Selection of The Most Appropriate Technology For Waste Mineral Oil Refining Project

Selection of the
Most Appropriate Technology

for Waste Mineral Oil Refining
Project
Technical Research Report

2012
THIS PROJECT WAS FINANCIALLY SUPPORTED BY 2011 DIRECT OPERATION SUPPORT

PROGRAM OF ISTANBUL DEVELOPMENT AGENCY
The content of this study, prepared within the framework of the Selection of the Most Appropriate Technology for Waste Mineral Oil Refining Project supported by Istanbul
Development Agency, does not reflect the views of Istanbul Development Agency or the Ministry of Development.
PETDER has the sole responsibility for the content of the study.
PROGRAM:
Istanbul Development Agency 2011 Direct Operation Support Program
AGREEMENT NO: NAME OF THE PROJECT:
İSTKA/2011/DFD/50 Selection of the Most Appropriate Technology for Waste

Mineral Oil Refining
PROJECT MANAGER: REPORT TERM:
Designed by Petroleum Industry Association. 15 January 2012 - 15 April 2012

PETDER does not have any associates for
this project.
ADDRESS OF THE PROJECT MANAGER:
Kaptanpaşa Mah. Piyalepaşa Bulvarı Ortadoğu Plaza No: 73 Kat: 5 D:10, Okmeydanı
34384 Şişli - İSTANBUL
FINAL BENEFICIARIES AND/OR TARGET GROUPS:
The final beneficiaries of this project are; local and foreign investors wishing to make
investments in the area of waste oil re refining, the Refining and Regeneration
Facilities in Turkey (31 facilities), the Ministry of Environment and Urban Planning,
Energy Market Regulatory Authority, Istanbul Metropolitan Municipality,
Universities, Mineral Oil Producers, Institutions Authorized by the Ministry of
Environment and Urban Planning, researchers interested in the subject and all waste
generators as it concerns public health.
PETDER-Petroleum Industry Association Page 2/65

INDEX
1 PROJECT SUMMARY ........................................................................................................................................... 5

2 PROJECT INTRODUCTION ................................................................................................................................ 7
2.1 AIMS OF THE PROJECT ................................................................................................................................. 7
2.2 RESTRICTIONS AND EXEMPTIONS ............................................................................................................ 7
3 WASTE OIL MANAGEMENT .............................................................................................................................. 9
3.1 WASTE OIL MANAGEMENT IN TURKEY ................................................................................................. 10
3.2 WASTE OIL MANAGEMENT IN OTHER COUNTRIES ............................................................................. 14
3.3 EU COUNTRIES, USA AND TURKEY COMPARISONS ........................................................................... 18
4 WASTE MINERAL OIL RECOVERY METHODS .......................................................................................... 20
4.1 PREPARIND WASTE MINERAL OILS FOR REUSE .................................................................................. 22
4.2 RECYCLING OF WASTE MINERAL OILS .................................................................................................. 23
4.3 RECOVERY OF WASTE MINERAL OILS AS ENERGY ............................................................................ 22
5 RE REFINING TECHNOLOGIES ...................................................................................................................... 24
5.1 ACID CLAY METHOD .................................................................................................................................. 23
5.2 CEP PROCESS ................................................................................................................................................ 25
5.3 MOHAWK PROCESS..................................................................................................................................... 27
5.4 HYLUBE PROCESS ....................................................................................................................................... 28
5.5 REVIVOIL PROCESS..................................................................................................................................... 30
5.6 AVISTA OIL SOLVENT EXTRACTION PROCESS .................................................................................... 31
5.7 CYCLON PROCESS ....................................................................................................................................... 32
5.8 INTERLINE PROCESS................................................................................................................................... 33
5.9 RELUBE PROCESS ........................................................................................................................................ 33
5.10 MEINKEN PROCESS ..................................................................................................................................... 33
5.11 PROP PROCESS ............................................................................................................................................. 33
5.12 SNAMPROGETTİ PROCESS......................................................................................................................... 34
5.13 SOTULUB PROCESS ..................................................................................................................................... 34
5.14 ENTRA PROCESS .......................................................................................................................................... 35
5.15 ATOMIC VACUUM PROCESS ..................................................................................................................... 35
5.16 MATTHYS - GARAP PROCESS .................................................................................................................... 35
5.17 ROSE PROCESS ............................................................................................................................................. 36
5.18 PROTERRA PROCESS................................................................................................................................... 36
5.19 FEMD- TECH PROCESS ................................................................................................................................ 37
5.20 SEQUOIA PROCESS ...................................................................................................................................... 37
5.21 TWFE PROCESS ............................................................................................................................................ 37
5.22 STP PROCESS ................................................................................................................................................ 37
5.23 RECYCLON PROCESS .................................................................................................................................. 38
6 COMPARISON OF AVAILABLE TECHNOLOGIES ..................................................................................... 40
6.1 ACID CLAY METHOD .................................................................................................................................. 41
6.2 HYDROPROCESSING METHODS ............................................................................................................... 41
6.3 SOLVENT EXTRACTION METHODS ......................................................................................................... 41
6.4 RE REFINING TECHNOLOGIES IN TURKEY .......................................................................................... 42
6.4.1 Technologies Implemented in Re refining Facilities ............................................................................... 43
6.4.2 Operating Conditions of the Facilities .................................................................................................... 46
6.4.3 Products Prodcued at the Facilities ........................................................................................................ 46
6.4.4 Waste Generated at the Facilities in the Production Process ................................................................. 47
6.4.5 Assessment of the Facilities in terms of Management Strategies ............................................................ 47
6.4.6 Areas to Improve in the Production Process at the Facilities ................................................................... 47
7 SUGGESTIONS REGARDING PROJECT IMPLEMENTATION ................................................................. 49
7.1 DETERMINING THE CAPACITY OF THE RE REFINING PLANT ........................................................... 49
7.1.1 Determining the Potential Amount of Feedstock ...................................................................................... 49

7.1.2 Regional Resources to Supply Feedstock ................................................................................................ 50
7.1.3 Determining the Feedstock Processing Capacity of the Plant .................................................................. 51
7.2 CHOOSING THE MOST APPROPRIATE TECHNOLOGY TO BE USED IN THE PLANT ..................... 52
7.3 PRE-FEASIBILITY STUDY OF THE PLANT ............................................................................................... 53
7.3.1 Selection of the Location of the Plant and Size of the Site ...................................................................... 53
7.3.2 Preliminary Financial Studies .................................................................................................................. 57
8 GENERAL ASSESSMENT ................................................................................................................................... 62
BIBLIOGRAPHY ........................................................................................................................................................... 65

1 PROJECT SUMMARY
An industrial refining facility built in accordance with the models in developed countries, that
removes the contaminants (PAH, chloride compounds, heavy metals etc.) in the waste oil and
produces base oil conforming to the standards does not exist in Turkey.
According to calculations, approximately 400-450 thousand tons of mineral oil is consumed in

Turkey generating nearly 200-250 thousand tons of waste mineral oil after use. According to data
from the Ministry of Environment and Urban Planning, 45-50 thousand tons of waste oil is recorded
and collected in Turkey. The remaining 200 thousand tons of oil is collected illegally by purchasing,
used as illicit fuel under the name of Number 10 Lube or blended with other fuels, offered to the
market as unqualified oil, combusted for heating in uncontrolled environments or disposed
improperly. Briefly, waste mineral oils are collected to a large extent but only a proportion is
recorded and processed legally.
According to data from the Ministry of Environment and Urban Planning, 32% of recorded waste
oils is combusted in cement, lime and iron and steel factories for energy recovery, 64% is processed
in refining and regeneration facilities for recovery as feedstock, 4% is disposed by disposal facilities.
Combustion of waste oils in iron and steel, cement and lime factories for energy recovery and
production of neutral base oil removing all the contaminants in the waste oils by means of
appropriate advanced refining technologies are recovery methods widely implemented in developed
countries and approved by EU legislation. These methods aim to prevent overconsumption of
petroleum resources and contribute to the economy by means of the products produced using these
technologies.
40% of the mineral oils that have detrimental impacts on the environment and human health is
generated in Marmara Region. Waste mineral oils are blended with fuel to a great extent, offered to
the market as products that do not comply with the standards after being processed with
inappropriate methods and used for illegal activities under the name of Number 10 Lube. This
project aims to prevent the negative impacts of the waste oils to the air, water and soil ecosystem of
Istanbul by producing high quality products conforming to the standards, to improve the life quality
in the cities and to contribute to the waste management system practices.

