Regenerated Lube Base Oil Blending After Hydro-Dewaxing
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Solution Overview
Problem
Existing methods fail to effectively utilize waste lubricants as feedstock for producing high-quality lube base oils, resulting in disposal and inefficient use of resources, while high-quality lube base oils are in demand with specific properties like high viscosity index and low volatility.
Innovation Solution
A method involving dewaxing and blending processes using waste lubricant-derived refined oil fractions, including hydrotreating, hydro-dewaxing, and hydrofinishing, to produce a lube base oil mixture meeting Group III or higher standards by utilizing catalysts like EU-2 zeolite and metals such as Co, Ni, Pt, Pd, Mo, W, and blending with separate lube base oils.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If waste lubricant is used as feedstock for producing lube base oil, then resource utilization is improved and environmental impact is reduced, but the quality of the produced oil deteriorates due to high impurity content
Solution Approach 1:
The patent segments the waste lubricant processing into multiple distinct stages: hydrotreating to remove sulfur and nitrogen, hydro-dewaxing to reduce wax content and improve pour point, and hydrofinishing to achieve final quality specifications. Each stage targets specific impurities or properties, allowing systematic transformation from low-quality waste lubricant to high-quality Group III lube base oil
Solution Approach 2:
The patent employs parameter changes by adjusting process conditions at each stage: temperature, pressure, catalyst types, and residence time are optimized to progressively transform the chemical composition and physical properties of the oil, converting waste lubricant with high impurity content into lube base oil meeting Group III specifications
2Manufacturing precision
If advanced hydrocracking reactions are used to produce Group III lube base oils, then the viscosity index and stability are improved, but the production cost and process complexity increase
Solution Approach 1:
The patent implements continuous processing where waste lubricant flows through a sequence of interconnected units (hydrotreating reactor, hydro-dewaxing reactor, hydrofinishing reactor) without interruption. This continuous action maintains consistent product quality and improves efficiency compared to batch processing, while the integrated design reduces overall complexity
Solution Approach 2:
The patent uses universal catalyst systems and processing conditions that can handle various types of waste lubricant feeds. The same basic process train (hydrotreating + hydro-dewaxing + hydrofinishing) can process different waste lubricant compositions to produce Group III lube base oil, making the process adaptable and reducing the need for multiple specialized units
3Use of energy by moving object
If waste lubricant is refined and used as fuel oil, then energy recovery is achieved, but the value utilization deteriorates as a high-value resource is downgraded to low-value fuel
Solution Approach 1:
The patent recovers valuable lube base oil from waste lubricant through systematic refining processes, preventing the downgradation that occurs when waste lubricant is simply converted to fuel oil. By removing impurities and restoring quality, the process recovers the high-value lubricating function rather than discarding it for low-value combustion
Solution Approach 2:
The patent changes the chemical parameters of waste lubricant through controlled chemical reactions (hydrogenation, hydrocracking, isomerization) to transform it from a degraded state suitable only for fuel into a refined state suitable for high-value lubricant applications, thereby maximizing resource value utilization
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method efficiently transforms low-quality waste lubricants into high-quality lube base oils, reducing environmental impact by recycling waste lubricants and achieving properties like high viscosity index, low volatility, and low impurity content, thus meeting Group III lube base oil standards.
Implementation Method 1
the hydro-dewaxing may be carried out in the presence of a catalyst including at least one of an EU-2 zeolite carrier, an alumina carrier, and a silica-alumina carrier
Implementation Method 2
The obtained refined oil fraction is then subjected to hydro-dewaxing to transform n-paraffin to iso-paraffin through an isomerization reaction, thereby improving low-temperature characteristics (securing a low pour point) and maintaining a high viscosity index
Implementation Method 3
The hydro-dewaxing may be carried out in the presence of a catalyst including at least one of an EU-2 zeolite carrier, an alumina carrier, and a silica-alumina carrier
Data Source
AI summary
A method of producing a lube base oil mixture includes providing a waste lubricant-derived refined oil fraction derived from a waste lubricant containing a lube base oil of API Group I or II. The waste lubricant-derived refined oil fraction contains an ionic refined oil, a first regenerated base oil, or a combination thereof, dewaxing the waste lubricant-derived refined oil fraction to produce a second regenerated base oil, and blending the second regenerated base oil with a separate lube base oil to produce a lube base oil mixture of Group III or higher. The method has an economical advantage because low-quality waste lubricant is used as a feedstock for the production of higher quality lube base oils. In addition, the method is advantageous in an environmentally friendly aspect because waste lubricant is reused rather than being disposed of.