Method for producing base oil from waste oil, and the generation of microspheres and organic or mineral salts from the produced waste

Abstract

In this invention, a method for the production of base oil from waste oil is elucidated, comprising the following stages: (a) The substantial removal of pollutants and asphalts from waste oil using a precipitating agent and an accelerant agent for precipitation, utilizing a solvent or without using a solvent. (b) The removal and recovery of the solvent and other low-boiling-point compounds. (c) The elimination of remaining pollutants in the base oil through an acidic agent. (d) Enhancement of color and acidity of the produced base oil. (e) Optionally, use the hydrogenation process. Moreover, in this invention, valuable materials such as microspheres and organic or mineral salts are produced from the wastes generated in the aforementioned stages. Which is produced through the mixing of the generated waste in the stages of producing base oil from waste oil, under appropriate conditions, and, through several processes, the resulting products are purified.

Description

METHOD FOR PRODUCING BASE OIL FROM WASTE OIL, AND THE GENERATION OF MICROSPHERES AND ORGANIC OR MINERAL SALTS FROM THE PRODUCED WASTE

[0001] This invention is generally focused on the production of base oil from waste oil, incorporating industrial and practical methods for removing pollutants from waste oil. It facilitates the high-quality reutilization of waste oil to produce base oil, which can be further utilized in related industries. Additionally, it involves a method for producing microspheres and organic or mineral salts using the waste generated from the processes of recovering base oil.

[0002] Specifically, this invention not only enhances the efficiency of base oil production from waste oil but also generates valuable materials from the resulting waste. Moreover, it is an environmentally friendly method.

[0003] In today's world, with the advent of various industries and mass automobile production, a significant volume of used lubricant oil is generated annually from engines and other sources. The disposal of this oil into the environment poses irreparable damage to ecosystems due to pollutants, heavy metals, reactive substances, and oxidation byproducts. Some countries utilize waste oils as a fuel source, but burning them introduces hazardous pollutants into the environment. Additionally, the limited petroleum resources pose challenges to the production of these oil derivatives.

[0004] In the past, waste oils, as exemplified in patent US5514272, were recycled using acid-based methods. However, these methods, while cost-effective, produce large quantities of hazardous acidic sludges, and their disposal into nature causes irreversible environmental damage. Consequently, while still practiced in some developing nations, this method has become obsolete in many developed countries.

[0005] Alternative methods for waste oil recycling have been proposed, such as the separation of asphalts, additives, and product decomposition from base oil through vacuum distillation. For example, it is described in detail in the patent WO94 / 07798.

[0006] Other methods similar to EP3078730A1 have been introduced, including asphalt and other impurity removal in a vacuum and thin-film evaporation. In some other methods, such as US4233140, asphalts and impurities are separated from waste oil through solvent extraction, followed by vacuum and hydro-finishing processes to produce base oil, and in patent US6712954, methods involving distillation, thin-film evaporation, and solvent extraction were employed to produce base oil from waste oils.

[0007] Considering that the mentioned inventions are efficient, yet due to the high operational costs and efficiency challenges of catalytic hydrogenation processes, as well as the drawbacks of vacuum distillation and solvent extraction in the aforementioned methods, many related companies face considerable challenges. Moreover, the waste generated from the waste oil recovery process presents disposal challenges and environmental issues.

[0008] In many prior inventions (US10066171B2,US11873463B2), polar organic compounds, such as N-methyl-2-pyrrolidone (NMP), have been utilized as extraction solvent, and their preparation and production pose challenges and are cost-intensive in numerous countries. In this invention, polar organic compounds have been employed as one of the constituents forming the precipitating agent, with its consumption rate significantly lower than methods utilizing NMP as an extraction solvent. Consequently, its consumption rate is significantly lower compared to NMP, which has been utilized as an extraction solvent. Additionally, this invention introduces the possibility of using other polar organic compounds that are abundantly accessible and cost-effective. It is noteworthy that the polar organic compounds employed in this invention possess the capability of recovery and reuse.

[0009] This invention has the capability to conduct the processes for producing base oil from waste oil both with and without the use of a solvent. However, the utilization of a solvent significantly impacts the speed, efficiency, and quality of the base oil production process from waste oil. The solvent used may encompass a broad spectrum of non-polar organic solvents that are easily accessible.

[0010] In the present invention, by facilitating the processes of removing pollutants and asphalts from waste oil at room temperature and atmospheric pressure, the production process of base oil from waste oil is conducted with high efficiency and quality. Additionally, the presented processes contribute to the reduction of operational and capital costs.

[0011] As mentioned, in some methods, a significant portion of asphalts and pollutants is removed from waste oil using various suitable solvents, and these processes take place at specific temperatures and pressures. However, in the present invention, a precipitating agent is introduced and produced, which can be utilized both in the presence and absence of a solvent, and a substantial portion of ashphalts and pollutants is removed from waste oil. On the other hand, a compound or a combination of compounds are introduced and produced as accelerant agents for precipitation which in addition to increasing the rate of asphalts and pollutants separation from waste oil, enhance the efficiency of base oil extraction from waste oil. By employing suitable precipitating and accelerant agents, the separation of asphalts and pollutants can be achieved at room temperature and atmospheric pressure.

[0012] In some inventions, the execution of the hydrogenation process is a mandatory step, which, in itself, is a costly process. However, the present invention is capable of producing high-quality base oil without undergoing the hydrogenation process. Nevertheless, the hydrogenation process can be optionally employed to further enhance the quality of the base oil if desired.

[0013] In the mentioned inventions and other related innovations, during the process of producing base oil from waste oil, pollutants and wastes are generated, posing an environmental challenge in the removal of these compounds. In the present invention, the possibility is provided not only to eliminate the production of harmful pollutants and waste but also to utilize them for the production of valuable materials such as microspheres and salts (organic or mineral), which find numerous applications in various industries. Overall, in this invention, base oil is produced from waste oil, contributing to environmental preservation and yielding unique compounds with versatile applications.

[0014] In the present invention, in addition to the mentioned processes, it is possible to extract the remaining oil in acidic sludges or alkaline asphalts after the production of microspheres and salts. Subsequently, it is feasible to produce base oil from these sources, minimizing the loss of waste oil.

[0015] In the current invention, stages have been presented for the production of base oil from waste oil, each with several preferred embodiments. Depending on economic conditions, environmental factors, or other relevant conditions, suitable embodiments from different stages can be selected, allowing the execution of the process. Another reason for the existence of various embodiments is the production of base oil in different processes. For instance, base oil can be produced in continuous or non-continuous processes, and the processes can be carried out in the presence or absence of a solvent.

[0016] For a better understanding of various embodiments of the present invention, the following diagrams are provided:

[0017] is a schematic diagram of one of the preferred embodiments of stage (a).

[0018] is a schematic diagram of another preferred embodiment of stage (a).

[0019] is a schematic diagram of another preferred embodiment of stage (a).

[0020] is a schematic diagram of one of the preferred embodiments of stage (b).

[0021] is a schematic diagram of another preferred embodiment of stage (b).

[0022] is a schematic diagram of another preferred embodiment of stage (b).

[0023] is a schematic diagram of one of the preferred embodiments of stages (c) and (d).

[0024] is a schematic diagram of another preferred embodiment of stages (c) and (d).

[0025] is a schematic diagram of one of the preferred embodiments of stage (e).

[0026] is a schematic diagram of another preferred embodiment of stage (e).

[0027] is a schematic diagram of one of the general processes for producing base oil from waste oil.

[0028] is a schematic diagram of one of the general processes for producing base oil from waste oil.

[0029] is a schematic general diagram of the process for producing microspheres and organic or mineral salts, along with purification and extraction processes for the remaining oil in the wastes produced in the previous processes.

[0030] is an image of microspheres captured using scanning electron microscope.

[0031] is an image of microspheres captured using scanning electron microscope.

[0032] is an image of microspheres captured using scanning electron microscope.

[0033] is an image of microspheres captured using scanning electron microscope.

[0034] In the present invention, high-quality base oil is produced from waste oil, while generating valuable materials such as microspheres, organic or mineral salts from the byproducts of the oil production process; and the residual oil in the waste is then extracted and recovered.

[0035] Within the context of the invention, the term "waste oil" generally refers to lubricants that have been used in industries, engines, or cars and have lost their functionality.

[0036] Within the context of the invention, the term "precipitating agent" is used to refer to compounds or compositions that cause the coagulation and precipitation of contaminants or asphalts from waste oils. The precipitating agent is formed from the reaction of several other compounds, and it exhibits suitable chemical properties for the precipitation of pollutants and asphalts.

[0037] Within the context of the invention, the term "accelerating agent or accelerant" refers to compounds or compositions that enhance the rate of precipitation and reduce the volume of precipitations resulting from contaminants and asphalts present in waste oils. As a result, it leads to an improvement in the quality and yield of the base oil produced from waste oils.

[0038] Within the context of the invention, the precipitating and accelerant agents involved in the precipitation of pollutants and asphalts are different from the solvents used, allowing for the maximum separation of asphalts and pollutants from waste oil. These compounds can be utilized both in the presence and absence of a solvent.

[0039] Within the context of the invention, the term "asphalt" refers to heavy materials encompassing polymers, heavy hydrocarbons, and other pollutants present in waste oil. It is considered one of the main components of pollutants in waste oil.

[0040] Within the context of the invention, the term "compounds containing asphalt-free oil" refers to compounds or compositions in which asphalts and their contaminants have been predominantly separated from waste oils.

[0041] Within the context of the invention, the term "continuous systems" refers to systems in which a final product is produced at the end of the process for the input materials provided at the beginning of the production process, and the system's operation continues in a continuous flow. In contrast, the term "non-continuous systems" is used to describe systems where input materials are introduced all at once into the process, progress through various stages, and ultimately result in the production of the product.

[0042] Within the context of the invention, the term "solvent" refers to non-polar organic liquid compounds that are used in various stages of a process.

[0043] Within the context of the invention, the term "neutralization" refers to a process in which the acidity of base oil or oil-containing compounds is neutralized from an acidic or basic state using one or more neutralizing agents, converting it into an inert or neutral state.

[0044] Within the context of the invention, the term "bleaching" refers to a process in which one or more bleaching agents are used to adsorb contaminants from base oil or oil-containing compounds, improving the color of base oil or oil-containing compounds.

[0045] Within the context of the invention, the term "microsphere" refers to simple spherical particles, hollow, granular, porous or non-porous spherical particles with sizes ranging from 0.001 to 1000 micrometers.

[0046] Within the context of the invention, the term "separator systems" refers to systems that play a significant role in separating acidic sludges, asphalts, bleaching and neutralizing agents, microspheres, salts, polar compounds, or other solid particles from liquid compounds. These systems encompass methods such as precipitation, centrifugation, filtration, or combinations thereof.

[0047] Within the context of the invention, the recovered compounds in various stages of the present invention have the potential for reuse in the invention.

[0048] In general, a method for producing base oil from waste oil consists of the following stages:a) optional removal of volatile compounds from waste oil; coagulation of pollutants or asphalts from waste oil at the appropriate temperature and pressure using a precipitating agent; utilization of an accelerant agent in the precipitation of pollutants and asphalts; separation of pollutants or asphalts from oil-containing compounds using one or more separation systems; if necessary, the use of one or more neutralizing agents; execution of the processes in this stage can be carried out with or without the use of a solvent;b) removal and recovery of the solvent if used in stage (a); removal and recovery of water, polar organic compounds, light hydrocarbons, and if necessary, the separation of different fractions of base oil at the appropriate temperature and pressure, or obtaining a suitable fraction of base oil; if necessary, the removal of salts and residual solid compounds from oil-containing compounds;c) removal of residual pollutants in the oil obtained from the previous stage at the appropriate temperature and pressure using one or more acid agents; elimination of acid sludges through one or more separation systems; execution of the processes in this stage can be carried out with or without the use of a solvent;d) removal and recovery of the solvent if used in stage (c); recovery of color and acidity of the base oil through bleaching and neutralization processes at the appropriate temperature and pressure; optional removal of light compounds from base oil using one or more gas separators; removal of the bleaching and neutralizing compounds used from base oil;e) enhancement of the base oil quality through the utilization of an optional hydrogenation process at suitable temperature and pressure;and all of the mentioned stages can be executed continuously or non-continuously.

[0049] illustrates one of the preferred embodiments of the present invention at stage (a), wherein, the process of removing pollutants and asphalts from waste oil takes place in the presence of a solvent.

[0050] The waste oil is conveyed through line 10 to a heat exchanger or heater 11, and after reaching the appropriate temperature, it is transferred through line 12 to the evaporation vessel 13. In this vessel, the volatile compounds present in the waste oil undergo evaporation and are expelled through line 14. Subsequently, the waste oil is transferred through line 15 to cooler 16 to reduce its temperature. Then, it is introduced into the mixer 18 via line 17.