A preliminary feasibility study has been carried out within the framework of the project by means of
a comparative analysis of the legislation and technological developments regarding the re refining of
the waste mineral oils and the practices in Turkey in order to select the most appropriate technology
for the re refining of the waste mineral oils collected from Istanbul and neighboring cities.
We wish that this report prepared within the scope of the project will be beneficial to the local and
foreign investors wishing to make investments in Turkey.
We express our thanks to the Ministry of Development, Istanbul Development Agency for their
financial support, and experts and consultants whose knowledge and experience we have benefited
from.
Petroleum Industry Association

İstanbul, 20 April 2012

2 PROJECT INTRODUCTION
2.1 AIMS OF THE PROJECT
The main aim of this project is to prevent the damage to the ecosystem of Istanbul and Turkey
caused by the waste mineral oils, 40% of which is generated in Marmara region and illegally blended
with fuel, offered to the market as products that do not comply with the standards after being
processed with inappropriate methods and used for illegal activities under the name of Number 10
Lube or combusted in uncontrolled environments. The target issues in order to achieve this goal are
mentioned below and the report tries to answer the probable questions that might be raised on these
issues.
- To outline the technical, economic and social requirements of the first waste oil refining
plant in Turkey that will process waste oil to produce Group I or Group II high quality
base oil in compliance with the standards TS 13369 and ASTM 6074 and to contribute to
the economy by means of reusable base oil production.
- To determine the logistic framework necessary for the collection and disposal of waste
mineral oils mainly in İstanbul.
- To be able to contribute to the additions and amendments to the Waste Oil Control
Regulation required because of the flaws that occur during the practices while meeting the
requirements of the regulation.
- To determine the appropriate technology that will enable the recovery of waste oils
primarily as feedstock in accordance with EU Waste Directive and to work out a solution
for Istanbul based on this technology.
2.2 RESTRICTIONS AND EXEMPTIONS
The analysis and assessments in this report are based on the knowledge and experience provided by
experts, data obtained from field surveys and observations and documents obtained from relevant
sources. The factors that were faced during the compilation of this data and that have direct impacts
on the framework of the analysis and the factors that were excluded from this report are mentioned
below and need to be considered in the course of assessments.

- “Waste Oils” mentioned in many parts of this report include waste mineral oils. Other
waste oils such as vegetable oils or synthetic lubricants are excluded from this definition
and this report.
- The study conducted is limited to the examination of documents gathered by PETDER.
- The content of this study, prepared within the framework of the Selection of the Most
Appropriate Technology for Waste Mineral Oil Refining Project supported by Istanbul
Development Agency, does not reflect the views of Istanbul Development Agency or the
Ministry of Development. PETDER has the sole responsibility for the content of the
study.
- The evaluations regarding the institutions are based on examinations carried out on-site
and on the date of examination. The changes that have taken place after the preparation of
the report regarding the equipment or the organization of the facility and their impacts
should be taken into consideration for an objective assessment.

3 WASTE OIL MANAGEMENT
Hazardous waste, one of the detrimental effects of industrialization, has been widely discussed in
developed and developing countries recently. Waste mineral oil, that is also considered as hazardous
waste, has been a significant part of the waste management plans of these countries. Waste oil
management is necessary in order to minimize the negative impacts of the waste oil on the
environment and human health, and to reuse this hazardous waste by means of the most appropriate
technologies to contribute to the national economy. In this respect, the key groups in the waste oil
management system; oil producers, waste oil generators, waste oil transporters, recovery and
disposal facilities, licensed parties, all the relevant official bodies need to cooperate within the
framework of the regulations in the legislation. Moreover, at each step of waste oil management, it is
important to take the necessary measures to ensure that waste management is carried out without
endangering human health, without harming the environment. The aim should be continuous
improvement and the public should be regularly informed regarding the progress.
Although it is possible to observe some differences among the waste oil management systems in
different countries because of the diversities in social and economic habits and priorities in
environmental activities, this does not change the fact that the activities mentioned above should be
carried out. In order to maintain a nation-wide waste oil management system, it is necessary to
determine the aims at each step from analysing the waste oil at the source until the recovery or
disposal phase and “Health, Safety, Environment and Security” factors should be considered while
defining the aims.
In the Waste Directive 2008/98/EC of the European Parliament and of the Council of 19 November
2008, issues such as separate collection of waste oils, adoption of an appropriate waste management
strategy and prevention of environmental damages caused by landfill are highlighted. According to
the Waste Hierarchy presented in the Directive, waste should be reduced (prevention), prepared for
reuse (reclaiming), recycled to be feedstock (recycling), recovered as energy (energy recovery) and
disposed if there is no other alternative (disposal). However, the directive also necessitates carrying
out Life Cycle Assessments in the waste oil recovery processes. Because the results of the life cycle
assessment might depart from this hierarchy for the management of some wastes. Therefore, waste
hierarchy presented in the EU legislation might be altered based on the results of the life cycle
assessment. Reuse, which is presented as the second option, might be considered as the last option
even after disposal based on the results of the life cycle assessment.

Life Cycle Assessments provide valuable information on the issues such as recovering waste oil as
base oil by means of various refining methods or in the form of energy using the most appropriate
methods with minimum environmental impacts. These studies vary depending on the type of waste
oil, the refining method used etc., and even on the transportation distances. As a result of this
directive that necessitates taking the Life Cycle Assessments into consideration, many countries have
prioritized energy recovery in waste oil management. However, in terms of waste management in
Turkey, the knowledge and experience on Life Cycle Assessments is not sufficient and such
scientific methods are not employed in waste management planning.
3.1 WASTE OIL MANAGEMENT IN TURKEY
In the course of the EU harmonization studies conducted by the Ministry of Environment and Urban
Planning, the waste directive 2008/98/EC of the European Union serves as the basis for the
legislative arrangements on the subject in Turkey. The first legal regulation pertaining to the waste
oil management in Turkey is the ‘Waste Oil Management Regulation’ issued by the Ministry of
Environment and Forestry, as it was then called, effective after its publication in the Official Gazette
dated 21.01.2004 and numbered 25353. The regulation is based on a dynamic model that imposes
liabilities on waste oil producers, motor oil producers, local authorities, directorate, recovery and
disposal facilities. In this model, motor oil producers’ and importers’ liability to collect motor oil and
the principle of “the liability of producers, importers and those releasing motor oil products to the
market” mentioned in Article 11 of the Environment Law numbered 2872 became effective.
When the market supply and demand of mineral oil in Turkey is analyzed, it is observed that a
demand surplus of 1 million 50 thousand tons of mineral oil occurred in 2011. The main reason for
this is the illegal activities carried out under the name of Number 10 Lube that is imported in order to
be used as base oil in mineral oil industry and widely used and sold in the diesel market. Therefore, it
has become difficult to determine the actual amount of mineral oil consumption in Turkey accurately
and make a sound assessment on the amount of waste oil generation.
According to data from the Energy Market Regulatory Authority (EMRA), the number of licensed
Mineral Oil Producers in Turkey was 310 by the end of 2011. The mineral oil consumption in
Turkey could be only roughly calculated based on; mineral oil market data provided on a voluntary
basis by ALPET, BP, CASTROL, LUKOIL, OPET, POAŞ, SHELL, TOTAL and MOIL, foreign
trade statistics published by TSI and declarations submitted to the Ministry of Environment and

Urban Planning. According this data, mineral oil consumption, which was 416 thousand tons in
2010, totaled 411 thousand tons in 2011.
Figure 3.1.1- Amount of Mineral Oil consumed in Turkey in 2010 and 2011 (thousand ton/year)
In accordance with the annual consumption figures, the amount of oil that is defined as waste after
being used is estimated to be approximately 250 thousand tons. However, according to 2010 data
from the Ministry of Environment and Forestry, 43.959 tons of waste oil was recorded and collected
while the remaining 206.041 tons of waste oil could not be recorded.
An assessment based on the recorded waste oil that has been collected displays that 14.575 tons of
waste oil was recovered as energy in cement, lime, iron and steel plants, 28.140 tons of waste oil was
recovered as feedstock in refining and regeneration facilities, 1.244 tons of oil was disposed in
disposal facilities.
In the period following the publication of the regulation, amendments in the regulation were made on
30.07.2008 because of the problems faced during the collection, transportation, categorization of
waste oils and the release of the recovered products to the market regarding the application of these
processes. The aim of the amendments was to have a more applicable regulation with a wider scope.
However, it is obvious that more studies should be conducted regarding this Regulation as there is an
increase in misuse of imported base oils and the waste oil recovery practices have not yet reached the
desired levels and qualifications.

The regulation authorizes the “Motor Oil Producers” or “Authorized Bodies” for the collection of
waste motor oils. It is forbidden for persons and organizations other than these parties to collect oil.
Petroleum Industry Association (PETDER) has been assigned as an “Authorized Body” by the
Ministry of Environment and Forestry regarding the nation-wide collection and recovery as
product/energy or disposal of Waste Motor Oils in licensed facilities. In this respect, the statistical
data regarding the “waste motor oil collection” activities carried out by the association since 2004
within the framework of Waste Oil Management Regulation is a significant source in terms of waste
oil management in Turkey. According to this data on Waste Motor Oil, the amount of waste motor
oil collected in 2011 was 20.576 tons. 9% of the waste motor oil collected was recovered as
feedstock in licensed refining and regeneration facilities, 83% was recovered as energy at cement,
lime or iron and steel factories and 8% was transferred to the disposal facilities as hazardous waste.
Figure 3.1.2- Yearly Amounts of Waste Mineral Oils Collected by PETDER (ton)

Figure 3.1.3- The breakdown of the categories of waste motor oils collected in 2011
The breakdown of the sources of waste motor oils collected in 2011 is as follows:
55% from Garages, 9% from Industrial Car Parks, 6% from Public Institutions, 4% from
Municipalities, 6% from Construction and Mining Industry, 2% from Oil Producers, 15% from
Military Organizations, 1% from Transport Companies and the remaining 1% from Washing and
Lubricating Stations and other institutions.
Figure 3.1.4- The breakdown of the sources of waste motor oils collected in 2011

The regional breakdown of the total waste engine oil collected in 2011 is as follows:
8 thousand 466 tons from Marmara Region, 2 thousand 802 tons from Aegean Region, 3 thousand
622 tons from Central Anatolia Region, one thousand 902 tons from Black Sea Region, 2 thousand
107 tons from Mediterranean Region, 835 tons from Southern Anatolian Region, 842 tons from
Eastern Anatolian Region.
Figure 3.1.5- Regional Breakdown of the Total Waste Motor Oil Collected in 2011
When the cities are listed according to the amount of waste motor oil collected in 2011, the top ten
cities from the most to the least are İstanbul, Ankara, İzmir, Kocaeli, Bursa, Adana, Tekirdağ,
Kayseri, Antalya and Zonguldak. The cities where the amount of waste motor oil collection was the
least are Şırnak, Muş, Ağrı, Kilis and Bitlis.
3.2 WASTE OIL MANAGEMENT IN OTHER COUNTRIES
Upon examining the waste oil management strategies in other countries, it has been observed that
rather than a single standard approach, there are various different approaches. In the legal regulations
worldwide waste oils are treated in two different ways which are recovery as feedstock or energy and
disposal as hazardous waste.
In the Kline Report, which is an important reference in waste oil recovery, it is stated that a total of
32.3 million tons of mineral oil was used worldwide in 2009 and that 22.4 million tons of waste oil
was generated after use. 16.5 million tons (74%) of this amount was collected but it was not possible
to collect the remaining 5.9 million tons (26%) of waste oil for recovery and it could not be recorded
how this amount was used.

