vacuum and speed of sound
Highest reactivity in the atmosphere of the reactor with extreme high friction
Na+ and K+ as reacting catalytic for finishing the cleaning process
This process is absolute robust and stabile in daily operation
Relative low investment budget for this type of plant
Outcome of base oil is very high
Process cost are very low
Material balance on the next pages:
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22. Total Process „Basestock“ with Plasma Tube Reactor
100 % Feed Used Oil
ca. 90 % Used Oil
+ ca. 5 % Water
+ ca. 1 % Light Oil (Fuels)
+ ca. 2 % Gasoil
+ ca. 1 % Esters
+ ca. 1 % Unvaporables
Dehydration
Prevaporization
Alkaline Base
+ ca. 1,7%
Plasma Tube
Reactor
5 % Water
1 % Light Oil (Fumes)
2 % Gasoil
ca. 51,0 % Lubeoil 1
ca. 37,9 % Lubeoil 2
Bleaching Clay
ca. +2,08 %
4,8 % Residue
+0,7% Sulfuric Acid 96%
Settler
Acid Tar
ca. 1,4%
Agitator
Vaporisator
Rectification
Spindleoil 2
ca. 5,64%
Spindleoil 1
ca. 24%
Bleaching Clay
Niagarafilter
Used Clay
ca. 3,94%
Agitator
Oil Fumes + Water
Filterpress
Used Clay
Blow Vessel
Base Stock
ca. 56,7%
Air
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23. ORS Oil Recycling Process
Functional Process Diagram PTR 20.000
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24. Used Oil Recycling Plant
P&I-Diagram
Top View
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25. ORS Oil Recycling Process
Process Flow Diagram PTR 2000
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26. The ORS Oil Recycling Process
Used oil is processed using a combination of different
procedures of thermal process engineering:
• Dehydration
• Evaporation
• Total Distillation (Plasma Tube Reactor)
• Decoloration
• Rectification
• Filtration
• Oil blending to final products
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27. Dehydration
100 % Feed Used Oil
ca. 90 % Used Oil
+ ca. 5 % Water
+ ca. 1 % Light Oil (Fuels)
+ ca. 2 % Gasoil
+ ca. 1 % Esters
+ ca. 1% Unvaporables
Dehydration
5 % Water
1 % Light Oil (Fumes)
90 % Used Oil
2 % Gasoil
1 % Esters
1% Unvaporables
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28. The ORS Oil Recycling Process
Used oil is processed using a combination of different
procedures of thermal process engineering:
• Dehydration
• Evaporation
• Total Distillation (Plasma Tube Reactor)
• Decoloration
• Rectification
• Filtration
• Oil blending to final products
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29. Evaporation
Feed
90 % Used Oil
+ ca. 2 % Gasoil
+ ca. 1 % Esters
+ ca. 1% Unvaporables
Prevaporization
2 % Gasoil
90 % Dryoil
1 % Ester
1% Unvaporables
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30. The ORS Oil Recycling Process
Used oil is processed using a combination of different
procedures of thermal process engineering:
• Dehydration
• Evaporation
• Plasma Tube Reactor
• Decoloration
• Rectification
• Filtration
• Oil blending to final products
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31. Plasma Tube Reactor
Total Evaporation / Distillation
Feed
90 % Dryoil
+ ca. 1 % Esters
+ ca. 1 % Unvaporables
Alkaline Base 1,7%
Plasma Tube
Reactor
ca. 51,0 % Lubeoil 1
ca. 37,9 % Lubeoil 2
4,8 % Residue (Bottom Product)
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32. Plasma Tube Reactor
P&ID Plasma Tube Reactor
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33. Plasma Tube Reactor
P&ID Seperator
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34. Plasma Tube Reactor
P&ID Distillation
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35. The ORS Oil Recycling Process
Used oil is processed using a combination of different
procedures of thermal process engineering:
• Dehydration
• Evaporation
• Plasma Tube Reactor
• Decoloration
• Rectification
• Filtration
• Oil blending to final products
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36. Decolorization and Rectification
Feed
Lubeoil 1 and 2 in Mixture
+ 0,7% Sulfuric Acid 96%
Settler
Bleaching Clay +2,08%
Agitator
Acid Tar ca.1,4%
Vaporisator
Rectification
Basestock-Clay-Mix
ca. 58,78%
Spindleoil 2
ca. 5,64%
Spindleoil 1
ca. 24%
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37. The ORS Oil Recycling Process
Used oil is processed using a combination of different
procedures of thermal process engineering:
• Dehydration
• Evaporation
• Plasma Tube Reactor
• Decoloration
• Rectification
• Filtration
• Oil blending to final products
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38. Filtration and Finishing
Feed
Basestock-Clay-Mix
Niagarafilter
Used Clay
ca. 3,94%
Bleaching Clay
Agitator
Oil Fumes + Water
Filterpress
Used Clay
Blow Vessel
Air
Base Stock
ca. 56,7%
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39. Summary of Raffinate
The following components are separated
• Base oil
• Gas oil
• Spindle oil
• Gasoline
• Waste water
• Asphalt
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40. Content
1.
2.
3.
4.
5.
6.
7.
Fluid Solutions – Oil Recycling Solutions
Why Oil Recycling?
Why Plasma Tube Reactor?
The Oil Recycling Process
Plasma Tube Reactor PTR 20.000
3D Plant Plot Plan
Return of Investment Calculation
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41. Fluid Solutions Plasma Tube Reactor
Fluid Solutions Plasma Tube Reactor
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Fitted for ISO 668 container
High grade of pre-fabrication and testing
Cost effective transportation and installation
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42. Fluid Solutions Plasma Tube Reactor
All tubes are equiped with high
performance pipe fins, to ensure
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optimal heat transfer characteristic
longer operation lifetime
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43. Content
1.
2.
3.
4.
5.
6.
7.
Fluid Solutions – Oil Recycling Solutions
Why Oil Recycling?
Why Plasma Tube Reactor?
The Oil Recycling Process
Plasma Tube Reactor PTR 20.000
3D Plant Plot Plan
Return of Investment Calculation
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44. 3D-Plot Plan
of typical Oil Recycling Plant
Landscape 13.000 m² example with 130x100m
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45. 3D-Plot Plan
of typical Oil Recycling Plant
ISO View
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46. 3D-Plot Plan
of typical Oil Recycling Plant
Top View
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47. 3D-Plot Plan
of typical Oil Recycling Plant
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