[0051] The absence of volatile compounds ensures that in subsequent processes, the volatile compounds are not recovered along with the solvent, allowing the recovered solvent to maintain its quality.

[0052] To produce a precipitating agent, alkaline or basic compounds are introduced into the mixer 22 via line 19, polar inorganic liquid compounds (water) are introduced via line 20, and polar organic compounds are introduced via line 21. These components are mixed together within the mixer 22. The resulting product within the mixer 22 serves as a precipitating agent for precipitating pollutants and asphalts from the waste oil. Precipitating compounds are introduced into the mixer 18 via line 23 and thoroughly mixed with the waste oil. Subsequently, the resulting mixture is introduced into the mixer 25 through line 24, where it is effectively blended with precipitation-accelerant agents introduced from line 26. The resulting compounds are transferred to the mixer 28 via line 27, where they are thoroughly mixed with a solvent introduced from line 29. The resulting mixture is then conveyed through line 30 into the separator system 31, where pollutants and asphalts are separated from the mixture containing the solvent and base oil. The separated components are removed from the process through line 32. The mixture containing the solvent and oil is transferred to the next stage through line 33.

[0053] depicts another preferred embodiment of the present invention at stage (a). This embodiment is similar to the previous one, with the distinction that an additional process is introduced, resulting in a reduction of the basic properties of the output product from line 33. This embodiment is optionally performed in specific cases, and is carried out by adding a small amount of an acidic agent to the mixture containing the solvent and oil. Therefore, the mixture containing the solvent and oil is introduced into the mixer 34 via line 33, where it is thoroughly mixed with an acidic agent introduced from line 35. The resulting mixture has lost its basic properties and is then conveyed to the next stage of the process through line 36.

[0054] illustrates another preferred embodiment of the present invention at stage (a), wherein the process of removing pollutants and asphalts from waste oil is carried out without the use of a solvent. In this embodiment, some of the components forming the precipitating agent are mixed separately with the waste oil.

[0055] The waste oil is introduced into the reservoir 100 via line 10, where it is thoroughly mixed using the motor 101, which is connected to the agitator 103 through the intermediary 102. Alkaline or basic compounds are introduced via line 19, and polar inorganic liquid compounds (water) are introduced via line 20 into the mixer 104. Subsequently, the alkaline or basic compounds dissolved in water are introduced into the reservoir 100 via line 105, and are thoroughly mixed with the waste oil. Then, polar organic compounds are introduced into the reservoir 100 via line 21 and are also thoroughly mixed with the waste oil. Subsequently, the precipitation-accelerant agents for pollutants and asphalts are introduced into the reservoir 100 via line 26 and thoroughly mixed with the waste oil. The required duration and the intensity of mixing for each of the added compounds to the waste oil depend on the type of agitator and the speed at which the compounds mix. Subsequently, the mixed compounds are transferred to the separator system 107 via line 106, where pollutants and asphalts are separated from the waste oil. Asphalts and pollutants are then removed from the separator via line 108. Finally, the compounds containing asphalt-free oil are conveyed to the next stage through line 109.

[0056] To reduce the basic or alkaline properties of the asphalt-free oil compounds in the pathway 109, a mixer may be introduced, similar to, wherein, by adding a small amount of acidic agents, the asphalt-free oil compounds can be neutralized.

[0057] In the embodiments of the current invention mentioned in stage (a), one or more agitators are employed for mixing the mentioned compounds, which can include mechanical, magnetic; or a combination of such agitators, and other similar mixing systems. Preferably, a mechanical agitator is used. The agitators mix the compounds together at speeds ranging from 5 to 6000 rpm, preferably within the range of 100 to 1000 rpm. The required duration for the mixing of each of the mentioned compounds with waste oil may fall within the range of 0.01 to 1000 minutes. Preferably, each of the mentioned compounds is mixed with waste oil for a duration within the range of 5 to 20 minutes.

[0058] In the embodiments of the present invention mentioned in stage (a), if theandembodiments are utilized, it is preferable to perform the process continuously. Conversely, if theembodiment is employed, it is preferable to carry out the process non-continuously.

[0059] In all embodiments of the present invention mentioned in stage (a), the product obtained from stage (a) contains base oil along with additives, where a significant portion of asphalts and their pollutants has been removed. This resulting base oil may be used as a low-quality oil in various industries. However, it is recommended to perform the subsequent stages to enhance the quality of the base oil, as well as to remove any remaining pollutants and additives in it.

[0060] In the embodiments of the current invention described in stage (a), before the waste oil enters the processes (not shown in the figures), a separator such as a filter may be used to separate solid contaminants or large solid particles in the waste oil.

[0061] In the embodiments of the current invention described in stage (a), the precipitating agent consists of a polar inorganic liquid containing comprising water, one or more alkaline or basic compounds, and one or more polar organic compounds. Each of the polar inorganic liquid, alkaline or basic compounds, and polar organic compound is mixed together within a range of 0.01% wt to 50% wt, preferably in the range of 1% wt to 5% wt, based on the weight of the waste oil, and these components can be mixed together and then added to the waste oil, or they can be added separately to the waste oil and subsequently mixed. The selection of the precipitating agent and the manner in which it is added to the waste oil depend on the chosen embodiment in stage (a). The precipitating agent may be added into the waste oil using various alternative methods.

[0062] In the embodiments of the current invention described in stage (a), the basic or alkaline compounds include hydroxides, oxides, methoxides, or ethoxides from the first or second group of the periodic table metals, and / or non-alkaline basic compounds such as ammonium hydroxide, or a combination thereof; and / or other compounds exhibiting similar basic properties, are employed. Preferably, sodium hydroxide or potassium hydroxide, or a mixture of both, is the chosen option.

[0063] In the embodiments of the current invention described in stage (a), the polar inorganic liquid comprising water is employed. Preferably, water is blended with alkaline or basic compounds to form a homogeneous solution, which is then combined with polar organic compounds. Subsequently, this mixture is introduced to the waste oil and thoroughly mixed. Alternatively, an aqueous solution containing alkaline or basic compounds can be mixed with the waste oil, followed by the addition of polar organic compounds and thorough mixing.

[0064] In the embodiments of the current invention described in stage (a), the polar organic compounds include alcohols, ethers, esters, ketones, phenols, furfural, N-methyl-2-pyrrolidone (NMP), methyl-ethyl-ketone (MEK), sulfolane, DMSO, dimethylformamide, or combinations thereof; and the alcohols may consist of methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol, octanol, nonanol, decanol, their various isomers, or a combination thereof, and / or similar compounds. Additionally, some water-soluble non-polar organic compounds, such as methylene glycol, ethylene glycol, polyethylene glycol, or a combination thereof, and / or similar compounds, may be employed. Preferably, one or more polar organic compounds, including ethanol, propanol, butanol, or a combination thereof, are used, with their purity falling within the range of 0.01% to 99.99%, and preferably in the range of 70% to 99%.

[0065] In the embodiments of the current invention described in stage (a), a preferred sample of the precipitating agent consists of water within the range of 0.01wt% to 50wt%, preferably within the range of 1% wt to 5% wt, based on the weight of the waste oil. One or more alkaline or basic compounds, including sodium hydroxide, potassium hydroxide, or a combination thereof within the range of 0.01wt% to 50wt%, and preferably within the range of 1% wt to 50% wt, based on the weight of the waste oil. One or more polar organic compounds, such as ethanol, butanol, propanol, or a combination thereof within the range of 0.01wt% to 50wt% and preferably within the range of 1% wt to 5% wt, based on the weight of the waste oil. These components can be mixed together and then added to the waste oil, or they can be added separately to the waste oil and subsequently mixed.

[0066] In the embodiments of the current invention described in stage (a), the accelerant agent for precipitating pollutants and asphalts consists of one or more types of surfactants, including anionic surfactants, non-ionic surfactants, amphoteric surfactants, or a combination thereof. Additionally, it may include an aqueous solution of one or more types of surfactants, including anionic surfactants, non-ionic surfactants, amphoteric surfactants, or a combination thereof, or other surfactants that enhance the rate of precipitation of pollutants or asphalts. The consumption of the accelerant for precipitating pollutants or asphalts falls within the range of 0.01% wt to 50% wt, and preferably within the range of 1% wt to 5% wt, based on the weight of the waste oil.

[0067] In the embodiments of the current invention described in stage (a), the anionic surfactants, non-ionic surfactants or amphoteric surfactants include sulfate surfactants, sulfonate surfactants, phosphate surfactants, carboxylate surfactants, sodium dedecyl sulfate, sodium laureth sulfate, fatty alcohols, alcohol sulfates, ammonium lauryl sulfate, sodium lauroyl sarcosinate, sodium myreth sulfate, sodium pareth sulfate, sodium lauryl sulfate, phosphate esters, alpha olefin sulfonate, ammonium laureth sulfate, betaine, or a combination thereof, and / or other surfactants that enhance the precipitation rate of pollutants or asphalts. Among the mentioned surfactants, some may not be suitable for application due to their effciency, properties, or economic considerations. However, a combination of these surfactants could prove beneficial. For this reason, the preferred surfactants for the mentioned processes are anionic surfactants,

[0068] In the embodiments of the current invention described in stage (a), the aqueous solution contains one or more types of surfactants, and the surfactants content falls within the range of 0.01% wt to 99.99% wt, and preferably within the range of 5% wt to 50% wt based on the total weight of the solution. Some surfactants are in a solid state; therefore, the formation of an aqueous solution of surfactants can be advantageous, potentially having a more significant impact on the efficiency and precipitation rate of asphalts. On the other hand, due to the presence of water, aqueous solutions of surfactants may have a more pronounced effect on the process of increasing precipitation rate.

[0069] In the embodiments of the current invention described in stage (a), a preferred sample of the accelerant agent for the precipitation of pollutants or asphalts comprises an aqueous solution of sodium dodecyl sulfate, and the amount of accelerant agent consumed falls within the range of 0.01wt% to 50wt%, and preferably within the range of 1% wt to 5% wt based on the weight of the waste oil. This solution is added to the waste oil-containing compounds and thoroughly mixed.

[0070] In the embodiments of the current invention described in stage (a), subsequent to the mixing of the precipitating agent with waste oil, the accelerant agent is added, augmenting the precipitation rate and concurrently reducing the volume of precipitated asphalts and pollutants. The precipitating agent induces the coagulation of asphalts, while the accelerant agent promotes an increased rate of precipitation for pollutants or coagulated asphalts. In non-polar organic environments, the type of accelerant agent has a direct influence on the precipitating agent and waste oil asphalts due to its chemical nature, thereby enhancing the precipitation rate.

[0071] In the embodiments of the current invention described in stage (a), if necessary, one or more neutralizing agents may be used to neutralize compounds containing asphalt-free oil with a basic property. The neutralizing agent used at this stage comprises one or more organic or inorganic acids, and the amount added is such that the compounds containing asphalt-free base oil become neutral or have their basic or alkaline properties reduced; these organic or inorganic acid compounds include sulfuric acid, nitric acid, hydrochloric acid, acetic acid, formic acid, or a combination thereof, and / or similar compounds. The use of such neutralizers in this stage is an optional process and may prove beneficial in certain specific cases.

[0072] In the embodiments of the current invention described in stage (a), if the flash point of the waste oil is higher than the boiling point for the solvent used or if the waste oil has low volatility, the initial heating process for evaporating volatile compounds may be omitted. In such cases, the waste oil can be introduced directly into the process at step (a) through line 17.

[0073] In the embodiments of the current invention described in stage (a), the separation process of asphalts or pollutants can be carried out in the presence of a solvent or without using a solvent. To enhance the efficiency and quality of the extracted base oil from the waste oil, it is preferable to use a solvent.

[0074] In the embodiments of the current invention described in stage (a), the temperature in this stage is chosen based on the type of solvent used and may fall within the range of -30°C to +40°C, preferably in the range of +5°C to +25°C.

[0075] In the embodiments of the current invention described in stage (a), for the separation of asphalts and pollutants from waste oil, it is possible to utilize a precipitating agent without the use of an accelerant agent. However, employing an accelerant agent offers significant advantages, including increased precipitation rate and enhanced efficiency in the production of base oil from waste oil.

[0076] In the embodiments of the current invention described in stage (a), by employing suitable precipitating agents, accelerant agents and solvent, the separation of asphalts and pollutants can be achieved at room temperature and atmospheric pressure.

[0077] illustrates one of the preferred embodiments of the present invention at stage (b), where solvents, polar organic compounds, water, and other light hydrocarbons are removed and recovered from the product of stage (a). This process is recommended for non-continuous systems.