Figure 3.2.1- Waste Mineral Oil Collection Rates on a Global Scale
An analysis of the total waste oil collected indicates that 12.9 million tons (78%) of waste oil was
used as additional fuel for energy recovery, 2.6 million tons (16%) of waste oil was recovered as
feedstock and the remaining 1 million tons (6%) of waste oil was disposed.
In GEIR 2008 report, an analysis based on the amount of waste oil collected indicates that 50% of
the waste oils collected in the European countries was used as additional fuel for energy recovery
and 37% was recovered as feedstock for production. It is stated in the report that the EU average of
recorded and recollected waste oils is 74%.
Figure 3.2.2- Distribution of Waste Mineral Oil Recovery Methods on a Global Scale

The waste oil management practices in some of the EU countries and North America are summarized
below:
In France; ADEME “French Environment and Energy Management Agency” implements the waste
oil management policy. The waste oils are collected by collectors and transporters authorized by
ADEME. Waste oil collection rate is 44%. 41% of the waste oils collected are used in cement
factories or other allowed facilities for energy recovery. 42% of waste oils is processed in re refining
facilities for recovery as feedstock. (GEIR, 2008).
In Germany; waste oils are categorized under different groups: non-chloride, non-halogen, PCB and
halogen based, biologically soluble, insulating, heat transfer, oil/water separator oils. Waste
generators are free to deliver their used oils for recovery either as feedstock or energy. However,
with the regulation in 2002, recovery as feedstock was prioritized. 29% of the waste oils collected
are used in cement, lime or iron and steel factories for energy recovery. 26% of the waste oils
collected is processed in re refining facilities for recovery as base oil and nearly 105 thousand tons of
imported waste oil is processed to produce base oil. (GEIR, 2008).
In Italy; waste oils are managed and collected by a consortium (COOU) consisting of mineral oil
producers, waste oil collectors and refining facilities. This consortium works under the authority of
the Ministers of Industry, Finance, Health and Environment. COOU is responsible from the
collection, quality controls and processing of waste oils. There are approximately 80 collectors in
Italy. Waste oil collection rate is 49%. 15% of the waste oils collected are used in cement factories or
other allowed facilities for energy recovery. 82% of waste oils is processed in re refining facilities for
recovery as feedstock. (GEIR, 2008).
In the United Kingdom; there are lots of collectors. Waste oil collection rate is 50%. A great
proportion of the waste oil (68%) are combusted as additional fuel in iron and steel plants and
cement factories for energy recovery. Some of the waste oils (6%) are exported to EU countries to be
re refined. (GEIR, 2008).
In Finland; the government has authorized a company called EKOKEM for waste oil management.
Waste oil collection rate is 30%. (GEIR, 2008). Until 2007 all the waste oil collected was used for
energy recovery. In 2007 EKOKEM signed a 5 year protocol with the only refinery in Finland and
since 2007 a part of the waste oils collected is delivered to this refinery.

In Spain; waste oil management is carried out by two non-profit organizations founded by mineral
oil producers and importers. One of these organizations, SIGAUS, has been carrying out its activities
since 2008 with 105 members and 94% market share. The market share of the other authorized
organization SIGPI is 6%. Waste oil collection rate is 40%. 44% of the waste oils collected are used
in cement factories or other allowed facilities for energy recovery. 56% of waste oils is processed in
re refining facilities for recovery as feedstock. (GEIR, 2008).
In Portugal; waste oil management is carried out by a non-profit organization, SOGILUB with the
cooperation of Portuguese Businessmen’s Association and Recovery Associations founded in 2005
and Petroleum Association. The only authorized institution for waste oil collection is SOGILUB.
Waste oil collection rate is 45%. 59% of the waste oils collected are used in cement factories or other
allowed facilities for energy recovery. 12% of waste oils is processed in re refining facilities for
recovery as feedstock. 12% of the waste oils collected is imported to Spain for recovery as
feedstock. (GEIR, 2008).
In Greece; ELTEPE SA, founded in 2004 following the formation of the legislative framework, was
authorized for the collection of waste oils (setting up a national system for the collection of waste
oils). The amount of collection that was 8.000 tons before increased to 40.000 after 2004. The system
enables the collection of waste oils by licensed collectors and its sale to the refineries. Greece has
banned the reuse of waste oils that have gone only through pre-treatment and not recovered as energy
of refined.
In the USA; the refining industry is rather small and reuse of waste oils as additional fuel for energy
recovery is promoted. A centralized management like those in the European countries for waste oil
management does not exist in the USA. In this respect, the states adopt different practices and
industry statistics differ in each state. In some states, collection activities are supported by the taxes
from mineral oil sales, in some states waste oils are regarded as hazardous waste in order to prevent
contamination. Some local authorities allocate funds to support collection activities. The federal
policy of the USA government supports the reuse of re refined oils, recycling of waste oils by means
of different processes including incineration and disposal of waste oils.
In conclusion, this study indicates that waste oil recovery methods differ from country to country and
that there is no single model implementation that can be considered as the most appropriate.

3.3 EU COUNTRIES, USA AND TURKEY COMPARISONS
A graphical model was preferred to display the waste oil management data in order to demonstrate
the recorded waste oil collection capacities and the recovery practices in EU countries, USA and
Turkey more clearly. When the recorded waste oil collection capacities are compared, it is observed
that Turkey’s waste mineral oil collection capacity is very low compared to EU countries and USA.
In terms of waste oil management in Turkey, a significant amount of waste oil is uncontrolled and
therefore there is a great deal of unrecorded activity in the sector. (Figure 3.3.1)
EU Countries (*)
Recorded
74% Unrecorded
26%
(*) GEIR,2006 Report

Total Amount of Mineral Oil= 5.7 0 million tons
Estimated Amount of Waste Oil = 2.85 million tons
USA(**)
Recorded
Unrecorded
69%
31%
(**) U.S. Department of Energy, 2006

Total Amount of Mineral Oil = 2.50 billion galons
Estimated Amount of Waste Oil= 1.37 billion galons
Turkey (***)
Unrecorded
Recorded
83%
17%
(***) Ministry of Environment and Forestry Action Plan

Total Amount of Mineral Oil = 363 thousand tons
Estimated Amount of Waste Oil = 250 thousand tons
Figure 3.3.1- Waste Mineral Oil Collection Rates (EU, USA and TR)

When the recovery methods of the waste oils collected and recorded are compared, it is observed that
Turkey prefers feedstock recovery processes more than EU countries and USA and energy recovery
processes are employed less than other countries. (Figure 3.3.2)
EU Countries
Energy Recovery
Feedstock Recovery 50%
37%
Disposal 13%
USA
Energy Recovery +
Disposal
83%
Feedstock Recovery
17%
Turkey
Feedstock Recovery
Energy Recovery
60%
33%
Disposal
7%
Figure 3.3.2- Waste Mineral Oil Recovery Methods (EU, USA and TR)

4 WASTE MINERAL OIL RECOVERY METHODS
The properties of mineral oils change in time due to the degradation of the hydrocarbons and the
additives in its content. Moreover, these oils lose their functionality with the addition of other
contaminants, such as dust, dirt, unburned fuel, moisture or corrosion by-products, that do not exist
in the original compound and these used oils are defined as waste oils.
Although used oils are defined as ‘Waste’ and regarded as hazardous waste, they have the potential
to be recovered as base oil or energy due to their calorific value and the hydrocarbons in their
content. (Table 4.1.1). This potential of waste oils can be recovered in accordance with the oil
reclaiming, recycling or energy recovery principles stated in the Waste Hierarchy presented in the
Waste Directive (2008/98/EC, 19.11.2008) issued by the European Union.
Type of Fuel Calorific Value (kcal/kg)

