Regan Brown
With the price of crude oil uncertain and the high cost of fuel, many are looking for alternative fuel sources. Used motor oil can be recycled and distilled into diesel fuel, which can be used in diesel generators, trucks, ships, fishing boats, and heavy machinery. The process of distilling used motor oil into diesel fuel involves several steps, including filtering out contaminants, heating the oil, distillation, and condensation. It is important to have the proper equipment and to prioritize safety when attempting to distill used motor oil into diesel fuel.
Characteristics and Values of Distilling Used Motor Oil for Diesel Fuel
| Characteristics | Values |
|---|---|
| Used motor oil type | Mineral oil, obtained by vacuum distillation of heavy fractions of petroleum |
| Water content | Influences oil yield; water percentage should be less than 5% for raw material recovery of more than 90% |
| Heating temperature | 248°F to remove water; 350-450°F for diesel fractions; higher temperatures up to 600°F for lower-quality diesel |
| Heating system | Heat transfer oil, fuel heating system, standard boiler steel |
| Distillation process | Removes water and separates low-boiling fuel oils such as gasoline and diesel |
| Gasoline distillation temperature | 180°C |
| Diesel distillation temperature range | 180 to 360°C |
| Diesel yield | 80%-85%, can reach up to 90% with certain methods |
| Residual material | Bituminous or asphalt, can be used for paving or sold for further refining |
| Catalysts | Used to remove colloid, wax, and other impurities; multiple catalysts are used in sequence for different purposes |
| Safety | Requires safe handling practices and proper equipment, including safety gear |
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What You'll Learn
Remove water and other solids from the used motor oil
Water is one of the most devastating contaminants in motor oil. The presence of water mixing in the lube oil can cause corrosion, which can incur costly damage to equipment and shorten its working life dramatically. Therefore, it is important to remove water and other solids from used motor oil before distillation.
One method to remove water from lube oil is coalescence, which involves joining water droplets to form a pool of water that can then be removed. Coalescing filters function best with low-viscosity fluids, and they have no solids-handling ability. The other common method is to use a centrifugal separator, which can remove both emulsified and free water, as well as solids. Centrifuges are relatively expensive, but they are also a means of removing other heavier contaminants and have a comparatively high throughput compared to other technologies. The downside of centrifuges is that only emulsified and free water will be removed.
Another method to remove water from oil is the vacuum dehydration process, which lowers the partial pressure, allowing water to boil at a much lower temperature. By heating the oil to 150°F to 160°F, water is vaporized inside the dehydrator without causing excessive oil degradation. Vacuum dehydrators can remove 80-90% of dissolved water, but they are costly and have a comparatively low flow rate.
In the distillation process, the used motor oil is boiled and gasified, and the impurities in the waste oil settle during the heating process. The oil gas then enters the condensation system after being catalyzed by the catalyst. The reactants in the catalytic tower can remove the colloid and wax in the oil gas generated by the used motor oil, and the oil will become clearer after degumming and dewaxing.
A disc-stack centrifuge can also be used to remove fine metal and carbon particles from used motor oil. Under the force of a centrifuge, the heavier metal particles are pushed outward, and the ash particles flocculate to form bigger solids that separate under the high g-force. Oil centrifuges can also separate the water phase from the used oil while simultaneously removing any solid contaminants.
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Heat the oil to 248°F to 250°C
Heating the oil is a crucial step in the process of distilling used motor oil into diesel fuel. The ideal temperature range for this process is 248°F to 250°C (approximately 480°F to 482°F). This temperature range is essential for effectively converting the used motor oil into a usable diesel fuel product.
Firstly, it is important to start with the cleanest used oil possible. This involves pre-filtering the oil through fine mesh screens to remove any large contaminants, such as dirt, metal, or water. By removing these impurities, the distillation process will be more efficient and produce a higher-quality diesel fuel.
Once the oil has been adequately filtered, it can be transferred to the distillation apparatus, which can be a purpose-built fuel processor, a still, or an improvised setup. This distillation equipment will heat the oil and facilitate the separation of the different fuel fractions based on their boiling points.
As the oil is heated to the target temperature range of 248°F to 250°C, it undergoes a process called pyrolysis, where the oil is broken down into smaller molecules. This high temperature causes the oil to vaporize and turn into oil gas. The specific boiling point range for diesel fuel is between 350°F and 450°F.
During the heating process, it is crucial to monitor the temperature closely to ensure that it remains within the target range. Adjustments may need to be made to maintain the desired temperature. Additionally, the heating should be stopped once residue accumulates, and the diesel flow slows, indicating that the distillation process is complete.
The resulting vapors from the heated oil rise and enter a condensing coil or a similar cooling system, where they are cooled and condensed back into a liquid state, yielding the desired diesel fuel product. This process effectively separates the diesel fuel from the water, as the fuel floats on top of the water, making it easier to remove and collect.
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Gasify the oil
Gasifying the oil is a crucial step in the process of distilling used motor oil to create diesel fuel. This process involves heating the used motor oil to high temperatures, causing it to boil and turn into a gas. Here is a detailed guide on how to gasify used motor oil:
Preparation
Firstly, collect the used motor oil and filter it through fine mesh screens to remove any large contaminants, such as dirt, metal, or water. It is important to start with the cleanest oil possible, as this will improve the final diesel fuel's quality.