[0078] The mixture of solvent and asphalt-free oil is introduced into the vessel 200 through one of the lines 33 or 36. Subsequently, the mixture of solvent and asphalt-free oil is transferred to the pump 202 via line 201 and then conveyed to the heat exchanger 204 through line 203. The temperature in the heat exchanger is raised within the range of the boiling point of the solvent, and then the mixture is returned to the vessel 200 via line 205. The evaporated solvent is transferred to the condenser 207 via line 206. Subsequently, the recovered solvent is conveyed through line 208 – with valve 209 open and valve 210 closed – to line 211, and then introduced into the solvent storage tank 212. The recovered solvent is returned to the process cycle through line 29. In case of a solvent shortage, it can be supplied through line 213.

[0079] After evaporating and recovering the solvent, the temperature is increased using the heat exchanger 204 to vaporize water, polar organic compounds, and other light hydrocarbons from the asphalt-free oil. The heat exchanger raises the temperature to the range of 100°C to 500°C, preferably within the range of 300°C to 360°C. The other evaporated components are transferred to the condenser 207 via line 206, and the recovered products are conveyed to line 214 through line 208 with valve 209 closed and valve 210 open. Subsequently, they are transferred to the phase separation vessel 215.. In the vessel 215, non-polar organic compounds and other light hydrocarbons are positioned in the upper phase and are transferred to the storage tank 217 through line 216. The recovered compounds in tank 217 may be utilized as fuel or for other similar applications.

[0080] Water and polar compounds move to the lower part of the vessel 215 and are transferred to the vessel 219 via line 218. In vessel 219, the temperature is raised to a level where polar organic compounds can be separated from water or other polar compounds. If the polar organic compounds have a lower boiling point than water, they can be separated from water by increasing the temperature to the boiling point range of the polar organic compounds. Therefore, the compounds present in the vessel 219 are transferred to the pump 221 via line 220 and then conveyed to the heat exchanger 223 through line 222. After raising their temperature, they are returned to the vessel 219 via line 224. The evaporated polar organic compounds are transferred to the condenser 226 via line 225, and the recovered compounds are conveyed to the storage tank 228 through line 227. The stored polar organic compounds are then returned to the process cycle through line 21. In case of a shortage of polar organic compounds, they can be supplied through line 229. Water and other polar compounds are removed from the process through line 225. If the boiling point range of the polar organic compounds is higher than that of water, it may be possible to purify the polar organic compounds further by evaporating and separating water, returning them to the process cycle.

[0081] After removing and recovering the solvent, polar organic compounds, water, and other light hydrocarbons from the asphalt-free oil, it is optional to separate solid particles or formed salts from the base oil. For this purpose, one or more separators, such as filtration methods, centrifuges, or a combination of them, or other similar separation systems, can be used. Therefore, the obtained product is transferred through line 231 to the filter 232, and from there, conveyed to the cooler 235 via line 234 to reduce the temperature of the obtained product. Furthermore, impurities are removed through line 233. Subsequently, the oils are moved to the next stage through line 236.

[0082] illustrates one of the preferred embodiments of the present invention at stage (b), where solvents, polar organic compounds, water, and other light hydrocarbons are removed and recovered from the product of stage (a). This process is recommended for continuous systems.

[0083] The mixture of solvent and asphalt-free oil is introduced into the vessel 300 through one of the lines 33 or 36. Subsequently, the mixture of solvent and asphalt-free oil is transferred to the pump 302 via line 301 and then conveyed to the heat exchanger 304 through line 303. The temperature in the heat exchanger is raised within the range of the boiling point of the solvent, and then the mixture is returned to the vessel 300 via line 305.

[0084] The evaporated solvent is transferred to the condenser 307 via line 306 and the recovered solvent is conveyed to the mixer 309 through line 308. If the polar organic compounds have a similar boiling point to the solvent or are miscible with the solvent, a strong polar inorganic liquid compound, such as water or basic aqueous solutions, or polar liquid compounds are added to the mixer 309 via line 310 to be mixed well with the solvent and separate the polar organic compounds from the solvent. The resulting mixture is transferred to the phase separator vessel 312 via line 311. The recovered solvent is returned to the process cycle through line 29. In case of a solvent shortage, it can be supplied through line 313. The separated water and other polar compounds accumulated at the bottom of vessel 312 are transferred to the phase separator vessel 325 through line 314. If the recovered solvent does not contain polar organic compounds, or if the polar organic compounds are not miscible with the solvent, the process related to adding water or other strong polar compounds and mixing them can be omitted from the system.

[0085] After the separation of the solvent, the asphalt-free oil is transferred from line 305 to line 315 and then transferred to vessel 316. In vessel 316, water, polar organic compounds, and other light hydrocarbons are separated from the asphalt-free oil.

[0086] For this purpose, the asphalt-free oil is transferred from line 317 to pump 318 and then, through line 319, to heat exchanger 320. Subsequently, it is returned to vessel 316 via line 321. The heat exchanger increases the temperature of the asphalt-free oil to the range of 100°C to 500°C, preferably within the range of 300°C to 360°C. The vaporized compounds are then transferred to condenser 323 via line 322, and the recovered compounds are sent to phase separator vessel 325 through line 324. Light and non-polar hydrocarbons accumulate in the upper part of vessel 325 and are transferred to storage tank 327 through line 326. They can be utilized as fuel or for other similar applications.

[0087] Water and polar compounds move to the lower part of the vessel 325 and are transferred to the vessel 329 via line 328. In vessel 329, the temperature is raised to a level where polar organic compounds can be separated from water or other polar compounds. If the polar organic compounds have a lower boiling point than water, they can be separated from water by increasing the temperature to the boiling point range of the polar organic compounds. Therefore, the compounds present in the vessel 329 are transferred to the pump 331 via line 330 and then conveyed to the heat exchanger 333 through line 332. After raising their temperature, they are returned to the vessel 329 via line 334. The evaporated polar organic compounds are transferred to the condenser 336 via line 335, and the recovered compounds are conveyed to the storage tank 338 through line 337. The stored polar organic compounds are then returned to the process cycle through line 21. In case of a shortage of polar organic compounds, they can be supplied through line 339. Water and other polar compounds are removed from the process through line 340. If the boiling point range of the polar organic compounds is higher than that of water, it may be possible to purify the polar organic compounds further by evaporating and separating water, returning them to the process cycle.

[0088] After separating the solvent, polar organic compounds, water, and other light hydrocarbons from the asphalt-free oil, the resulting compound is transferred from line 321 to line 341. From there, it is conveyed to the cooler 342 to reduce its temperature. Subsequently, it enters the next stage through line 343.

[0089] represents another preferred embodiment of the present invention at stage (b). In the previous stage, no solvent was used. Also, polar organic compounds, water, and other light hydrocarbons are removed and recovered from the product of stage (a). This process is recommended for both continuous and non-continuous systems.

[0090] The asphalt-free oil is introduced into vessel 400 through line 109, and there it is transferred to pump 402 via line 401. Subsequently, it passes to heat exchanger 404 via line 403, and then it is returned to vessel 400 through line 405. The heat exchanger elevates the temperature of asphalt-free oil to the range of 100°C to 500°C, preferably within the range of 300°C to 360°C. The evaporated compounds are transferred to condenser 407 through line 406, and the recovered compounds are introduced into mixer 409 through line 408. On the other hand, a strong polar compound, such as water or basic aqueous solutions, or polar liquid compounds are introduced into mixer 409 via line 410 and mixed thoroughly with the compounds from line 408. In this step, the majority of polar organic compounds are removed from the non-polar light hydrocarbons, and the odor resulting from the evaporated compounds from vessel 400 is reduced. The resulting mixture is transferred to the phase separator vessel 412 through line 411. The light hydrocarbons and non-polar compounds, which are located in the upper part of vessel 412, are transferred to tank 414 through line 413. These compounds can be used as fuel or for other similar applications.

[0091] Water and polar compounds move to the lower part of the vessel 412 and are transferred to the vessel 416 via line 415. In vessel 416, the temperature is raised to a level where polar organic compounds can be separated from water or other polar compounds. If the polar organic compounds have a lower boiling point than water, they can be separated from water by increasing the temperature to the boiling point range of the polar organic compounds. Therefore, the compounds present in the vessel 416 are transferred to the pump 418 via line 417 and then conveyed to the heat exchanger 420 through line 419. After raising their temperature, they are returned to the vessel 416 via line 421. The evaporated polar organic compounds are transferred to the condenser 423 via line 422, and the recovered compounds are conveyed to the storage tank 425 through line 424. The stored polar organic compounds are then returned to the process cycle through line 21. In case of a shortage of polar organic compounds, they can be supplied through line 426. Water and other polar compounds are removed from the process through line 427. If the boiling point range of the polar organic compounds is higher than that of water, it may be possible to purify the polar organic compounds further by evaporating and separating water, returning them to the process cycle.

[0092] After removing and recovering polar organic compounds, water, and other light hydrocarbons from asphalt-free oil, the obtained product is transferred to cooler 429 through line 428 to lower its temperature. Subsequently, it enters the next stage through line 430.

[0093] In all embodiments mentioned in stage (b), if the water or polar organic compounds present in the mixture containing solvent and asphalt-free oil are minimal, it might be possible to omit the processes of removing and recovering polar organic compounds, water, or other polar compounds, and only perform the removal and recovery processes for the solvent, light hydrocarbons, or various fractions of base oil.

[0094] In the embodiments of the current invention described in stage (b), for the removal and recovery of solvent, polar organic compounds, water, other light hydrocarbons, or various fractions of base oil, distillation systems with continuous or non-continuous flow are employed, ranging from 1 to 10 distillation columns. When continuous flow systems are used, preferably 1 to 3 distillation columns are employed, and when non-continuous flow systems are used, preferably 1 to 2 distillation columns are employed.

[0095] It may be possible to obtain various fractions of the base oil by utilizing other distillation columns. Considering that the objective of the invention is to achieve a high-quality product accompanied by a reduction in operational costs, these processes are not explicitly presented in the figures. However, optionally, by employing various distillation columns at different pressures, different fractions of the base oil can be obtained.

[0096] In the embodiments of the current invention described in stage (b), the solvent used in stage (a) is vaporized by one or more heat exchangers or heaters and are condensed and recovered through one or more condensers or coolers. Additionally, polar organic compounds, water, and other light hydrocarbons are vaporized by one or more heat exchangers or heaters and are condensed and recovered through one or more condensers or coolers.

[0097] In the embodiments of the current invention described in stage (b), if the polar organic compounds are miscible with the solvent, the addition and mixing of strong polar liquid compounds, including water or basic aqueous solutions, or polar liquid compounds result in the separation of most of the polar organic compounds from the solvent. Subsequently, in another distillation process, the polar organic compounds are separated from the water; alternatively, it is possible to reuse them without separating the polar organic compounds from the water in the stage (a) of the process.

[0098] In the embodiments of the current invention described in stage (b), the mixture of polar organic compounds and polar inorganic compounds, once recovered, is separated from each other through evaporation processes and then recovered; alternatively, without separating them from each other, they may be used as one of the constituents of precipitating agents.

[0099] In the embodiments of the current invention described in stage (b), in the mixture of recovered polar organic compounds and water, the temperature is elevated using one or more heat exchangers or heaters to a range encompassing the boiling point of one of the polar organic or water, which has a lower boiling point. As a result, compounds with lower boiling points vaporize and are subsequently condensed and recovered using one or more condensers or coolers. If the polar organic compounds have a lower boiling point compared to water, the polar organic compounds are evaporated and recovered. If water has a lower boiling point compared to the polar organic compounds, water is evaporated, and the remaining components with higher boiling points are either reused in the process, or alternative methods are employed for the separation of polar organic compounds from water (or other polar inorganic liquid compounds). It is also possible to use the recovered polar organic compounds and water without separating them as one of the precipitating agents.

[0100] In the embodiments of the current invention described in stage (b), it is possible to change the temperature required for the separation of the solvent, polar organic compounds, water, other light hydrocarbons, or various fractions of base oil by altering the pressure in the evaporation vessels. This depends on the type of solvent used and the type of the waste oil. In general, the pressure may fall within the range of 0.001 to 35 bars. If a solvent such as hexane is used, the process of evaporation and solvent recovery can be carried out at atmospheric pressure. To reduce the boiling point of the solvent, polar organic compounds, water, other light hydrocarbons, or various fractions of base oil, one or more pressure reduction systems in the evaporation vessels may be employed.

[0101] In the embodiments of the current invention described in stage (b), the temperature for evaporating the solvent, polar organic compounds, water, other light hydrocarbons, and various fractions of base oil depends on the nature and type of the solvent and polar organic compounds used in stage (a), as well as the type of waste oil. In general, the temperature in this stage may vary within the range of 10°C to 500°C and is preferably within the range of 80°C to 360°C. The temperature in each specific part of the process is determined based on the boiling point range of the solvent, polar organic compounds, water, other light hydrocarbons, and various fractions of base oil. Preferably, the temperature increases incrementally to separate the components according to their respective boiling points.