Natural Gas 13.000
Diesel 10.250
Waste Oil 9.600
Fuel Oil 6 9.600
Lignite 4.600
Table 4.1.1- Calorific Values of Various Fuels
EU and other developed countries’ legislations and practices on this issue regard waste oil as a
significant alternative energy source because of its high calorific value and support the processes that
will enable the recovery of waste oil as base oil by means of advanced industrial refining techniques.
A comparison of the total environmental impacts of waste oil regeneration and energy recovery
processes does not provide a definite decision about which is a more preferable process in terms of
environment and economy. (Table 4.1.2). This decision should be made concentrating on the key
environmental impacts and taking into account the whole life-cycle of products and materials.
In order to make a sound assessment on this issue, the total environmental impacts of the processes
to be implemented (collection, transportation, recycling and disposal impacts) should be considered
as a whole, the environmental impacts at each step should be assessed comparatively. By assessing
these processes with this approach, the necessity to take a series of requirements into consideration
emerges. These requirements are to make sure that the recovery technology employed does not create

an additional waste problem compared to the former situation of the product and that the product is
more productive than the former product in terms of energy.
Regeneration
Environmental Impacts* (Vacuum Distillation + Clay Energy Recovery
Treatment)
Waste - +
Emissions + _
Energy Consumption - +
Fossil Fuels Consumption + -
Global Warming Potential - +
Water Consumption - +
* European Commission Critical Review of Existing Studies and LCA on the Regeneration and Incineration of Waste Oils
Table 4.1.2- Environmental Impacts of recovery and regeneration methods to be considered
The table above indicates that there is a balanced situation between the energy recovery of the waste
mineral oils and re refining waste oils in order to produce base oil. According to this table, energy
recovery gives better results in terms of the wastes generated during the process, energy consumption
and global warming potential compared to regeneration process. On the other hand, in terms of total
emissions and fossil fuel consumption, refining practices give better results.
4.1 PREPARING FOR RE-USE
Oil reclaiming, that is, preparing waste oils for reuse is often confused with recycling which is used
for the recovery of the waste oil as feedstock. Preparing the waste oil for reuse can be defined as the
waste oil generator’s removing the contaminants in the waste oil and replacing the degraded
additives or having a mineral oil producer carry out this process. The ultimate aim is to prepare the
waste oil for reuse. In this respect, the mineral oil producer should take samples at the places where
mineral oil is used to conduct analysis in order to determine the amount of additives in the mineral
oil or to check the functionality of the oil. After this step, removing the contaminants in the oil with
simple processes carried out at the place where mineral oil is used or improving the quality by means
of additives can be defined as preparing for reuse.

4.2 RECYCLING
Recycling of waste mineral oils as feedstock can be defined as the removal of all pollutants,
oxidation products and particles from the waste oil to result in original oil suitable for the use
intended as per national and international standards and specifications.
The main principle is producing base oil from the waste oil that involves small quantities of
contaminants (water, fuel, sand, oxidation products etc.), is not biologically soluble and involves less
than 50 ppm PCB/PCT. Re refining for recovery is one of the technological options.
Recovery of the waste oils as base oil, which is the subject of this project, is a method employed for
its positive contribution to the effective use of raw materials and reduction of emission values as long
as it is carried out by means of appropriate technologies.
4.3 ENERGY RECOVERY
Recovery of waste oil as energy means adding the waste oil to the fuel to be used for energy in
licensed facilities. Using waste mineral oil as additional fuel in cement and iron and steel industry is
a worldwide practice for energy recovery. After the removal of the suspended solid contaminants and
water, a certain amount of the waste oil is added to the fuel and used in cement, lime, iron and steel
production facilities and power plants.
Recovery of waste oils as energy is a waste treatment process that involves the combustion of oil at
1300-1400 0C to eliminate the contaminants in the oil. This process called incineration is widely
preferred in developed countries as it is an effective treatment of hazardous wastes. This method is
especially effective for the mineral oils that have lost their technical properties.

5 RE-REFINING TECHNOLOGIES
Used oil recycling technology has undergone significant changes over the past decade. With the
newly developed re-refining technologies it is possible to produce higher quality, sometimes even
API Group II base oil compared to the traditional and old acid clay method. The major concern in
the sector is that the consumers do not differentiate between the recovered lubricants and the
lubricants produced with simple physical extraction or chemical treatment and Group II high quality
refining products. There are a large number of re-refining technologies and the most widely
acknowledged ones are explained in detail in the following chapters.
5.1 THE ACID / CLAY RE-REFINING METHOD
In this process which has been widely used by re-refining facilities, used oil is initially subjected to
filtration and dewatering mechanisms. Light products (Ethane, Methane etc.) are removed at the
initial distillation step. It is then contacted with sulfuric acid which extracts oxygen compounds,
asphalt, resin derivatives, other nitrogen and sulphur based compounds and metal contaminants from
the oil. At the end of this process, desirable concentrations of paraffin and naphtalene molecules
remain in the oil. Next, the oil is mixed with active clay to remove the colour and odor. After the
filtration step, the product has the necessary qualifications to produce base oil. Figure 5.1.1 provides
the flow chart of the process.
One of the main drawbacks of this process is that it causes environmental pollution due to generation
of acid sludge and acid gas emission. Both residues are considered as hazardous waste as they
contain toxic metals and sulfuric acid and disposal costs are high. Therefore, many countries have
banned this process. However, it is still used in countries like Brazil, India and China to produce low
quality market product. Spent clay is usually used in ceramic and cement industries. Although there
are facilities that employ this technology in Turkey, it cannot be claimed that the production in these
facilities follow the requirements of the process as the acidification step of the process is skipped
because of the risks and the difficulty of the process.

Water and
Light
Products Gas Oil
Waste Oil
Clay Derivatives
Treatment
Distillation and
Filtration
Base Oil
Acid Acidic Sledge

Acidification
Heavy
Residue
Clay Clay Treatment Clay and Filter (Asphalt)
and Filtration Waste
Figure 5.1.1- Acid Clay Method Flowchart

5.2 CEP PROCESS
This process was designed by Chemical Engineering Partners (CEP), a process technology company
offering a range of products and services for re-refining of waste / used lubricating oils. The process
is based on composition of feedstock, thin film evaporation and hydro processing.
Feedstock Analysis
In this method, the feedstock needs to be analyzed beforehand due to some criteria that should be
considered regarding the process and several restricting requirements in order to maximize the life
span of the existing equipment. Based on the figures at the end of the analysis, chemical treatment
should be carried out in order to reduce fouling in the process equipment. During the chemical
treatment, the water and the volatile compounds in the feedstock are eliminated. Next, the
contaminants in the oil such as used additives and the impurities that can contaminate the catalyst are
removed.
Thin Film Vacuum Distillation

After the pre treatment, the feedstock is delivered to a film evaporator that operates under vacuum.
Used oil is mixed and coked by continuously rotating pedals in the evaporation tank. The lubricant is
evaporated, the residue is asphalt material. The vacuum allows separation at temperatures below oil
cracking temperatures. The lower temperatures and short residence time in the wiped film evaporator
minimize coking that occurs in other types of distillation equipment. At this step, the additives and
high boiling hydrocarbons are separated from the base oil. The chemical additives and the heavy
metals that were in the initial lubricant remain in the asphalt that is now a product. Asphalt is sold to
be used in various areas such as roofing.
Hydro treating
In the final stage of the process, three hydro treating (Hydro finishing) reactors are used in series to
reduce sulfur to less than 300 ppm and increase saturates to over 90%, meeting the key specifications
for API Group II base oil. The final step is vacuum distillation to separate the hydro treated base oil
into multiple viscosity cuts in the fractionator.The flowchart of the process is provided in Figure
5.2.1. Hydro processing technology is one of the most widely used distillation processes to eliminate
undesirable components such as sulphur, nitrogen, metals or unsaturated hydrocarbons. The major
facilities that use this technology commercially are: Evergreen (Newark, CA, USA), Universal
Lubricants (Wichita, KS, USA) Heartland Petroleum (Columbus, OH, USA.) and L&T Recoil
(Hamina, Finland).

Figure 5.2.1- CEP Process Flow Chart

5.3 MOHAWK PROCESS
This process was initiated as a technological cooperation by Mohawk and CEP in 1989. First the
contaminants in the waste oil are removed with chemical treatment. Following this pre-process stage,
the light hydrocarbons and water are separated with atmospheric flash distillation. At the next step,
diesel fuel fractions are removed with flash distillation under vacuum. After this, asphalt is separated
from the oil in the thin film evaporator. Light products go through hydro finishing process at high
pressure (1000 psi) over a standard catalyst. In the final stage, different types of base oil are
produced by distillation. (Figure 5.3.1)
H2
Hydroprocess
Unit
Light Gases 4
Light Gases 0,5
Water 10 Diesel 6
Diesel 0,5
Flash
Flash Vacuum Vacuum
Distillation Distillatio Distillation Distillation Light
Medium 65
Chemical Additive Heavy

Pretreatment
Unit
Waste Oil 100 Thin Film

Evaporator
Asphalt 14
Figure 5.3.1- Mohawk Process Flow Chart
Mohawk process has been licensed for Evergreen (USA and Canada). With the improvements in the
available technology, the amount of water which must be treated as effluent was reduced and special
steps realized catalyst life to 8 – 12 months. It is possible to use the asphalt produced during the
process directly in construction industry and the quality of the product is quite high. The following
facilities employ this process: North Vancouver (Canada) 600 barrel/day, Evergreen (USA)
50kt/year and Southern Oil Refineries (Australia) 20kt/year. According to a research published in
1996, feedstock cost constitutes 42.7% of the total product cost in Mohawk Process.