Heating the Oil
The filtered oil is then heated to 100°F (37.8°C), and activated charcoal is mixed in. The oil is heated using a heating system, such as a boiler, to a temperature of around 250°C. This temperature can vary depending on the specific process and equipment used, with some sources suggesting heating to 248°F (120°C) or even up to 752°F (400°C). The heating process causes the oil to boil and vaporize, turning it into a gas.
Catalytic Process
During the heating process, impurities in the oil will continue to settle. The oil gas then enters a catalytic tower or undergoes a catalytic process. This step involves the use of catalysts, such as catalyst A and catalyst B, which react with the oil gas to remove colloids, wax, and other asphaltic impurities. This process is known as degumming and dewaxing, and it helps to clarify and purify the oil.
Condensation
After the catalytic process, the oil gas enters a condensation system or coil. Here, the hot oil vapors cool down and condense back into a liquid state, separating into distinct fuel fractions based on their boiling points. Diesel fuel has a higher boiling point than gasoline, typically ranging from 350-450°F (176-232°C). The condensed diesel fuel is then collected in a receiver tank, separate from the gasoline and other residues.
Further Distillation
To further purify the diesel fuel, it can be distilled again at higher temperatures, typically above 450°F (232°C). This step helps to remove any remaining impurities and improve the overall quality of the diesel fuel. The distillation process may be repeated multiple times to achieve the desired level of purity and combustion.
It is important to note that distilling used motor oil requires proper equipment, safety gear, and safe handling practices. The temperatures involved are extremely high, and the process can be dangerous if not performed correctly.
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Cool the vapours to condense them into diesel
The process of distilling diesel fuel from used motor oil is called pyrolysis, a thermal decomposition process that breaks down organic matter in the absence of oxygen. After the used motor oil has been heated and boiled in the pyrolysis reactor, it must be cooled to condense the vapours into diesel fuel. This is done using a condenser or a cooling system.
The condenser cools the products of the pyrolysis process, causing them to condense into liquids. This step is crucial for converting the vapours into diesel fuel. The cooling system will cool the diesel oil gas into diesel. Circulating water can be used to cool the steamed oil gas, and the cooling water can be cleaned and recycled without causing waste.
The safety precautions are essential when producing diesel fuel from used motor oil. The pyrolysis process can be dangerous if not done properly, as the products can be flammable and toxic. It is important to always wear personal protective equipment (PPE), including gloves, goggles, a respirator, and a fireproof apron, and to work in a well-ventilated area.
Once the vapours have been cooled and condensed, the diesel fuel must be separated from the other products of the pyrolysis process. This can be done using a separator. The final diesel product can be used in diesel generators, trucks, ships, fishing boats, heavy machinery, and boilers. It has a wide range of applications and a great sales market.
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Add motor oil additives to improve fuel properties
Motor oil additives are used to improve the oil's cold-flow ability, protect seals, and increase viscosity stability. They can also help reduce friction and maximise fuel efficiency.
Friction modifiers are one such additive that helps reduce friction and improve fuel efficiency. Pour-point depressants are another type of additive that helps lubricants flow at lower temperatures and deliver better wear protection during startup. They modify wax formation to help lubricants flow more smoothly at lower temperatures.
Seal-swell agents are yet another type of additive that helps prevent leaks by swelling elastomeric seals. Viscosity modifiers, as the name suggests, help reduce the rate of viscosity change when temperatures rise or fall. This helps the lubricant perform better over a broader temperature range.
Motor oil additives can also be classified as "protective" additives, which enhance the lubricant's protective properties. Engine parts or gears churning can mix air into the oil, resulting in foam. Anti-foamants, or defoamers, are additives that reduce the surface tension of foam bubbles and speed up their collapse. This prevents foam from gurgling out of the dipstick tube.
Oxidation increases the rate at which a lubricant breaks down, so antioxidants are added to slow this process and extend lubricant life. Metal deactivators are also used to slow oxidation by reducing the catalytic effect of metals.
Aftermarket oil additives are available off-the-shelf and promise to increase fuel economy, reduce wear, or restore an old engine. However, these additives may disrupt the oil's chemistry and reduce its ability to protect the engine. It is generally recommended to avoid mixing lubricants and using aftermarket additives. Instead, it is suggested to use a good synthetic oil that offers improved wear protection, reduced oil consumption, and maximum fuel economy.
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Frequently asked questions
You will need a distillation apparatus, a condenser, a receiver tank, tubing and fittings, and a heating element.
First, filter the oil through fine mesh screens to remove dirt, metal, or water. Next, heat the oil to 100°F and mix in activated charcoal. Re-filter the oil after a few hours to improve purity. Test a sample of the filtered oil to check viscosity, clarity, and combustibility. Transfer the prepared oil into the distillation apparatus tank or pot. Gradually heat the oil to 350-450°F. Adjust the heating to maintain the target distillation temperature. Stop heating when residue accumulates and diesel flow slows.
It is important to emphasize safety and proper handling when reclaiming and repurposing waste oils. Ensure that you have the proper equipment and a safe heating and distillation system in place. Only use clean, thin, combustible oil for diesel production.