[0102] In an alternative preferred embodiment of stage (b), not illustrated in the figures, optionally in another way, the obtained oil mixture may enter distillation columns after stage (a). Following the separation of the solvent (if utilized in stage (a)), the pressure within the distillation columns may range from 0.001 to 0.01 bars, preferably within the range of 0.002 to 0.004 bars. The temperature at the bottom of the distillation column may fall within the range of 250°C to 360°C, preferably within the range of 280°C to 300°C. Through the distillation process, various fractions of the base oil may be obtained. Optionally, the base oil may undergo further treatment stages, such as hydrogenation or other processes, to enhance its quality; and there is no need to do next steps to produce the base oil.

[0103] presents one of the preferred embodiments of the present invention in stages (c) and (d). In these stages, the remaining impurities in base oil are removed using an acidic agent in the presence of a solvent. Additionally, through bleaching and neutralization processes, the base oil is obtained as the output product.

[0104] The resulting products from stage (b) are introduced into the mixer 500 through one of the lines 236, 343, or 430. In the mixer 500, they are mixed with an acidic agent supplied through line 501.

[0105] The resulting compounds are introduced into the mixer 503 through line 502. In the mixer, they are effectively mixed with a solvent supplied through line 504. The resulting compounds are transferred to separator 506 through line 505. In the separator, the acidic sludge is separated from the mixture containing the base oil and solvent. Acidic sludge obtained is removed from the process through line 507, and the base oil and solvent are transferred to vessel 509 via line 508. In this vessel, the used solvent evaporates and is separated from the base oil. For this purpose, the compounds in vessel 509 are transferred to pump 511 through line 510. Subsequently, they are conveyed through line 512 to heat exchanger 513, where the temperature of the incoming compounds is raised to the range of the boiling point of the solvent. Then, the mixture is returned to vessel 509 via line 514. The evaporated solvent is transferred to condenser 516 through line 515 and recovered. The recovered solvent is then conveyed to storage tank 518 through line 517, and from there, it is returned to the process cycle via line 504. In case of solvent shortage, it can be supplied through line 519.

[0106] After evaporating the solvent, the recovered base oil is transferred from line 514 to line 520 and then conveyed to vessel 521. In this vessel, the bleaching and neutralization processes are conducted. The bleaching agents enter the vessel through line 522, while the neutralizing agents enter through line 523, achieving a thorough mixture with the base oil. The bleaching and neutralizing agents can be mixed simultaneously or separately with the base oil. Preferably, the bleaching agents are first added to the base oil and mixed, followed by the addition of the neutralizing agents to the base oil and thorough mixing. To achieve and maintain the desired temperature in vessel 521, a heater 524 may be utilized. For the removal of light components from the base oil and inducing turbulence in vessel 521, one or more separator gases, can be employed. For this purpose, a gas flow is established in the lower part of vessel 521 through line 525, and the introduced gases into vessel 521, along with impurities and light hydrocarbon compounds, are expelled through line 526. Optionally, to enhance turbulence in vessel 521, one or more agitators may be used.

[0107] The mixture of base oil along with bleaching and neutralizing agents is transferred through line 527 to separator or filter press 528 to remove impurities such as bleaching and neutralizing agents from the base oil. Subsequently, the separated impurities are expelled through line 529, and base oil is obtained as the final product through line 530.

[0108] The required heat for vessel 521 can be supplied through various methods, such as using heating elements, heaters, heating coils, or other alternative methods.

[0109] represents another preferred embodiment of the present invention in stages (c) and (d), wherein the remaining impurities in the base oil are removed using an acidic agent without using a solvent. Additionally, through the processes of bleaching and neutralization, the base oil is obtained as the final output product.

[0110] The resulting products from stage (b) are introduced into the mixer 600 through one of the lines 236, 343, or 430. In the mixer 600, they are mixed with an acidic agent supplied through line 601.

[0111] The obtained compounds are transferred to the separator 603 through line 602, where the acidic sludge is separated from the base oil. The resulting acidic sludge is removed from the process via line 604, and the base oil is transferred to the vessel 606 through line 605, where the processes of bleaching and neutralization take place.

[0112] In vessel 606, the bleaching and neutralization processes are conducted. The bleaching agents enter the vessel through line 607, while the neutralizing agents enter through line 608, achieving a thorough mixture with the base oil. The bleaching and neutralizing agents can be mixed simultaneously or separately with the base oil. Preferably, the bleaching agents are first added to the base oil and mixed, followed by the addition of the neutralizing agents to the base oil and thorough mixing. To achieve and maintain the desired temperature in vessel 606, a heater 609 may be utilized.

[0113] For the removal of light components from the base oil and inducing turbulence in vessel 606, one or more separator gases, can be employed. For this purpose, a gas flow is established in the lower part of vessel 606 through line 610, and the introduced gases into vessel 606, along with impurities and light hydrocarbon compounds, are expelled through line 611. Optionally, to enhance turbulence in vessel 606, one or more agitators may be used.

[0114] The mixture of base oil along with bleaching and neutralizing agents is transferred through line 612 to separator or filter press 613 to remove impurities such as bleaching and neutralizing agents from the base oil. Subsequently, the separated impurities are expelled through line 614, and base oil is obtained as the final product through line 615.

[0115] The required heat for vessel 606 can be supplied through various methods, such as using heating elements, heaters, heating coils, or other alternative methods.

[0116] In the preferred embodiments mentioned, owing to the fact that the base oil compounds or the solvent extracted from the separators 506 or 603 have an acidic property, an optional neutralizing agent can be introduced (not depicted in the figure) to reduce the acidic property of the base oil compounds or the solvent, thereby preventing corrosion and damage to pipelines and vessel.

[0117] In the embodiments of the current invention described in stage (c), to remove the remaining impurities in the base oil obtained from stage (b), one or more organic or inorganic acidic compounds or a combination thereof, are employed. The consumption amount of the acidic compound falls within the range of 0.01vol% to 50vol%, preferably in the range of 1vol% to 15vol% based on the total volume of the obtained base oil. The organic or inorganic acidic compound may include sulfuric acid, nitric acid, hydrochloric acid, acetic acid, formic acid, or a combination thereof, and / or similar compounds. The purity level of the acid compounds may range from 1% to 99.99%, with a preference for the highest purity level available.

[0118] In the embodiments of the current invention described in stage (c), in a preferred sample of sulfuric acid, with a purity preferably in the range of 95% to 99.99%, the amount of sulfuric acid consumed is within the range of 0.01vol% to 15vol%, and preferably within the range of 0.5vol% to 7vol% based on the total volume of the obtained base oil. When a solvent is used, the amount of sulfuric acid used is preferably in the range of 0.5vol% to 4vol%, and preferably within the range of 1vol% to 2vol% based on the total volume of the obtained base oil. In the absence of a solvent, the amount of sulfuric acid used is preferably in the range of 0.5vol% to 7vol%, and preferably within the range of 1vol% to 4vol% based on the total volume of the obtained base oil.

[0119] In the embodiments of the current invention described in stage (c), the temperature for mixing the base oil-containing compounds with acid compounds is chosen within the range of 5°C to 40°C, preferably within the range of 5°C to 30°C.

[0120] In the embodiments of the current invention described in stage (d), when a solvent is used, after the separation of the acidic sludge from the base oil-containing compounds, the temperature is raised to the boiling range of the solvent using one or more heat exchangers or heaters so that the solvent evaporates. Then, the evaporated solvent is condensed and recovered using one or more condensers or coolers. It is also possible to lower the boiling point of the solvent using one or more pressure-reducing systems and then evaporate and recover it from the base oil-containing compounds.

[0121] In an alternative method, it is possible to transfer the compounds containing a mixture of solvent and base oil to stage (d). Where, after mixing with bleaching and neutralizing agents, the temperature is increased to evaporate the solvent. Then, the evaporated solvent is condensed and recovered using one or more condensers or coolers.

[0122] In the embodiments of the current invention described in stage (d), the bleaching compounds in this stage may include active or non-active bentonite, silica, alumina, clay, activated carbon, or a combination thereof, and / or other similar compounds with bleaching properties for base oil. The consumption amount of bleaching compounds falls within the range of 0.01wt% to 50wt%, preferably in the range of 1wt% to 8wt%, based on the total weight of the base oil.

[0123] In the embodiments of the current invention described in stage (d), the neutralizing compounds used in this stage comprise alkaline or basic compounds of hydroxides, oxides, methoxides, and ethoxides of first or second group periodic table metals, and / or non-alkaline basic compounds, or a combination thereof, and / or other similar compounds with neutralizing properties for base oil, or other compounds that create the appropriate acidity for the base oil. The consumption amount of neutralizing compounds falls within the range of 0.01wt% to 50wt%, preferably in the range of 1wt% to 4wt%, based on the total weight of the base oil.

[0124] In the embodiments of the current invention described in stage (d), a preferred sample consists of bentonite and calcium oxide. Bentonite, as a bleaching compound, is used in the range of 0.01wt% to 50wt%, preferably within the range of 1wt% to 8wt%, based on the total weight of the base oil. Calcium oxide, as a neutralizing agent, is used in the range of 0.01wt% to 50wt%, preferably within the range of 1wt% to 4wt%, based on the total weight of the base oil.

[0125] In the embodiments of the current invention described in stage (d), the temperature of the bleaching and neutralization process is in the range of 40°C to 240°C, preferably in the range of 170°C to 220°C.

[0126] In the embodiments of the current invention described in stage (d), optionally, the use of one or more separating gases, including steam, inert gases, non-hydrogenating gases, or a combination thereof, can separate the remaining light compounds from the base oil and increase the flash point of the base oil. The addition of a separating gas can be used in various stages or between the mentioned stages and is preferably used in stage (d). It is possible to recover the separating gases and light hydrocarbons with different processes and reuse them.

[0127] In the embodiments of the current invention described in stage (d), for maximum separation of the base oil from the bleaching and neutralizing compounds and increasing the efficiency of base oil production, the separated bleaching and neutralizing compounds may be subjected to a solvent wash, and the residual base oil is extracted from it.

[0128] The hydrogenation process is an optional step in the present invention. It may not be necessary for producing high-quality base oil, but it can be performed in some specific cases to enhance the quality of the base oil and this process increases the degree of saturation of the base oil and removes some impurities. The hydrogenation process is carried out using a hydrogenation reactor at the appropriate temperature and pressure. Conventional hydrogenation process reactors may be employed in this process.

[0129] illustrates one of the preferred embodiments of the present invention in stage (e), where an optional hydrogenation process is employed to enhance the quality of the base oil. This process increases the degree of saturation of the base oil and removes some impurities.

[0130] In this process, the base oil produced is transferred to the heat exchanger 701 through one of the lines 530 or 615. Along this path, hydrogen gas is injected into the base oil via line 700. Subsequently, by providing the required heat through heat exchanger 701, hydrogen-containing base oil is transferred to the hydrogenation reactor 703 through line 702.

[0131] This reactor contains a classified catalyst bed 704. As the base oil passes through the catalyst bed in the presence of hydrogen, the pollutant molecules are hydrogenated, and other hydrocarbon products are saturated. These pollutants may include sulfur, nitrogen, oxygen, heteroatoms, and other similar impurities present in the base oil.

[0132] Subsequently, the product flow is transferred to the vessel 706 via line 705, where volatile components and hydrogenated impurities, along with unused hydrogen gas, are removed through line 707. For optimal separation of volatile components and hydrogenated impurities, steam, inert gases, non-hydrogenating gases, or a combination of these can be used by introducing them through line 708. The final product, containing high-quality base oil, is discharged through line 709.

[0133] Hydrogen gas may be injected not only along the mentioned paths but also even after the heat exchanger or at various points within the hydrogenation reactor. It is important to note that the pressure and temperature required in the hydrogenation process are provided by the hydrogenation reactor.

[0134] illustrates one of the preferred embodiments of the present invention in stage (e), where an optional hydrogenation process is employed to enhance the quality of the base oil. This process increases the degree of saturation of the base oil and removes some impurities.

[0135] In this process, the base oil produced is transferred to the heat exchanger 801 through one of the lines 530 or 615. Along this path, hydrogen gas is injected into the base oil via line 800. Subsequently, by providing the required heat through heat exchanger 801, hydrogen-containing base oil is transferred to the hydrogenation reactor 804 through line 802.

[0136] In the path leading to the hydrogenation reactor, a catalyst flow is injected into the hydrogen-containing base oil through line 803. In the hydrogenation reactor 804, the pollutant molecules are hydrogenated, and other hydrocarbon products are saturated. These pollutants may include sulfur, nitrogen, oxygen, heteroatoms, and other similar pollutants present in the base oil.

[0137] Subsequently, the product flow is transferred to the vessel 806 via line 805, where volatile components and hydrogenated impurities, along with unused hydrogen gas, are removed through line 807. For optimal separation of volatile components and hydrogenated impurities, steam, inert gases, non-hydrogenating gases, or a combination of these can be used by introducing them through line 808.

[0138] The mixture containing base oil and catalyst is transferred to the separator 810 through line 809, where the separated catalysts are removed from the process through line 811, either by disposal or reduction, and the high-quality base oil is obtained as the final product through line 812.