5.4 HYLUBE PROCESS
UOP designed HyLube™ Technology upon demand from Puralube in 1995. This process that
operated on a continuous basis is made up of three stages: Pre Treatment, Catalytic Hydro processing
and Product Recovery and Finishing
Pre Treatment
The feedstock is first filtered to remove solids and then mixed with hot hydrogen in a specially
designed, pressurized mixing chamber. The heated mixture is sent to a flash separator and the flash
separator bottoms liquid is routed to a residue stripper. The combined flash separator vapour and
residue stripper overheads are processed through a catalytic guard reactor for soluble metals removal.
The asphalt residue is suitable for use in asphalt industry. The gas concentration evaporated in the
flash separator involves hydrocarbons up to the level of C4 and it is sent to the catalyst unit. Initial
mixing of hot hydrogen gas with the feed at 4800C and 80 bar pressure results in the separation of the
high value lubricating oil molecules in a high pressure / high temperature environment, which avoids
coking and fouling.
Catalytic Hydroprocessing
In the multi-stage high-pressure system, the gaseous hydrocarbon materials are initially separated
from the residual impurities and metal compounds (guard reactor), and then processed for
desulphurization. Using patented hydrogenation catalysts, a deep saturation of olefins and aromatics
is achieved (conversion reactor), which are then hydro finished at adequate high temperatures and
pressures. These processes involve intense desulphurization and elimination of other heteroatom's of
all base oil fractions.
Product Recovery and Finishing

After depressurization, whereby the surplus hydrogen is scrubbed to remove the chlorides and
sulphides generated in the hydrogenation stages, the hydrogen is used as a recycle gas. Processing
conditions such as pressure, space velocity, and hydrogen circulation rate are diverse from unit to
unit depending on feedstock quality. The processed feedstock is converted into a wide boiling range
hydrocarbon product, which is subsequently fractionated into neutral oil products of different
viscosity by vacuum distillation to be used for lube oil blending. Among these products, besides base
oil fractions, by-products such as naphtha, gas oil, gas fuels are also of high quality. For example, the
sulphur level in the diesel product with high cetane number is below 5ppm. Production of such
products is preferred to compensate for the high catalyst costs in the process. (Figure 5.4.1)

Figure 5.4.1- HyLube Process Flow Chart

5.5 REVIVOIL PROCESS
Revivoil™ process was developed jointly by Axens and Viscolube in Viscolube facilities. It is made
up of three sections: Pre Flash, Thermal De-Asphalting and High Pressure Hydro finishing.
Pre Flash
Water present in the used oil feedstock has to be removed. In this stage, the feedstock is heated to
140 degrees Celsius and then distilled in a column where the water and light hydrocarbons are
separated.
Thermal De-Asphalting TDA

The dehydrated oil is distilled at 360 degrees Celsius in a vacuum de-asphalting column (TDA). The
asphaltic and bituminous products remain at the bottom.
High Pressure Hydro Finishing

The base oil fractions and vacuumed gas oil content are treated with hydrogen in the catalytic reactor
and go through hydro processing in order to improve product quality. The H2S that is generated
during the reaction is refined and returned to the process as hydrogen feedback. With the following
stripping step, the base oil and diesel fractions with the desired properties are produced. As a result
of these treatments, the metals, organic acids and other residual compounds involving sulphur and
nitrogen are eliminated from the base oil mixture. Moreover, this process adjusts the colour and
temperature stability requirement to produce base oil. This process is applied in: Viscolube (Pieve
Fissiraga, Italy) 100 kt/year, Agip Petrol Refinery (Ceccano, Italy), Jedlizce Refinery (Poland)
80kt/year, Surabaya Refinery (Indonesia) 40kt/year, Merak Refinery (Indonesia), Huelva and
Cartagena Refineries (Spain), Hellas Refinery (Greece) and other facilities in Pakistan and Serbia.
(Figure 5.5.1)

Figure 5.5.1- Revivoil Process Flow Chart
5.6 AVISTA OIL SOLVENT EXTRACTION PROCESS
Avista Oil (USA) bought the licence of the process from Enprotec Vaxon (Denmark) in 2000 and
commercialized the process under the name of Avista Oil Solvent Extraction –Vaxon™ Technology.
The process consists of chemical process, vacuum distillation and solvent extraction stages. This
process is used in Dollbergen-Uetze and Kalundborg facilities of Avista Oil to produce Group I Base
Oil.
In the initial stage of the process, the water and light hydrocarbons in the feedstock are separated
with pre-flash. In the chemical treatment that follows, alkali hydroxides (NaOH, KOH) and the
chloride compounds, metals, additives and acid compounds in the used oil are extracted. The
extraction takes place when the oil soluble alkali hydroxides compound with the asphaltic molecules
of the undesired substances in the waste oil with the help of the catalyst. The remaining light
hydrocarbons, the catalyst, base oil derivatives and other residues are extracted in a series of
extractions following the chemical treatment. At the solvent extraction stage of the process,
Enhanced Selective Refining-ESR™ method is used. At ESR stage, the extracted oil is fed into the

extraction column from the bottom. While the oil keeps rising, polar solvents such as
dimethylformamide and N-Methyl-2-pyrrolidone (NMP) are added from the top of the column for
liquid/liquid extraction and polycyclic aromatic hydrocarbons and heteroatomic compounds are
extracted. The bottoms product of this extraction can be used as asphalt material or energy source.
The solvent in the distillate can be stripped and recycled at the next step. The remaining neutral base
oil compounds are distilled under vacuum at the final stage and fractionated. (Figure 5.6.1)
Figure 6.6.1- Avista Oil Process Flow Chart
5.7 CYCLON PROCESS
Used oils taken from storage tanks are dehydrated and the light hydrocarbons are removed by
distillation. The oils in the residues are extracted with propane in the de-asphalting unit and sent to
the hydro processing unit where the other oils will be processed. Then they are treated with hydrogen
and fractionated based on the desired base oil features. After the additives are added they are ready
for sale. Cyclon Hellas Company in Greece uses this process with an annual capacity of 34 kt/year.

5.8 INTERLINE PROCESS
In the first stage, the used oil is treated with ammonium hydroxide and/or potassium hydroxide to
neutralize acidic contaminants. Then the oil is mixed with propane for the selection of hydrocarbons.
In the next stage, the oil is refined in the licensed Interline process. With this process, the additives
and the solid impurities remain in the asphalt residue. In the final stage, base oil is produced by
vacuum distillation and clay adsorption. With this process, it is possible to produce 70-75% base oil
by separating the water, degraded additives, wear metals and other contaminants in the oil. Some
facilities in UK, USA, South Korea and Spain use this technology.
5.9 RELUBE PROCESS
Used oils taken from storage tanks are dehydrated and the light hydrocarbons are removed with
distillation. Next, vacuum distillation is carried out in the Thin Film Evaporator at 320 oC to remove
the heavy residues that contain various contaminants and other undesirable compounds. Then the oils
are mixed with hydrogen and the sulphur, oxygen and nitrogen based compounds are separated with
the help of the catalyst. This improves the quality of the base oil produced. There are recovery
facilities that employ this technology in the USA, Greece and Tunisia.
5.10 MEINKEN PROCESS
The waste oil passes through the filters to remove solid impurities and it is dehydrated by distillation.
The dewatered oil is treated with 4-5% active clay for adsorption and filtered before being sent to the
film evaporator. The film evaporator operates at 290 co and 10–15 kPa. In this process, the fuel
fraction is separated from the oil and base oils are produced with repeating clay filtering. The
disadvantages of this process are that it produces waste streams like acid sludge and spent clay
resulting in a problem of waste disposal. Therefore, it has been replaced by newer technologies.
5.11 PROP PROCESS
Prop technology was developed by Phillips Petroleum Company. The key elements of the process are
the chemical demetalization and a hydrogenation process. The first step is mixing an aqueous
solution of diammonium phosphate with heated base oils in order to separate metals and other
residual compounds. Then the mixture is filtered to remove the metallic phosphates' generated as a

result of this reaction. In the second stage, water and light hydrocarbons are removed through air
stripping. After the stripping phase, hydrogen is added to the mixture and a bed of clay is used to
absorb the remaining traces of contaminants to avoid poisoning of the catalyst. In the final stage, the
oils go through Ni/Mo catalyst in the hydrogenation reactor. The sulphur, oxygen, chloride and
nitrogen compounds in the oil are eliminated and the colour of the oil is improved with this process.
5.12 SNAMPROGETTI PROCESS
In the first stage, the water and the light hydrocarbons are eliminated in the extraction column. Next,
waste oil is refined with liquid propane at 75–95oC in the Propane De-Asphalting Unit and distilled
under vacuum. With this step, the majority of the contaminants such as asphalt compounds, oxidized
hydrocarbons and suspended solids are separated from the oil. In the final stage, base oils with
different properties are produced in the hydro processing unit. Today, a facility in Italy with an
annual capacity of 55 kt/year employs this technology.
5.13 SOTULUB PROCESS
The main distinction of this process is that a chemical called Antipall is added to the mixture at the
beginning of the refining process in order to prevent blockages in the equipment. In the next stage,
used oil goes through vacuum distillation for the removal of water and light hydrocarbons. The
dehydrated oil is heated again to approximately 280°C and drawn to a stripper where gas oil is
removed from the oil under vacuum. The stripped oil is delivered to a distillation column coupled
with a thin film evaporator where it is distilled under high vacuum in order to shorten distillation
time. This operation results in a distillate and a bottom asphaltic residue where heavy metals,
chemical additives, polymers and degraded products are concentrated.
This process requires additional refining steps for the improvement of product quality. Today two
facilities in Tunisia (16 kt/year) and Kuwait (20 kt/ year) employ this technology. In order to process
1 ton of waste oil, 15 kg Antipall, 65 kwh electricity, 85 kg fuel oil, 800 kg vapour, 2 m 3 water, 6 kg
HCl and 0.4 kg heating oil is consumed.

5.14 ENTRA PROCESS
This process is based on rapid feed rate of the waste oil into the reactor. The injection process takes
place under high temperature and vacuum with retention time in the order of milliseconds. During
this process, evaporation and/or chemical reactions fractionate the bonds of the organometallic
compounds resulting from additives while preserving the structure of hydrocarbon and synthetic
lubricants. After the fractionation, the oil is refined with 1% sulphuric acid and %1 clay producing
sludge. Sodium and natural absorbents are used to bind the environmentally hazardous compounds
generated during the process. During thermal degradation, temperature should be under control to
prevent the degradation of useful compounds. To be able to employ this technology, the waste oil
that will be fed into the system should be selected and categorized according to its source.
5.15 ATOMIC VACUUM PROCESS
Pre-treatment of the used oil is carried out using two natural polymers to remove carbon sludge
substantially. Molecular distillation is employed in this process to recycle 95% of the available oil.
The distilled oil is bleached using active clay to get metals free base oil of required viscosity. The
clay also improves the color and odor of the final product. Approximately 180 grams of clay is used
to refine 4 liters of used oil.
5.16 MATTHYS - GARAP PROCESS
This method is a used oil recovery process in which centrifugation is used. This process is based on
the principle of the degradation of stable emulsions in the oil by increasing the centrifugal force of
the equipment to over 6000 G. The first step of this process is the centrifugation of the waste oil
under 80 oC in order to separate the large particles in the oil. Next, the water, solvents and light
hydrocarbons in the oil are removed by flash distillation at 180 oC. Also some additives are fed into
the pre flash unit in order to reduce residues and prevent corrosion of the equipment. After the pre
treatment, the oil is distilled at 360 oC in the vacuum distillation column so that the oil, gas oil and
heavy products are separated. After the oil is cooled, it is mixed with acid and the refining continues.
The acidic tar generated as a result of these chemical reactions is removed by centrifugation. After
the acidic oil is neutralized and treated with clay, it is filtered and turned into base oil. Today, there
are two facilities in France using this technology.

5.17 ROSE PROCESS
Deasphalted high quality base oil is produced with this method. ROSE technology is based on the
use of a light, readily available paraffinic solvent to extract deasphalted oil from a feedstock rich in
asphaltenes. The first stage of the process filtering used oil to eliminate the solid impurities. Next,
light hydrocarbons are removed and the oil is dehydrated by distillation at 120 oC and under
atmospheric pressure. Then ethane or propane is added to the oil under supercritical conditions (5-15
Mpa and 20-80 oC) to extract the contaminants. The contaminants are removed from the bottom of
the column and the oil – solvent mixture is delivered to the next distillation column that operates at
40-200 oC and 1-100 kPa. Here the solvents are separated from the lubricants. The solvent-free
extracts go through hydro processing to improve the content quality. The advantage of supercritical
solvent recovery process is the reduced operational cost. Moreover, the investment costs are lower as
the size and complexity of the facility are reduced.
5.18 PROTERRA PROCESS
This process is based essentially on vacuum distillation and solvent extraction applied to vacuum
distillates. Final products are two kinds of high quality base oil. By-products are vacuum residues,
light oils, effluent water, extracts and vapour that cannot be condensed. In the first step the used oil is
treated and light hydrocarbons are separated in flash drum. Also the additives that prevent blockage
in the equipment are added to oil at this stage. Next, the gas oil and asphalt compounds are separated
from the oil with vacuum distillation at 250 oC. The mixture is delivered to the liquid/liquid
extraction unit after it is cooled. At 40-65 oC, the treated base oil fraction is extracted with 25-100%
N-Methyl-2-Pirrolidon (NMP), where unsaturated, aromatic and heteroatom containing molecules
are eliminated. Then the solvent is separated from the extract and returned to the process after being
refined. Although GF-3 base oil is produced with this process, the lack of hydrogenation unit at the
finishing stage prevents it from reaching API Group II standard. Today a facility with an annual
capacity of 205 kt is being established by Probex in Wellsville, Ohio (USA).

5.19 FEMD- TECH PROCESS
In the initial stage, the feedstock is dehydrated through the thin film evaporator at 95-100oC. Then it
goes through distillation under atmospheric conditions to separate solvent and fuel and base oil is
produced. The power consumption of the system is 0,245-0,262 kWh/lt and used mineral oil
consumption is 5-10 lt/ton. Product yield is 80%.
5.20 SEQUOIA PROCESS
Sequoia’s process technology for recycling used lubricating oils is based on distillation, adsorption
and hydro treating processes. Specially designed evaporators preserve oil quality and prevent
corrosion and fouling of equipment. To refine 1000 lt of used oil, 90 kWh electricity, 180000 kcal of
fuel, 700 liters of water and 0,2 kg of catalyst is consumed.. Product yield is 73%.
5.21 TWFE PROCESS
TWFE technology can extend the yields of saleable products up to 95% - 97% of the used oil feed.
The process is solvent-free. In the first stage, the waste oil is dehydrated and the solvent by-products
are removed. Next, it is processed through the wet film evaporator. In the final stage, it is refined
through hydro processing (API Group II) or clay-filter process (API Group I). The process is suitable
for waste oils involving high amounts of water and additives and for waste turbine, hydraulic and
synthetic lubricants.
5.22 STP PROCESS
The process consists of the following steps: dehydration, gas oil removal, vacuum distillation,
chemical processing / hydro processing and final fractionation. API Group I base oil is produced
through chemical processing and API Group II base oil is produced through hydro processing.
Usually at the end of the refining process, 7% water and light products, 5% gas oil, 75% base oil and
13% aspfaltenes are produced. Vacuum distillation is carried out under high vacuum conditions, high
temperature and by thin film evaporator. Thin film evaporator achieves oil purification from metals,
heavy polymers, and other contaminants. Hydro finishing provides deep removal of further
contaminants such as chlorinated, sulfurous, and oxygenated organic compounds and polyaromatic
hydrocarbons improving product quality. Finished oil is then fractionated to produce light oil (SN-
150) and heavy oil (SN-500).

5.23 RECYCLON PROCESS
Process yield is 95%. The steps involved in the process are refining with sodium and vacuum
distillation. Sodium is used in the process in order to turn the unsaturated olefines into high boiling
compounds. The compounds with low boiling point are separated from the dehydrated oil and it is
mixed with metallic sodium under high temperature. The reaction takes place at over 180 oC and
takes only a few minutes. Next, the products generated as a result of the reaction are sent to the
distillation column under 1 mbar. Oils with varying viscosities can be produced by fractionating
distillation.

6 COMPARISON OF AVAILABLE TECHNOLOGIES
It is possible to categorise waste oil re-refining technologies under three main titles. These
technologies are: 1- Acid-Clay Process, 2- Hydroprocessing, 3- Solvent Extraction. The main criteria
for the comparison of these methods are mentioned below and the advantages and disadvantages of
each method are listed under subtitles.
Acid-Clay Method is no more a widely preferred method due to the additional hazardous waste
(spent clay and acid sludge) generated during the process and the risks of contact with strong acids.
Therefore, it is possible to claim that Hydroprocessing and Solvent Extraction methods are the only
acceptable technologies in present-day conditions.
When the available methods are compared in terms of initial investment costs, Solvent Extraction
process requires a relatively small-scale investment. However, depending upon the technology
adopted, the total cost might be higher than Hydroprocessing due to the operating costs to make up
for the solvent loss. On the other hand, when compared to Hydroprocessing, catalyst is not required
in Solvent Extraction. Moreover, it is not necessary to establish a hydrogen gas supply facility in this
method and it poses a smaller risk concerning operation safety.
When the available methods are compared in terms of the qualities of the feedstock required to
obtain the intended product, it is observed that in order to obtain Group II/II+ oil in Solvent
Extraction method, the feedstock that will be processed needs to be a homogeneous mixture.
Therefore the quality of the base oil produced with this technology is directly related to the
feedstock. In this respect, despite the higher investment cost of Hydroprocessing technology, it is
advantageous because of the Group II quality product output it produces independent of the quality
and source of the feedstock. The major drawback of Hydroprocessing in this regard is that the
catalyst used is sensitive to the quality of the feedstock. For example, using low quality oils, such as
industrial waste oils, as feedstock might shorten the catalyst life.
Another point that should be considered is that the facilities all around the world using the same
technology and have similar product outputs are able to reduce cost of the OEM tests by exchanging
their stocks of different feedstock between each other. Companies like Puralube and CEP try this
approach in the facilities around the world that use their technologies and therefore have a significant
advantage in the base oil market.