[0139] In the embodiments of present invention mentioned in stage (e), hydrogen gas and / or catalyst may be injected not only along the mentioned paths but also even after the heat exchanger or at various points within the hydrogenation reactor. It is important to note that the pressure and temperature required in the hydrogenation process are provided by the hydrogenation reactor.

[0140] In the embodiments of the current invention described in stage (e), for the hydrogenation process, one or more hydrogenation reactors can be used either separately or in combination. Additionally, a combination of serial and parallel reactors can be employed. Serial reactors are used to enhance the product's quality, while parallel reactors are used to increase the product output and maintain a continuous process. To induce turbulence in the hydrogenation reactors, one or more internal agitators can be used. The hydrogenation process can be performed between any of the stages, but it is preferably used as a final process to enhance the quality of the base oil.

[0141] In the embodiments of the current invention described in stage (e), the hydrogen flow rate is typically in the range of 20 to 1800 scf and preferably in the range of 30 to 110 scf per barrel of base oil used.

[0142] In the embodiments of the current invention described in stage (e), the hydrogenation process temperature is chosen within the range of 80°C to 550°C, preferably in the range of 340°C to 440°C. The process pressure for hydrogenation is typically chosen within the range of 4 to 260 bars, and preferably in the range of 28 to 55 bars.

[0143] In the embodiments of the current invention described in stage (e), the catalysts used may include one or more catalysts containing metallic elements from groups VI(b), V(b), and VIII of the periodic table. Preferably, compounds such as cobalt, nickel, molybdenum, and vanadium, or combinations thereof, and / or similar catalytic compounds, may be used. If a fixed-bed hydrogenation reactor is employed, compounds of these elements can be placed on metallic catalyst supports. These supports can be used in series or parallel configurations with varying levels of porosity to enhance the process. If a particulate catalyst is used, carriers like carbon, alumina, silica, or combinations thereof, or other carriers, can be used to host the catalysts for the hydrogenation process. Compounds such as nickel-molybdenum, cobalt-molybdenum, nickel-tungsten, and / or similar compounds can be placed on the mentioned carriers for the hydrogenation process.

[0144] In the embodiments of the current invention described in stage (e), after the hydrogenation process, for better separation of impurities, light hydrocarbon compounds, or volatile gases from the base oil, one or more pressure reduction systems can be used in various vessels. The pressure range of these systems may vary and can be within the range of 8 bars to a complete vacuum. Additionally, the product may be transferred to other distillation vessels for obtaining different fractions of base oil with varying viscosities.

[0145] In the embodiments of the current invention described in stage (e), for better removal of impurities, light hydrocarbons, and hydrogen from the base oil, one or more separator gases may be used after the hydrogenation process. These separator gases can include steam, inert gases, non-hydrogenating gases, or a combination of them, or similar gases.

[0146] In the embodiments of the current invention described in stage (e), during the hydrogenation process, it is possible that a portion of the hydrogen gases does not undergo reaction and may be removed, along with gaseous impurities from the base oil using a separator gas. To this end, it is feasible to recover hydrogen gases and / or separator gases through alternative processes for subsequent utilization in hydrogenation procedures.

[0147] For the hydrogenation process, various methods and different hydrogenation reactors can be employed. In this invention, only two embodiments of these have been mentioned. It is evident that the hydrogenation process can be conducted using various methods and different reactor configurations.

[0148] illustrates a schematic overview of the entire process for producing base oil from waste oil using a solvent. It is recommended to carry out these processes in continuous systems.

[0149] provides a schematic overview of the entire process for producing base oil from waste oil without using solvent. It is recommended to carry out these processes in non-continuous systems.

[0150] andrepresent general designs derived from the combination of preferred embodiments described. Certainly, it is possible to create and utilize other general designs based on other preferred embodiments.

[0151] A method for the production of microspheres and organic or mineral salts from waste generated from previous processes is proposed as follows:f) mixing asphalts with basic properties obtained from stage (a) and sludges with acidic properties obtained from stage (c), or mixing acidic sludges with basic or alkaline asphalts that may have been produced from waste oil using other methods, at suitable temperature and pressure conditions, mixed by one or more agitators; if necessary, use one or more fluid streams; controlling parameters influencing the formation and type of microspheres; the removal and recovery of a portion of water, polar organic compounds, light hydrocarbons, and solvents from the mixture containing microspheres; the separation of polar organic compounds from the solvent in case of polar organic compounds being dissolved in the solvent;g) separation of oil and non-polar organic compounds from compounds containing microspheres and polar compounds using solvents and separator systems; removal and recovery of the solvent from the extracted oil; neutralizing acidity if necessary for the extracted oil;h) removal and recovery of the remaining solvent in polar compounds; separation of microspheres from salts and polar compounds using water and separator systems; removal and recovery of water and other polar compounds from the produced salts;and all of the mentioned stages can be executed continuously or non-continuously.

[0152] illustrates one of the preferred embodiments of the present invention in stages (f), (g), and (h). Within these stages, the processes of production and purification of microspheres and organic or mineral salts is done. Additionally, the recovery of solvents, oil, polar organic compounds, and water from the generated waste in preceding stages is also depicted.

[0153] The basic or alkaline pollutants and asphalts, produced and separated in stage (a), are introduced into vessel 900 through one of the lines, either 32 or 108. On the other hand, the acidic sludges, derived from stage (c), are introduced into vessel 900 via one of the lines, either 507 or 604. The compounds entering vessel 900 are thoroughly mixed by agitator 901, which is connected to motor 903 through intermediary 902. Furthermore, heater 904 ensures the temperature required for the formation of microspheres within vessel 900. In the event of a decrease in the viscosity of the mixed compounds, it is possible to utilize one or more streams of fluid flow entering vessel 900 through line 905. The fluid flow serves to increase the viscosity of the compounds present in vessel 900.

[0154] During the process of microspheres production, a portion of the solvents, polar compounds, and volatile substances undergo evaporation. The evaporated compounds are transferred to condenser 907 through line 906. If the polar organic compounds are miscible with the solvent, the recovered solvent may be mixed with one or more strong polar compounds, such as water or basic aqueous solutions, or polar liquid compounds to separate the polar organic compounds from the solvent. For this purpose, the recovered compounds are transferred through condenser 907 to line 908 and then directed to mixer 909. In mixer 909, they are thoroughly mixed with one or more strong polar compounds, such as water or basic aqueous solutions entering through line 910. Subsequently, the resulting mixture is transferred through line 911 to phase separator vessel 912. The recovered solvent and non-polar compounds are located in the upper part of vessel 912 and from there, are directed through line 913 to storage tank 914. From there, they can be utilized as a solvent in various processes of the present invention, and / or through additional distillation, further purified for use in different stages of the present invention. Additionally, in case of a solvent shortage in the microspheres production process, solvent replenishment can be achieved through line 915.

[0155] In the lower part of vessel 912, water and other collected polar compounds are conveyed to vessel 917 through line 916. If the boiling point of the polar organic compounds is lower than that of water, it is possible to separate them from water by raising the temperature to the boiling range of the polar organic compounds. For this purpose, the compounds in vessel 917 are transferred to pump 919 via line 918. From there, they are conveyed to heat exchanger 921 through line 920. In the heat exchanger, the temperature is raised to the boiling point range of the polar organic compounds and then returned to vessel 917 through line 922. The evaporated polar organic compounds are transported to condenser 924 via line 923, and the recovered compounds are transferred to storage tank 926 through line 925. These recovered compounds may be reused in the processes of stage (a). Water and other remaining compounds with a boiling point higher than that of the polar organic compounds are transferred through line 922 to line 927 and directed to tank 928. They can be further conveyed to line 910 to be reintroduced into the process cycle, or alternatively, utilized as one of the constituents forming the precipitating agent in stage (a). Similarly, the polar organic and inorganic compounds exiting from the bottom part of vessel 912 through line 916 can be used without separation as one of the constituents forming the precipitating agent in stage (a).

[0156] If the boiling point of the polar organic compounds is higher than that of water, a small portion of them may undergo evaporation and recovery in the microspheres production process. The majority of these compounds, along with microspheres and salts, remain alongside salts and microspheres until the final processes.

[0157] Microspheres and salts, along with oil and other produced compounds are transferred from vessel 900 to cooler 930 through line 929. From there, they are conveyed to mixer 932 through line 931, where they are effectively mixed with a solvent entering from line 933. This mixing process ensures the dissolution of oil and other non-polar compounds in the solvent, increasing the viscosity of the mixed compounds.

[0158] The mixed compounds are transferred to separator 935 through line 934. Microspheres and salts tend to remain in polar compounds; therefore, in separator 935, they are separated from the solvent and other non-polar compounds. The solvent, oil, and other separated non-polar compounds are transferred to vessel 937 through line 936. In vessel 937, the compounds are pumped to pump 939 through line 938. From there, they are directed to heat exchanger 941 through line 940. After raising the temperature to the boiling point range of the solvent, they are returned to vessel 937 through line 942. The evaporated solvent is transferred to condenser 944 via line 943, and the recovered solvent is returned to solvent storage tank 914 through line 945. Compounds containing solvent-free oil are transferred to line 946 from line 942 and from there to mixer 947. Oil-containing compounds, due to their presence in the microspheres production process, exhibit acidic properties. Therefore, the introduced oil in mixer 947 is mixed with a basic or alkaline neutralizing compound entering mixer 947 through line 948 to achieve the desired acidity for oil. Subsequently, the compounds containing oil enter filter 950 through line 949 and exit through line 951. Furthermore, impurities are removed through line 952.

[0159] The obtained oil may be reintroduced into waste oil and enter the processes of the present invention. Alternatively, it can undergo a separate recycling process based on the mentioned processes, or other recycling methods can be employed to produce base oil from it. Therefore, the remaining oil in acidic sludges and asphalts is extracted after microspheres production.

[0160] The washing process of microspheres, salts, and other polar compounds with a solvent may be repeated multiple times to ensure the effective separation of the majority of non-polar compounds and oil from them.

[0161] Microspheres, salts, and other polar compounds, along with the remaining solvent, are transferred from separator 935 to heat exchanger 954 via line 953. After raising the temperature to the boiling point range of the solvent, they are conveyed to vessel 956 through line 955. In this vessel, the remaining solvent in the compounds containing microspheres and salts evaporates and is transferred to condenser 958 through line 957. The recovered solvent is then directed to solvent storage tank 914 through line 959. To enhance the evaporation of the solvent, it is possible, similar to previous methods, to establish a cyclic process wherein the compounds within vessel 956 are transferred to heat exchanger 954 and subsequently returned to vessel 956. Alternatively, other thermal systems and heaters may be employed for vessel 956. Or the utilization of a pressure reducer in vessel 956 results in a decrease in the boiling point of the solvent. Consequently, this leads to an enhancement in the evaporation of the solvent from microspheres and other polar compounds. It is preferred to use a solvent with a lower boiling point to facilitate the solvent evaporation process more efficiently.

[0162] After the evaporation of the solvent, microspheres, salts, and other polar compounds are transferred to mixer 961 through line 960. In the mixer, they are effectively mixed with a strong polar compound, such as water entering through line 962. In this mixer, salts and other polar compounds dissolve in water, while microspheres remain insoluble in water.

[0163] After the mixing is completed, the compounds are transferred from mixer 961 to separator 964 through line 963. In the separator, water and dissolved polar compounds are separated from microspheres. The separated aqueous solution is transferred to vessel 966 via line 965. In this vessel, the temperature is raised to the boiling point range of water by heater 967. The evaporated water is transferred to condenser 969 through line 968, and the recovered water is directed to water storage tank 971 via line 970. It is then returned to the process cycle through line 962. If a water shortage develops, it can be supplied through line 972. After the evaporation of water, the remaining salts in vessel 966 are removed from the process through line 973 and can be utilized in other related industries.

[0164] If the polar organic compounds used in the preceding stages have a higher boiling point compared to water, they are removed along with the salts through line 973. These compounds can undergo another evaporation process, allowing for their recovery from other produced salts and be reused in the process again.

[0165] The purified microspheres are transferred to dryer 975 through line 974. After drying, they are removed from the process via line 976 and can be utilized in other related industries.

[0166] The washing process of microspheres, salts, and other polar compounds with water may be iteratively repeated to achieve the effective separation of the majority of polar compounds from the microspheres.

[0167] In the embodiment of the current invention described in stage (f), for the production of microspheres, acidic sludges are mixed with basic asphalts. In this mixture, for each weight unit of acidic sludge, 0.01 to 100 units of weight of basic asphalts, preferably 0.5 to 5 units of weight of basic asphalts, are utilized. The constituents of sludges or asphalts produced in preceding stages may comprise polymers, monomers, unsaturated oils, amorphous carbon compounds, or other heavy compounds.