6.1 ACID CLAY METHOD
Features
 Low capital investment. Makes it most cost effective for small and tiny scale plants.
 No advanced instruments, no skilled operators required.
 This is a proven technology that worked for many years worldwide.
Drawbacks
 Causes Environmental pollution due to generation of acid sludge and acid gas emission.
Disposal of acid sludge is a problem.
 High operation costs, continuous clay consumption, disposal cost of spent clay. The process
requires high temperatures
 Very high clay consumption, low yield, inconsistent quality. (High viskosity, API Group I
Base Oil),
 The sulphur and PAHs in the oil cannot be separated, the contaminants in the oil remain in the
base oil.
 Gives Lower yield due to loss of oil in sludge as well as clay since higher dosage of clay is
required.
 Life span of the equipment used in acidic environment is reduced.
6.2 HYDROPROCESSING METHODS
Features
 Product quality and yield are high (API Group II Base Oil),
 PBC and Chloride can be eliminated efficiently
 PNA can be eliminated efficiently at high pressure and temperature
Drawbacks
 The process requires high pressure, high temperature and hydrogen usage
 It requires high safety standards, H2S and HCl can be generated during the process
 Investment cost and operational costs are high, operational efficiency is low
 A separate facility needs to be established on the field in order to provide hydrogen to the
process continuously
 Expensive catalysts are required

6.3 SOLVENT EXTRACTION METHODS
Features
 “API Group II/II+ Base Oil” can be produced based on the quality of the waste oil,
 Toxic Polyaromatic Hydrocarbons (PAH) and PNA can be completely eliminated,
 All of the synthetic base oil compounds like PAO / hydrocarbon oils are preserved,
 The process is carried out under lower pressure and temperature compared to other
technologies,
 The process has high product operational efficiency,
 Small quantities of waste and comtaminants are generated, waste disposal cost is low.
Drawbacks
 The product quality is dependent upon the waste oil mixture used as feedstock. High quality
feedstock is required for high quality Group II, Group II+ base oil. In hydro processing, with
hydrogen saturation, the product quality is not dependent on the quality of the feedstock.
 Based on the waste oil used, the solvent costs can be high.
6.4 RE REFINING TECHNOLOGY IN TURKEY
A "Regulatory Compliance, Technical Capacity and Quality System Competence” study has been
carried out with the voluntary participation of 15 facilities licensed by the Ministry of Environment
and Urban Planning, in order to investigate the waste oil re refining practices on site within the scope
of the project. As the 15 facilities examined in this project constitute approximately 50% of the total
number of licensed re refining facilities in Turkey, (Figure 6.4.1), it is believed that the audit and
examination findings allow a general assessment within the scope of the project. Findings on the
subjects are analyzed in the following chapters.

Figure 6.4.1 – The Existing and Investigated Waste Oil Refining and Regeneration Facilities
6.4.1 Technologies implemented in the re refining plants
Two different processes have been observed in the facilities.

 Batch Production
 Continuous Production
Batch Production Process

It has been observed that in 14 of the 15 plants that have been investigated production is carried out
through a batch production process. These plants do not produce base oil, waste oil is processed to be
reused as mineral oil. The main steps of this process and the findings are as follows:
Waste Oil Collection Unit: Waste oils are categorized according to their source or chemical features
before processing and delivered to waste oil storage tanks of different capacities. The major
deficiencies of these units are; lack of waste oil marking in the storage tanks, lack of spill basin
around the tanks and lack of waste oil overfill prevention measures. Also, it has been observed that
an oil separator equipment to control contamination in the tank storage area in case of oil spills and
overfills does not exist in some facilities.
Settling: The waste oils stored are settled in tanks for 48 hours to dehydrate the oil and to settle the
residues. It has been observed that in some plants heat is applied during storage at this step of the
process. After this treatment, the bottom residues are delivered to the hazardous waste collection area
and the effluent water to the waste water treatment facility.

Pre Filtration: Waste oils are filtered through filter press or filter tubes before entering pre heating
process.
Pre Heating: Waste oils are heated up to 60-100 0C in pre heating reactors to eliminate the water in
the oil.
Re-settling: After the heating step, the water settles to the bottom of the tank because of the density
difference. The water at the bottom is drained off. The dehydrated product is stored in temporary
storage tanks.
Vacuum Reactor (Vacuum Distillation): The product is registered through mechanic filters or filter
press. It is distilled under vacuum (400-760 mm Hg) at 200-400 0C usually in vertical reactors. The
reactors are heated by hot oil circulating through coils. Another method used for heating is carried
out with fire tube boilers. Heating oil is used in this process. This treatment is preferred mostly in
horizontal reactors. Following the treatment in the reactor, water, solvent and oil compounds are
extracted as distillation product groups. The bottoms product in the reactor is asphalt residue.
Condensation: Each product group is condensed separately and stored in separate storage tanks.
Acidification: After distillation, acidification is carried out in order to eliminate the remaining
contaminants from the oil product groups. 0.1-2.0% H2SO4 is used at this step. The acidic sludge at
the end of this process is disposed as hazardous waste. It has been observed that acidification process
is used only in three plants.
Settling: The semi finished products are settled before being sent to the clay unit. The water and
residues at the bottom of the settling tank are removed.
Clay Unit: The dehydrated contaminant-free oil is treated with active clay, earth or Bentonit at 100-
120 0C in the clay reactor to improve colour. Clay consumption ranges between 1-5%.
Final Filtration: The oil goes through filter press at 60-800C. The filter cakes are stored in
hazardous waste storage tanks to be transported to licensed disposal facilities.
Storage: After the filtration, the oil is stored in end product storage tanks to be used as feedstock in
mineral oil production.
Blending Unit: Various additives are added to the base oil taken from the storage tanks.

Packaging: Although most of the plants have the capacity to pack the finished product according to
the relevant legislation, upon examination of the sales invoices of the facilities it has been observed
that the products are sold as bulk product.
Continuous Production Process

Out of the 15 facilities investigated, only 1 plant adopts continuous production process to produce
base oil. It has been stated that the process equipment of the plant is ready and it will start production
in the second quarter of 2012. The main steps of the process to be applied in this plant and the
findings are as follows:
Waste Oil Collection Unit: Waste oils are categorized according to their source or chemical features
before processing and delivered to waste oil storage tanks of different capacities.
Settling: The waste oils stored will be settled in tanks for 48 hours to dehydrate the oil and to settle
the residues. After this treatment, the bottom residues will be delivered to the hazardous waste
collection area and the effluent water to the waste water treatment facility.
Filtration: Waste oils are filtered through filter tubes before entering pre heating process.
Pre heating: The waste oil tanks are heated with superheated steam from the boilers in order to
dehydrate oil and preserve its viscosity. It is estimated that the water content of the waste oil received
will be approximately 10%.
Separator: Waste oil will go through the separator so that the water and the residues will be
eliminated. It is estimated that the ratio of water in the oil will be 1-3% after this step.
Filtration: Filtration will be carried out through Niagara press filters. Due to the technology of the
filter, filter cloth or filter paper cannot be used. Instead, filter cakes are formed between the filter
plates and filtration is carried out by filter cakes. Therefore, additives like filter powder or perlite are
added to the mixture to be filtered.
Flash/Evaporation Unit: The waste oil is heated up to 300°C in the atmospheric flash tank to
eliminate the remaining water and light distillates. Distilled water and light distillates obtained from
distillation are delivered to separate tanks. Accumulated water will be delivered to the waste water

treatment facility and the light distillates to the solvent recycling unit. The product obtained from the
evaporator under vacuum at 160°C is delivered to the feed tank of the fractionation unit.
Fractionation Unit: The dehydrated oil in the feed tank of the fractionation unit will be fed into the
two-stage column system for further purification and fractionation. The operating heat of the
columns is between 350-390 °C and the columns operate under vacuum. Thin Film Evaporator
fractionates the waste oil into two as bottoms product (bitumunous compounds) and end product. The
bottoms product will be stored in the temporary storage tank at the end of this step, then it will be
sent to the storage tank. The bottoms product can be used in high temperature conveyors in
construction industry or as auxiliary material in asphalt construction sites. The bottoms product is
stored in the asphalt tank. End products are processed with a mixture of steam and air at 150-200 0C
under a pressure of 2-3 bars to adjust viscosity. At the end of the whole process, the base oil will be
stored in three 25 m3 storage tanks according to its viscosity.
6.4.2 Operating Conditions of the Facilities
It has not been possible to observe the actual production process in any of the mineral oil recovery
plants investigated within the scope of the project. Two of the facilities were under construction and
there was ongoing process development in some of the other facilities. There was not an active
fractional distillation unit in any of the plants. Only one plant that was planned for continuous
production has this unit but this plant has not started production yet. A majority of the facilities do
not pay enough attention to the registration of the process requirements and sampling. There are
contaminated areas in production sites. The products are mostly sold in bulk form, most of the filling
and packaging facilities in these facilities are not used.
6.4.3 The products produced at the facilities
The lubricants produced at these plants are blended with various additives and sold as bulk products.
TS Certificates of these products are as follows:
 TS 12153- Lubricating oils, industrial oils and related products (Class L) - Moulding oils
(Group B) – Class 1: Produced from petroleum based base oil - Class 2: Recovered from
waste oil Type 2: Used after aqueous emulsion
 TS 10481- Lubricants, industrial oil and related products (class L) specification of categories
L-AN, L-FC, L-FD and L-G used for machine tools.