[0168] In the embodiment of the current invention described in stage (f), to increase viscosity for microspheres production, it is possible to use one or more fluid streams, including water, oils, lubricants, waste oils, base oils, polar organic liquid compounds, inorganic liquid compounds, non-polar organic liquid compounds, or a combination thereof, and / or similar compounds, wherein the volume ratio of the fluid streams to the microsphere-containing compounds falls within the range of 1:40 to 40:1, preferably within the range of 1:2 to 2:1.

[0169] In the embodiment of the current invention described in stage (f), for mixing acidic sludges and basic asphalts, one or more agitators are employed, which may encompass mechanical, magnetic, or a combination thereof, and / or other similar mixing systems. Preferably, a mechanical agitator is used. The agitators mix the compounds together at speeds ranging from 5 to 6000 rpm, preferably within the range of 400 to 1000 rpm.

[0170] In the embodiment of the current invention described in stage (f), the appropriate temperature for the formation of microspheres falls within the range of 40°C to 150°C, preferably within the range of 60C to 90°C.

[0171] In the embodiment of the current invention described in stage (f), to produce microspheres, either continuous or non-continuous processes may be employed, depending on the method of blending acidic sludges and basic asphalts and the heating procedure for the formation of microspheres.

[0172] In the embodiment of the current invention described in stage (f), parameters influencing the production and type of microspheres including the type of waste oil, fluid flow rate, mixing velocity of acidic sludges with basic or alkaline asphalts, acidity of the microsphere formation environment, temperature of microsphere formation, constituents of the precipitating agent, or accelerant agent might influence their size, morphology, size distribution, surface properties, and other physical or chemical characteristics; by altering these specified parameters, it is possible to produce microspheres with different morphologies, sizes, size distributions, surface properties, and / or physical and chemical properties.

[0173] For example, increasing fluid flow rate may result in particles with a more spherical morphology and a more uniform size distribution. Enhancing the acidic property of the reaction environment in microsphere production may reduce the porosity of microspheres, and alter the surface properties of the particles. Increasing the reaction temperature may lead to larger particle sizes. The abundance of pollutants in the waste oil can result in the production of a higher quantity of asphalt or sludge, consequently affecting the type and amount of the precipitating and accelerant agents. These mentioned factors significantly influence the quality and production of microspheres. An increase in the mixing velocity of acidic sludges with basic or alkaline asphalts is associated with a higher likelihood of the formation of microspheres with smaller sizes.

[0174] The produced microspheres encompass hollow, granular, porous or non-porous spherical particles with dimensions in the micrometer or nanometer scale. Modifying the aforementioned parameters may result in the production of microspheres with different physical and chemical characteristics, suitable for various industrial applications.,,andillustrate images depicting microspheres captured through scanning electron microscope. As observed, variations in the mentioned parameters can lead to the production of microspheres with different physical or chemical properties. As evident in the images, this invention enables the generation of a wide spectrum of microspheres by utilizing the wastes generated in preceding stages, considering the specified parameters.

[0175] In the embodiment of the current invention described in stage (f), the type and nature of formed salts may depend on various conditions, with one of the key factors being the type of alkaline or basic compounds utilized in stage (a) and the type of acidic compounds used in stage (c). If the acidic and basic compounds used are mineral, the resulting salt is also mineral, and if the acidic or basic compounds are of an organic nature, the formed salt may be an organic salt. For instance, employing sodium hydroxide in stage (a) and sulfuric acid in stage (c) results in the formation of a mineral salt, specifically sodium sulfate.

[0176] For the production of microspheres, basic asphalts or acidic sludges may be produced using other methods from waste oil. To this end, required pollutants or asphalts may be obtained from waste generated by waste oil distillation methods, solvent extraction methods, or the utilization of other coagulating or flocculating agents from waste oil. These processes may result in the production of basic or alkaline asphalts by mixing asphalts, pollutants, and / or polymers produced from waste oil with basic or alkaline compounds. Additionally, acidic sludges may result from the mixing of acidic compounds with asphalts, pollutants, and / or polymers derived from waste oil. The produced microspheres encompass hollow, granular, porous or non-porous spherical particles with dimensions in the micrometer or nanometer scale.

[0177] In the distillation method, asphalts or pollutants present in waste oil, typically remain at the bottom of the distillation columns after the evaporation of base oil. In solvent extraction methods, the extracted pollutants or asphalts may also be utilized in the process of producing microspheres. In alternative methods, the addition of coagulating or flocculating compounds can also induce the coagulation or flocculating of pollutants or asphalts in waste oil or solutions containing waste oil. Considering the information provided, various methods can be employed to separate asphalts or pollutants from waste oil. Acidic sludges are also obtained by mixing asphalts, polymers, or pollutants of the waste oil with organic or inorganic acids. These acids may include sulfuric acid, hydrochloric acid, nitric acid, phosphoric acid, acetic acid, formic acid, and other organic or mineral acids.

[0178] The basic properties of asphalts or the acidic properties of sludges produced from other methods should be tailored to facilitate the appropriate reactions for microsphere production. The nature of microspheres and the organic or mineral salts produced may depend on the type of acidic sludges or basic asphalts. For example, the combination of alkaline hydroxide compounds with acidic substances like sulfuric acid may provide a suitable reaction for the production of microspheres.

[0179] In the embodiment of the current invention described in stage (f), during the process of microsphere production, a portion of the solvent, polar organic compounds, water, and other light hydrocarbons is evaporated by one or more heat exchangers or heaters and subsequently recovered using one or more condensers or coolers. If the polar organic compounds are miscible with the solvent, the addition and mixing of strong polar liquid compounds, including water or basic aqueous solutions, or polar liquid compounds result in the separation of most of the polar organic compounds from the solvent. Subsequently, in another distillation process, the polar organic compounds are separated from the water; alternatively, it is possible to reuse them without separating the polar organic compounds from the water in the stage (a) of the process.

[0180] In the embodiment of the current invention described in stage (f), the mixture of polar organic compounds and polar inorganic compounds, once recovered, is separated from each other through evaporation processes and then recovered; alternatively, without separating them from each other, they may be used as one of the constituents of precipitating agents. In the mixture of recovered polar organic liquid compounds and polar inorganic compounds (water), the temperature is raised to the boiling point range of one of the polar organic compounds or water with the lower boiling point using one or more heat exchangers or heaters. This process results in the evaporation of the compounds with lower boiling points. The vapor is then condensed and recovered using one or more condensers or coolers. If the boiling point of polar organic compounds is higher than that of water, these polar organic compounds may not undergo evaporation in this stage and could persist along with polar salts until the final stages of the process. Subsequently, by increasing the temperature, the polar organic compounds can be evaporated and recovered.

[0181] In the embodiment of the current invention described in stage (f), strong polar compounds are compounds that have the ability to separate polar organic compounds from the solvent and may consist of various different compounds. The use of strong polar compounds, such as aqueous solutions of alkaline hydroxides in this step, may not only facilitate the separation of polar organic compounds from the solvent but also neutralize a significant portion of the gaseous compounds produced as a result of chemical reactions in the process of microsphere production.

[0182] In the embodiment of the current invention described in stage (g), after the formation of microspheres, the resulting mixture consists of microspheres, residual oil, organic and inorganic compounds, non-polar organic compounds, and organic or mineral salts. To achieve this, the addition of one or more non-polar organic solvents can increase viscosity and separate polar and non-polar compounds from each other. As a result, the oil dissolves in the solvent and is separated from the polar compounds using one or more separator systems. In subsequent processes, the solvent is evaporated from the oil using one or more heat exchangers or heaters and is condensed and recovered using one or more condensers or coolers. And in this way, the remaining oil in acidic sludges and asphalts is extracted after the production of microspheres. The extraction of oil from the generated waste leads to an increased production efficiency of oil. Moreover, it prevents environmental pollution caused by these organic pollutants.

[0183] In the embodiment of the current invention described in stage (g), the separation of oil and non-polar organic compounds from microspheres and polar compounds is accomplished through solvent washing within the range of 1 to 10 times; and preferably 1 to 3 times with the cleaning solvent to reduce the presence of non-polar compounds in polar compounds and microspheres. Subsequently, the solvent used in the washing stage can be evaporated and recovered.

[0184] In the present invention embodiments described in stages (a), (c), and (g), the solvents used are non-polar organic compounds, including aliphatic or aromatic solvents, or a combination thereof. Preferably, aliphatic solvents are utilized. The volume ratio of the solvents to the compounds containing base oil falls within the range of 1:70 to 70:1, preferably within the range of 1:2 to 2:1. The aliphatic solvents include alkanes, alkenes, alkynes, cycloalkanes, cycloalkenes, their various isomers; or a combination of them; and / or similar compounds. In this context, the alkanes consist of ethane, propane, butane, pentane, hexane, heptane, octane, nonane, decane, dodecane, normal propane, normal butane, normal pentane, normal hexane, normal heptane, normal octane, normal nonane, normal decane, normal dodecane, or a combination thereof, and / or other similar compounds with comparable properties. Among the mentioned solvents, some may not be suitable for application due to their effciency, properties, or economic considerations. However, a combination of these solvents could prove beneficial. For this reason, the preferred solvents for the mentioned processes are non-polar aliphatic organic solvents, specifically of the alkane type. Hexane or n-hexane is preferably used for systems at atmospheric pressure, and propane is preferably used for high-pressure systems.

[0185] In the embodiment of the current invention described in stage (g), the mixing solvent temperature for separating oil and non-polar organic compounds from microspheres and polar compounds is selected within the range of -30°C to +40°C, preferably within the range of +5°C to +20°C. After separating the solvent and non-polar compounds from polar compounds, the temperature is increased to allow the solvent to evaporate from the non-polar compounds and subsequently be recovered. The required temperature for solvent evaporation depends on the type of solvent. Additionally, it is possible to lower the boiling point of the solvent by using one or more pressure reducers, followed by evaporating the solvent from the non-polar compounds and recovering it.

[0186] In the embodiment of the current invention described in stage (h), the remaining solvent in microspheres and polar compounds is evaporated using one or more heat exchangers or heaters and subsequently condensed and recovered using one or more condensers or coolers.

[0187] In all the mentioned steps, after evaporation and recovery of the solvent, a separator vessel can be used to separate the polar compounds from the solvent.

[0188] In the embodiment of the current invention described in stage (h), compounds containing microspheres, salts, and other polar compounds are mixed with a strong polar compound such as water to separate the salts and other polar compounds from microspheres. Consequently, the salts and other polar compounds dissolve in water and are separated from microspheres using one or more separator systems. After separating the microspheres, in subsequent processes, water is evaporated and recovered from the aqueous solution containing salts and other polar compounds. If the boiling point of the polar organic compounds is higher than that of water, it is possible in later processes to increase the temperature of the salts to the range of the boiling point of polar organic compounds, enabling the evaporation and recovery of polar organic compounds.

[0189] In the embodiment of the current invention described in stage (h), for the separation of microspheres from salts and other polar compounds, water washing is employed, also within the range of 1 to 10 times, and preferably 1 to 3 times to reduce the percentage of polar compounds in microspheres. Subsequently, the water used in the washing stage can be evaporated and recovered.

[0190] In the embodiment of the current invention described in stage (h), various drying systems can be employed to dry microspheres and salts, enabling continuous or non-continuous drying based on specific process requirements and preparing them for use.

[0191] In the embodiment of the current invention described in stage (h), as described in stage (h), the chosen temperature range depends on the type of solvent and polar compounds, allowing each of them to evaporate and be recovered within the range of their respective boiling points.

[0192] In the embodiment of the current invention described in stage (f), (g) or (h), it is possible to change the temperature required for the separation of the solvent, polar organic compounds, water, other light hydrocarbons, or various fractions of base oil by altering the pressure in the evaporation vessels. This depends on the type of solvent used and the type of the waste oil.

[0193] In all the stages mentioned in the embodiments of the present invention, the solvent, polar inorganic compounds, polar organic compounds, other light hydrocarbon compounds, or various oil fractions are evaporated by one or more heat exchangers, heaters, or other temperature-enhancing systems and subsequently recovered and condensed by one or more condensers or other cooling systems.

[0194] In all the stages mentioned in the embodiments of the present invention, the pressure generally may range from 0.001 to 35 bars (except stage (e)). The pressure used in each process varies depending on the type of the solvent, the type of process, the required volume for production, ambient temperature, and other influential parameters. When low-boiling-point solvents are used in stage (a), (c), or (f), there is a need for vessels and systems capable of maintaining the required pressure to keep the solvent in a liquid state. In stage (b), (d), (g), or (h), the pressure should be within a range compatible with the temperature created to facilitate the evaporation of the solvent, water, polar organic compounds, other light hydrocarbons, or various base oil fractions, with the preference for using pressure reduction systems in these stages. Preferably, for cost reduction, solvents such as hexane or n-hexane are used to execute all the mentioned stages at atmospheric pressure. Furthermore, it is possible to use various isomers of the mentioned solvents, such as hexane, where n-hexane can be used.

[0195] In all the stages mentioned in the embodiments of the present invention, one or more separator systems are employed, utilizing various methods such as precipitation, centrifugation, filtration, or a combination thereof, to separate two different phases; this may include various centrifuges, different filtrations, and containers used for precipitation. The separator systems used in this invention are employed for the separation of acidic sludges, asphalts, bleaching agents, neutralizers, microspheres, salts, polar compounds, or other solid particles from liquid compounds.

[0196] In the embodiments of the present invention, all the mentioned stages can be conducted through either continuous or non-continuous processes. If separation systems such as certain centrifuges, filters, and / or separator systems similar to them are used to separate contaminants, acidic sludges, asphalts, bleaching agents, neutralizers, microspheres, salts, polar compounds, or other solid particles from liquid compounds, the processes are carried out continuously. On the other hand, if systems such as reservoirs or fixed tanks are used for sedimentation, the processes are carried out in a non-continuous manner. In processes where systems for the evaporation and recovery of solvents, water, polar organic compounds, other light hydrocarbons, or various fractions of base oil are used with a continuous input feed, the processes are continuous. Conversely, if the input feed is introduced all at once and the evaporation and recovery of solvents, water, polar organic compounds, other light hydrocarbons, or various fractions of base oil are done step by step, the processes are non-continuous.

[0197] In the embodiments of the present invention, the temperature in all stages may vary within the range of -30°C to +550°C, and the pressure in all stages may vary within the range of 0.001 to 260 bars, depending on the specific stage of the process. However, under normal conditions and using an appropriate solvent, it is feasible to conduct the process of producing base oil from waste oil at atmospheric pressure.

[0198] In the embodiments of the present invention, heat exchangers, heaters, or other temperature boosters are utilized which obtain energy from fossil fuels, electrical energy, solar energy, or a combination thereof. The choice of energy source depends on economic, environmental, and industrial conditions, as well as the production volume. Considering the aforementioned conditions, various energy sources can be utilized for carrying out processes.

[0199] In all the stages mentioned in the embodiments of the present invention, the mixer can encompass a wide range of mixing devices, such as simple mixers with one or more agitators, turbines, static mixers, anchor mixers, helical ribbons mixers, ribbon blender mixers, drum mixers, or a combination thereof, or various other types of mixers. The selection of the mixer depends on the type of the process, whether it is continuous or non-continuous. Agitators can include various types suitable for use in the mixer, evaporator vessels, microsphere production vessels, or other relevant locations in this invention.

[0200] In all the stages mentioned in the embodiments of the present invention, the processes for producing base oil from waste oil or manufacturing microspheres can be conducted at laboratory, mini-pilot, pilot, semi-industrial, or industrial scales. Due to the availability of raw materials for these processes in bulk, there is no limitation on laboratory or industrial-scale production. Moreover, the implementation of equipment for conducting the mentioned processes is feasible both at the laboratory and industrial scales.

[0201] The manner in which waste oil is generated under various conditions and the wide spectrum of different additives used in lubricating oils and other oils may have a significant impact on the production and quality of microspheres. In this invention, several different samples of waste oil have been utilized for microsphere production to provide a general method for microsphere synthesis and reduce the process-related errors and enhance microsphere quality. It is evident that understanding the nature of waste oil significantly contributes to minimizing process-related errors.

[0202] The present invention is not limited to the embodiments mentioned, as it is possible to create a new preferred embodiment by integrating the processes described in the mentioned embodiments or by utilizing other similar embodiments.

[0203] In the present invention, a general process is introduced for the production of base oil from waste oil and the production of microspheres from the generated wastes. It is evident that, by making modifications to this process, the same products can still be obtained. Therefore, the nature and innovation of this invention cannot be altered through minor adjustments.Example 1

[0204] The specifications of the waste oil used for the production of base oil in all examples are provided in [Table 1].

[0205] [Table 1].TestStandard test MethodResultUnitKinematc Viscosity at 40°CASTM D445105.0100cStKinematc Viscosity at 100°CASTM D44513.7097cStFlash Point-open cupASTM D92183°CPour PointASTM D97-33°CDensityASTM D12980.8808g / mL

[0206] 500 ml of waste oil were mixed with 30 ml of a precipitating agent containing 15 ml of 12.5 molar sodium hydroxide aqueous solution and 15 ml of ethanol. Then, 470 ml of n-hexane is mixed as a solvent with the obtained mixture. After 13 hour, the majority of pollutants and asphalts precipitate. The solution containing solvent and the asphalt-free oil is transferred to the evaporation vessel to allow the solvent, water, inorganic compounds, and other light hydrocarbons to evaporate and be recovered.

[0207] Subsequently, the obtained oil is mixed with the acid agent (sulfuric acid) at a volume ratio of 2.5% to oil, and then the resulting mixture is combined with a solvent (n-hexane) at a volume ratio of 50% to oil. The obtained acidic sludge removed from the process, and the mixture containing the solvent and oil are transferred to the evaporation vessel for the added solvent to evaporate and be recovered.

[0208] Then, the resulting mixture is combined with approximately 10 grams of the bleaching agent (bentonite) and 5 grams of the neutralizing agent (calcium oxide) at a temperature of 180°C. The mixture is transferred to a filter press to separate the added compounds such as the bleaching and neutralizing agents from the base oil. [Table 2] illustrates the specifications of the obtained base oil.

[0209] TestStandard test MethodResultUnitKinematc Viscosity at 40°CASTM D44568.6070cStKinematc Viscosity at 100°CASTM D4459.8925cStFlash Point-open cupASTM D92210°CPour PointASTM D97-9°CDensityASTM D12980.8690g / mLExample 2

[0210] 500 ml of waste oil were mixed with 30 ml of a precipitating agent containing 15 ml of 12.5 molar sodium hydroxide aqueous solution and 15 ml of ethanol. Then, 470 ml of n-hexane is mixed as a solvent with the obtained mixture. After 13 hour, the majority of pollutants and asphalts precipitate.

[0211] Next, the solution containing asphalt-free oil is mixed with 1.5 ml of the acid agent HCl to reduce its alkaline properties. The solution containing solvent and the asphalt-free oil is transferred to the evaporation vessel to allow the solvent, water, inorganic compounds, and other light hydrocarbons to evaporate and be recovered.

[0212] Subsequently, the obtained oil is mixed with the acid agent (sulfuric acid) at a volume ratio of 2.5% to oil, and then the resulting mixture is combined with a solvent (n-hexane) at a volume ratio of 50% to oil. The obtained acidic sludge removed from the process, and the mixture containing the solvent and oil are transferred to the evaporation vessel for the added solvent to evaporate and be recovered.

[0213] Then, the resulting mixture is combined with approximately 10 grams of the bleaching agent (bentonite) and 5 grams of the neutralizing agent (calcium oxide) at a temperature of 180°C. The mixture is transferred to a filter press to separate the added compounds such as the bleaching and neutralizing agents from the base oil. [Table 3] illustrates the specifications of the obtained base oil.

[0214] TestStandard test MethodResultUnitKinematc Viscosity at 40°CASTM D44556.3400cStKinematc Viscosity at 100°CASTM D4458.5735cStFlash Point-open cupASTM D92204°CPour PointASTM D97-6°CDensityASTM D12980.8691g / mLExample 3

[0215] 500 ml of waste oil were mixed with 30 ml of a precipitating agent containing 15 ml of 12.5 molar sodium hydroxide aqueous solution and 15 ml of ethanol. Next, the resulting mixture is mixed with 10 ml of the precipitation accelerating agent, which contains 0.38 molar sodium dodecyl sulfate aqueous solution. Then, 460 ml of n-hexane is mixed as a solvent with the obtained mixture. After 1 hour, the majority of pollutants and asphalts precipitate. The solution containing solvent and the asphalt-free oil is transferred to the evaporation vessel to allow the solvent, water, inorganic compounds, and other light hydrocarbons to evaporate and be recovered.

[0216] Subsequently, the obtained oil is mixed with the acid agent (sulfuric acid) at a volume ratio of 2% to oil, and then the resulting mixture is combined with a solvent (n-hexane) at a volume ratio of 50% to oil. The obtained acidic sludge removed from the process, and the mixture containing the solvent and oil are transferred to the evaporation vessel for the added solvent to evaporate and be recovered.

[0217] Then, the resulting mixture is combined with approximately 10 grams of the bleaching agent (bentonite) and 5 grams of the neutralizing agent (calcium oxide) at a temperature of 180°C. The mixture is transferred to a filter press to separate the added compounds such as the bleaching and neutralizing agents from the base oil. [Table 4] illustrates the specifications of the obtained base oil.

[0218] TestStandard test MethodResultUnitKinematc Viscosity at 40°CASTM D44564.9800cStKinematc Viscosity at 100°CASTM D4459.4329cStFlash Point-open cupASTM D92209°CPour PointASTM D97-9°CDensityASTM D12980.8703g / mLExample 4

[0219] 500 ml of waste oil were mixed with 30 ml of a precipitating agent containing 15 ml of 12.5 molar sodium hydroxide aqueous solution and 15 ml of ethanol. Next, the resulting mixture is mixed with 10 ml of the precipitation accelerating agent, which contains 0.38 molar sodium dodecyl sulfate aqueous solution. Then, 460 ml of n-hexane is mixed as a solvent with the obtained mixture. After 1 hour, the majority of pollutants and asphalts precipitate.

[0220] Next, the solution containing asphalt-free oil is mixed with 1.5 ml of the acid agent HCl to reduce its alkaline properties. The solution containing solvent and the asphalt-free oil is transferred to the evaporation vessel to allow the solvent, water, inorganic compounds, and other light hydrocarbons to evaporate and be recovered.

[0221] Subsequently, the obtained oil is mixed with the acid agent (sulfuric acid) at a volume ratio of 2% to oil, and then the resulting mixture is combined with a solvent (n-hexane) at a volume ratio of 50% to oil. The obtained acidic sludge removed from the process, and the mixture containing the solvent and oil are transferred to the evaporation vessel for the added solvent to evaporate and be recovered.

[0222] Then, the resulting mixture is combined with approximately 10 grams of the bleaching agent (bentonite) and 5 grams of the neutralizing agent (calcium oxide) at a temperature of 180°C. The mixture is transferred to a filter press to separate the added compounds such as the bleaching and neutralizing agents from the base oil. [Table 5] illustrates the specifications of the obtained base oil.

[0223] TestStandard test MethodResultUnitKinematc Viscosity at 40°CASTM D44561.1100cStKinematc Viscosity at 100°CASTM D4459.1131cStFlash Point-open cupASTM D92214°CPour PointASTM D97-6°CDensityASTM D12980.8702g / mLExample 5

[0224] In this example, the focus is on the production of microsphere and organic or mineral salts from the waste generated in the previous processes:

[0225] 5 grams of acidic sludge are added to 10 ml of basic asphalt compounds and mixed using an agitator at a speed of 150 rpm. During mixing, 2 ml of water and 1 ml of oil are added as fluids. The temperature is gradually increased to 70°C from the beginning of the process, and the evaporated compounds are recovered by a condenser. The resulting mixture is cooled by a cooler and mixed with a solvent. The volume ratio of the mixture containing microsphere to the solvent is 1:2. After complete mixing of the resulting mixture with the solvent, non-polar compounds are separated from the compounds containing microsphere, organic or mineral salts, and other polar compounds. Subsequently, the solvent and non-polar compounds move towards the evaporation vessel to separate the solvent from the remaining oil. On the other hand, the mixture containing microsphere, organic or mineral salts is mixed with water to separate the produced salts from microspheres. The aqueous solution containing salts is brought to the evaporation column to evaporate water, leaving the produced salts dry. On the other hand, microspheres, after washing with water and separation from salts, are dried and ready for packaging.

Claims

A method for producing base oil from waste oil consists of the following stages:a) optional removal of volatile compounds from waste oil; coagulation of pollutants or asphalts from waste oil at the appropriate temperature and pressure using a precipitating agent; utilization of an accelerant agent in the precipitation of pollutants and asphalts; separation of pollutants or asphalts from oil-containing compounds using one or more separation systems; if necessary, the use of one or more neutralizing agents; execution of the processes in this stage can be carried out with or without the use of a solvent;b) removal and recovery of the solvent if used in stage (a); removal and recovery of water, polar organic compounds, light hydrocarbons, and if necessary, the separation of different fractions of base oil at the appropriate temperature and pressure, or obtaining a suitable fraction of base oil; if necessary, the removal of salts and residual solid compounds from oil-containing compounds;c) removal of residual pollutants in the oil obtained from the previous stage at the appropriate temperature and pressure using one or more acid agents; elimination of acid sludges through one or more separation systems; execution of the processes in this stage can be carried out with or without the use of a solvent;d) removal and recovery of the solvent if used in stage (c); recovery of color and acidity of the base oil through bleaching and neutralization processes at the appropriate temperature and pressure; optional removal of light compounds from base oil using one or more gas separators; removal of the bleaching and neutralizing compounds used from base oil;e) enhancement of the base oil quality through the utilization of an optional hydrogenation process at suitable temperature and pressure;and all of the mentioned stages can be executed continuously or non-continuously.The method of claim 1, wherein the precipitating agent consists of a polar inorganic liquid containing comprising water, one or more alkaline or basic compounds, and one or more polar organic compounds; each of the components of the precipitating agent, is mixed within the range of 0.01%wt to 50%wt based on the weight of the waste oil, and these components can be mixed together and then added to the waste oil, or they can be added separately to the waste oil and subsequently mixed.The method of claim 2, wherein the basic or alkaline compounds include hydroxides, oxides, methoxides, or ethoxides from the first or second group of the periodic table metals, and / or non-alkaline basic compounds, or a combination thereof.The method of claim 2, wherein the polar organic compounds include alcohols, ethers, esters, ketones, phenols, furfural, N-methyl-2-pyrrolidone (NMP), methyl-ethyl-ketone (MEK), sulfolane, DMSO, dimethylformamide, or combinations thereof; wherein, the alcohols may consist of methanol, ethanol, propanol, butanol, pentanol, hexanol, heptanol, octanol, nonanol, decanol, their various isomers, or a combination thereof; and / or it may also involve certain water-soluble non-polar organic compounds, such as methylene glycol, ethylene glycol, polyethylene glycol, or a combination thereof.The method of claims 2 and 3 and 4, wherein a preferred sample of the precipitating agent consists of water within the range of 0.01wt% to 50wt% based on the weight of the waste oil, one or more alkaline or basic compounds, including sodium hydroxide, potassium hydroxide, or a combination thereof within the range of 0.01wt% to 50wt% based on the weight of the waste oil, and one or more polar organic compounds, such as ethanol, butanol, propanol, or a combination thereof within the range of 0.01wt% to 50wt% based on the weight of the waste oil; these components can be mixed together and then added to the waste oil, or they can be added separately to the waste oil and subsequently mixed.The method of claim 1, wherein the accelerant agent for the precipitation of pollutants or asphalts consists of one or more types of surfactants, including anionic surfactants, non-ionic surfactants, amphoteric surfactants, or a combination thereof; and / or an aqueous solution of one or more types of surfactants, including anionic surfactants, non-ionic surfactants, amphoteric surfactants, or a combination thereof; and the amount of accelerant agent consumed for the precipitation of pollutants or asphalts falls within the range of 0.01wt% to 50wt% based on the weight of the waste oil.The method of claim 6, wherein the anionic surfactants, non-ionic surfactants or amphoteric surfactants include sulfate surfactants, sulfonate surfactants, phosphate surfactants, carboxylate surfactants, sodium dedecyl sulfate, sodium laureth sulfate, fatty alcohols, alcohol sulfates, ammonium lauryl sulfate, sodium lauroyl sarcosinate, sodium myreth sulfate, sodium pareth sulfate, sodium lauryl sulfate, phosphate esters, alpha olefin sulfonate, ammonium laureth sulfate, betaine, or a combination thereof.The method of claim 6, wherein the aqueous solution contains one or more types of surfactants, and the surfactants content falls within the range of 0.01wt% to 99.99wt% based on the weight of the total aqueous solution.The method of claims 6 and 7 and 8, wherein a preferred sample of the accelerant agent for the precipitation of pollutants or asphalts comprises an aqueous solution of sodium dodecyl sulfate, and the amount of accelerant agent consumed falls within the range of 0.01wt% to 50wt% based on the weight of the waste oil; and this solution is added to the waste oil-containing compounds and thoroughly mixed.The method of claim 1, wherein subsequent to the mixing of the precipitating agent with waste oil, the accelerant agent is added, augmenting the precipitation rate and concurrently reducing the volume of precipitated asphalts and pollutants.The method of claim 1, wherein the neutralizing agent used in stage (a) comprises one or more organic or inorganic acids, and the amount added is such that the compounds containing asphalt-free base oil become neutral or have their basic or alkaline properties reduced; these organic or inorganic acid compounds include sulfuric acid, nitric acid, hydrochloric acid, acetic acid, formic acid, or a combination thereof.The method of claim 1, wherein for removal and recovery of the solvent, polar organic compounds, water, other light hydrocarbons, or various fractions of base oil, 1 to 10 distillation columns are employed in continuous or non-continuous flow systems.The method of claim 1, wherein in an alternative preferred embodiment of stage (b), optionally the oil mixture, after stage (a), enters distillation columns; following the separation of the solvent (if utilized in stage (a)), the pressure within the distillation columns ranges from 0.001 to 0.01 bars, and the temperature at the bottom of the distillation column ranges from 250°C to 360°C; and these conditions are set to obtain various fractions of the base oil; and optionally, additional processes such as hydrogenation and other treatments that contribute to the improvement of the quality of the base oil can be applied.The method of claim 1, wherein to remove the remaining pollutants in the base oil obtained from step (b), one or more organic or inorganic acidic compounds, or a combination thereof, are employed; and the consumption amount of the acidic compound falls within the range of 0.01vol% to 50vol% based on the total volume of the obtained base oil.The method of claim 1 or 14, wherein the organic or inorganic acidic compound may include sulfuric acid, nitric acid, hydrochloric acid, acetic acid, formic acid, or a combination thereof, and the consumed amount of sulfuric acid falls within the range of 0.01vol% to 15vol% based on the total volume of the obtained base oil.The method of claim 1, wherein the bleaching compounds used in stage (d) include active or non-active bentonite, silica, alumina, clay, activated carbon, or a combination thereof, and the consumed amount of bleaching compounds falls within the range of 0.01wt% to 50wt% based on the total weight of the base oil.The method of claim 1, wherein the neutralizing compounds used in step (d) comprise alkaline or basic compounds of hydroxides, oxides, methoxides, and ethoxides of first or second group periodic table metals, and / or non-alkaline basic compounds, or a combination thereof, and the consumed amount of neutralizing compounds falls within the range of 0.01wt% to 50wt% based on the weight of the base oil.The method of claims 16 and 17, wherein the bleaching compound bentonite is used within the range of 0.01wt% to 50wt% based on the weight of the base oil, and neutralizing compound calcium oxide is used within the range of 0.01wt% to 50wt% based on the weight of the base oil.The method of claim 1, wherein the hydrogenation process is carried out using a hydrogenation reactor at the appropriate temperature and pressure.A method for the production of microspheres and organic or mineral salts from waste generated from previous processes is proposed as follows:f) mixing asphalts with basic properties obtained from stage (a) and sludges with acidic properties obtained from stage (c), or mixing acidic sludges with basic or alkaline asphalts that may have been produced from waste oil using other methods, at suitable temperature and pressure conditions, mixed by one or more agitators; if necessary, use one or more fluid streams; controlling parameters influencing the formation and type of microspheres; the removal and recovery of a portion of water, polar organic compounds, light hydrocarbons, and solvents from the mixture containing microspheres; the separation of polar organic compounds from the solvent in case of polar organic compounds being dissolved in the solvent;g) separation of oil and non-polar organic compounds from compounds containing microspheres and polar compounds using solvents and separator systems; removal and recovery of the solvent from the extracted oil; neutralizing acidity if necessary for the extracted oil;h) removal and recovery of the remaining solvent in polar compounds; separation of microspheres from salts and polar compounds using water and separator systems; removal and recovery of water and other polar compounds from the produced salts;and all of the mentioned stages can be executed continuously or non-continuously.The method of claim 20, wherein for the production of microspheres, acidic sludges are mixed with basic asphalts; for each weight unit of acidic sludge, a range of 0.01 to 100 weight units of basic asphalts is employed.The method of claim 20, wherein one or more fluid streams, including water, oils, lubricants, waste oils, base oils, polar organic liquid compounds, inorganic liquid compounds, non-polar organic liquid compounds, or a combination thereof, are employed, wherein the volume ratio of the fluid streams to the microsphere-containing compounds falls within the range of 1:40 to 40:1.The method of claim 20, wherein for the purpose of mixing acidic sludges and basic asphalts, one or more agitators are employed, which may encompass mechanical, magnetic, or a combination thereof, in which compounds are mixed together at speeds within the range of 5 to 6000 rpm.The method of claim 20, wherein the appropriate temperature for the formation of microspheres falls within the range of 40°C to 150°C.The method of claim 20, wherein parameters influencing the production and type of microspheres including the type of waste oil, fluid flow rate, mixing velocity of acidic sludges with basic or alkaline asphalts, acidity of the microsphere formation environment, temperature of microsphere formation, constituents of the precipitating agent or accelerant agent might influence their size, morphology, size distribution, surface properties, and other physical or chemical characteristics; by altering these specified parameters, it is possible to produce microspheres with different morphologies, sizes, size distributions, surface properties, and / or physical and chemical properties.The method of claim 20, wherein other methods that may produce acidic sludges and basic asphalts from waste oil include waste oil distillation methods, solvent extraction methods, or the use of other coagulating or flocculating agents to separate asphalts and pollutants, which may result in the production of basic or alkaline asphalts by mixing asphalts, pollutants, and / or polymers produced from waste oil with basic or alkaline compounds; Additionally, acidic sludges may result from the mixing of acidic compounds with asphalts, pollutants, and / or polymers derived from waste oil.The method of claim 20 or 25 or 26, wherein, the produced microspheres encompass hollow, granular, porous or non-porous spherical particles with dimensions in the micrometer or nanometer scale.The method of claim 20, wherein in stage (g), the separation of oil and non-polar organic compounds from microspheres and polar compounds is accomplished through solvent washing within the range of 1 to 10 times; and in stage (h), for the separation of microspheres from salts and other polar compounds, water washing is employed, also within the range of 1 to 10 times, and the solvent and water are subsequently evaporated and recovered.The method of claim 1 or 20, wherein the solvents used are non-polar organic compounds, including aliphatic or aromatic solvents, or a combination thereof; and the volume ratio of the solvents to the compounds containing base oil in stages (a), (c), and (g) falls within the range of 1:70 to 70:1.The method of claim 29, wherein the aliphatic solvents include alkanes, alkenes, alkynes, cycloalkanes, cycloalkenes, their various isomers; or a combination of them; wherein, the alkanes consist of ethane, propane, butane, pentane, hexane, heptane, octane, nonane, decane, dodecane, normal propane, normal butane, normal pentane, normal hexane, normal heptane, normal octane, normal nonane, normal decane, normal dodecane, or a combination thereof.The method of claim 1 or 20, wherein the solvent, polar inorganic compounds, polar organic compounds, other light hydrocarbon compounds, or various oil fractions are evaporated by one or more heat exchangers, heaters, or other temperature-enhancing systems and subsequently recovered and condensed by one or more condensers or other cooling systems.The method of claim 1 or 20, wherein if the polar organic compounds are miscible with the solvent, the addition and mixing of strong polar liquid compounds, including water or basic aqueous solutions, or polar liquid compounds result in the separation of most of the polar organic compounds from the solvent; subsequently, in another distillation process, the polar organic compounds are separated from the water; alternatively, it is possible to reuse them without separating the polar organic compounds from the water in the stage (a) of the process.The method of claim 1 or 20 or 32, wherein the mixture of polar organic compounds and polar inorganic compounds, once recovered, is separated from each other through evaporation processes and then recovered; alternatively, without separating them from each other, they may be used as one of the constituents of precipitating agents.The method of claim 20, wherein the remaining oil in acidic sludges and asphalts is extracted after the production of microspheres.The method of claim 1 or 20, wherein the processes for producing base oil from waste oil or manufacturing microspheres can be conducted at laboratory, mini-pilot, pilot, semi-industrial, or industrial scales.The method of claim 1 or 20, wherein the temperature in all stages may vary within the range of -30C ° to +550°C, and the pressure in all stages may vary within the range of 0.001 to 260 bars, depending on the specific stage of the process.The method of claim 1 or 20 or 31, wherein heat exchangers, heaters, or other temperature boosters are utilized which obtain energy from fossil fuels, electrical energy, solar energy, or a combination thereof.The method of claim 1 or 20, wherein it is possible to change the temperature required for the separation of the solvent, polar organic compounds, water, other light hydrocarbons, or various fractions of base oil by altering the pressure in the evaporation vessels.The method of claim 1 or 20, wherein one or more separator systems are employed, utilizing various methods such as precipitation, centrifugation, filtration, or a combination thereof, to separate two different phases; this may include various centrifuges, different filtrations, and containers used for precipitation.The method of claim 1 or 20, wherein the mixer can encompass a wide range of mixing devices, such as simple mixers with one or more agitators, turbines, static mixers, anchor mixers, helical ribbons mixers, ribbon blender mixers, drum mixers, or a combination thereof; and the selection of the mixer depends on the type of the process, whether it is continuous or non-continuous.

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