 TS 11207- Lubricating oils for use in machines lubricated by complete dissipation type oiling
system
 TS 13350- Marine fuels – Products blended with fuel - This standard covers the products
recovered from petroleum based wastes and used by blending with marine Fuel specified in
TS ISO 8217 at certain ratios.
 TS 11485- This standard covers gear oils used for motor vehicles. It does not cover gear oils
for open or closed system.
 TS 11874- This standard covers blending oils recovered from waste oils and used in textile
industry.
 TS 13369- Lubricants – This standard covers paraffinic and naphtalene based base oils. This
standard was renewed on 31.01.2012. No companies have received the renewed certification
of the standard.
 TS ISO 11158- Lubricants, industrial oils and related products (class L) -- Family H
(hydraulic systems) -- Specifications for categories HH, HL, HM, HV and HG
Although some of the standards above contain the statement “Recovered From Waste Oils”, in some
of the standards this statement does not exist. When TSE website was checked regarding the
asphaltic materials obtained as bottoms product during the production process, it was observed that
no companies have received certification regarding these bottom products.
6.4.4 Waste Generated at the Facilities in the Production Process
The Hazardous Waste Storage Areas in the facilities have some defects in terms of legislative
requirements. The probable wastes that will be generated during the process and the waste codes are
given below:
 07 01 08, other still bottoms and reaction residues

 07 01 10, other filter cakes and spent absorbents
 15 01 10, packaging containing residues of or contaminated by dangerous substances
 19 11 01, spent filter clays
 19 11 05, sludges from on-site effluent treatment containing dangerous substances
There are some records indicating that the wastes generated at the facilities during the recovery
process are transferred to licensed disposal facilities in accordance with the waste codes above.
However, the amount of waste generated could not be correlated with the characterization of the

waste mineral oil received at the facility, the amount of chemicals used at the facility and production
figures. Therefore it is not possible to claim that all waste generated at the facilities are transferred to
licensed disposal facilities.
6.4.5 Assessment of the Facilities in terms of Management Strategies
Waste Oil Re refining Facilities have their management systems certified by accredited certification
authorities (ISO 9001-Quality Management System, ISO 14001-Environmental Management System
and OHSAS 18001-Occupational Health and Safety Management System). Although these facilities
are certified claiming that they meet the requirements of a management system, the investigations
reveal that these requirements are not fully met. For a more efficient implementation of the systems;
the defined procedure, directives and forms should be functional and tangible proof of this
functionality should be observed in the audits carried out by relevant parties regarding the practice of
these implementations. After the general assessment carried out at the facilities using the audit
checklist questions prepared for the examination of the management systems, it has been observed
that a majority of the waste oil re refining facilities have significant problems in meeting the
requirements of the Quality, Environment, Occupational Health and Safety Management Systems.
6.4.6 Areas to Improve in the Production Process at the Facilities
 It has been observed that sampling of the waste oil from its reception into the facility to the end
product has not been carried out properly. This impedes the traceability of the product.
 In the mass balances submitted to the Ministry, the amount of water in the waste oil and
disposed as effluent during the production is stated by the recovery facility and its accuracy can
only be confirmed by the laboratory results. Implementation of electronic data tracking systems
in order to maintain the traceability of these data will prove to be beneficial.
 Active clay consumption levels are not clear. Therefore the amounts of the waste generated and
the waste transferred to the disposal facilities cannot be compared properly. Although it is
claimed that the amount of acid and active clay consumptions is documented by laboratories, it
was not possible to access the documentation. Using laboratory facilities to determine acid and
clay consumption amounts before the process is beneficial for traceability.
 Technology Compliance Reports are prepared in the form of process description of the waste
oil from its reception into the facility to the end product. Each step that the waste oil goes
through during the process should be illustrated with examples, samples of the waste oil should

be taken at each step and the energy recovery yield of the processes should be indicated in the
reports.
 Storage tanks should be checked periodically. Wearing and cracks may occur due to corrosion.
 The facilities should keep samples of the waste oil during the process starting with the
feedstock.
 After sale follow up of the products is almost nonexistent. The products are offered to the
market under different names rather than Standard names.
Sectoral Problems and Expectations of Waste Oil Processors:

 Waste Oil Analysis Prices: Waste oil category analysis prices are around 1.000TL. Facilities
that produce 100-1000 kg waste oil find this price high. It is possible to make improvement by
adding the definition for waste oil collection from small scale waste oil generators into the
legislation.
 Difficulties of Waste Oil Collection: The feedstock of Waste Oil Recovery Facilities is the
waste of other facilities. Therefore raw material procurement is not steady and continuous. The
waste oil that is transferred from the Waste Oil Processor cannot be traced with efficient
process audits or energy consumption calculators. It can only be checked based on the
declaration of the facility. Naturally, these kind of audit problems create results susceptible to
exploitation.
 Waste Oil Prices: It is stated that in several tenders issued by the government agencies, waste
oil is offered to the market at a price of 2.000 TL/Kg. It is observed that when the processing
costs and other costs such as SCT are added to this price, the factory cost might be over the
sale price of the base oil.
 Licence Terms: EMRA and Environment permit term is 5 years. It is not possible for these
facilities to pay off in 5 years due to high investment costs. Remaining inactive due to
regulation changes would mean loss for the companies. Associating the regulations with the
standards, extending licence terms, defining and implementing audit criteria, increasing audit
frequency, defining and implementing penalty criteria would help to improve the processes.

7 SUGGESTIONS REGARDING PROJECT IMPLEMENTATION
The subject of this chapter is the pre-feasibility study (preliminary study) for the implementation of
this project that will contribute to the efforts to keep the risks that the waste mineral oils create for
the Marmara Region ecosystem under control.
The results of the preliminary surveys and the pre-feasibility studies conducted on issues considered
necessary are shared in the following pages as they are believed to have the potential to be beneficial
to the feasibility studies of the target group. Among the areas of study are: market and facility
capacity, sales and marketing, feedstock, region and location, project engineering, general expenses,
facility, management and sales expenses, labor force, project implementation and financial analysis,
investment costs, project finance, production costs and commercial profitability.
7.1 DETERMINING THE CAPACITY OF THE RE REFINING PLANT
One of the most realistic approaches to determine the capacity of a waste mineral oil re refining plant
that is to be built in the region stated within the framework of the project is to analyze available data
on the potential sources that will be used to supply the waste mineral oil that will be used as
feedstock in the plant.
7.1.1 Determining the Potential Amount of Feedstock
The calculations on the potential amount of feedstock are based on mineral oil market data provided
on a voluntary basis by mineral oil producers, Foreign Trade Statistics published by TSI and
declarations submitted to the Ministry of Environment and Urban Planning. According this data,
mineral oil consumption totaled 411 thousand tons in 2011.
According to scientific research, 65% of motor oils become waste after use. On the other hand,
process oils are completely used in the production process and do not generate any waste. For
hydraulic oils, this ratio is about 70%. A summary of the data obtained from the report on the results
of the research conducted on this issue is provided in Table 7.1.1(Concawe, 1996).
Based on this data, it can be claimed that 50% of mineral oils become waste after use. When the
amount of mineral oil consumption in Turkey in the last 2 years (Table3.1.1) is analyzed together
with this data, it is possible to state that the amount of waste mineral oil generated in Turkey will
never be less than 200 thousand tons and that the amount of waste motor oil will never be less than
150 thousand tons under normal circumstances.

Based on the consumption data, it is estimated that there is a potential of 250 thousand tons of waste
mineral oil that can be recovered. In this respect, it will be a more reasonable attitude to take into
consideration this figure for the studies to determine the capacity of the plant.
Type of Lubricant Waste Oil Generated (%)

Transformer Oils 95
Gear Oils 75
Hydraulic Oils 70
Motor Oil 65
Metal Processing Oils 20
Process Oils 0
Table 7.1.1- Waste oil ratios generated after Mineral Oil use (Source: Concawe)
7.1.2 Regional Resources to Supply Feedstock
The research on the resources to supply waste oil as feedstock to the re refining plant that will
be built in the region stated within the framework of the project is based on PETDER’s city-
wise waste mineral oil collection statistics in 2011. The main reason for this is that there is not a
more valid database on the issue and that waste mineral oil is the most appropriate feedstock for the
re refining facilities.
In 2011, PETDER collected 20.576 tons of waste motor oil from all over Turkey. In the assessment
based on the city-wise amounts in this data it is projected that a region of 22 cities including Istanbul
and neighboring cities, that is whole Marmara Region, Northwestern parts of Western Black Sea,
Northern Aegean and Central Anatolia Regions, can provide feedstock for the plant to be built. The
main reason for this projection is that the waste oil collected from these cities in the region that is
selected as the feedstock resource constitutes 66% of the total waste motor oils collected all over
Turkey. The cities in this region and the amount of waste motor oil collected from these cities in
2011 is displayed in Table 7.1.2.

Amount
Source Region
(ton)
Marmara 8.467
1 İstanbul 4.691
2 will
Table 7.1.2- The amounts of Waste Motor Oil Collected in 2011 from the cities that Bursaprovide feedstock
904
These cities have been selected due to the various means of transportation and the reasonable logistic
transportation distance to Istanbul and neighboring cities as well as the potential amounts of waste oil
that will be generated in each city in the future. In relatively distant locations,
3 Kocaeli (İzmit) temporary
919 storage
facilities can be built in order to minimize waste oil transportation costs or the wastes in these areas
can be recovered as energy.
7.1.3 Determining the Feedstock Processing Capacity of the Plant4 Tekirdağ 623
It is observed that 66% of the waste oil collected by PETDER across the country is generated in
Istanbul and the neighboring cities examined within the framework of the project. Based on the
assumption that 200-250 thousand tons of waste oil was generated upon consuming 411 thousand
5 Çanakkale 459
tons of mineral oil in 2011, the potential amount of waste oil feedstock for a refinery plant that will
be built in this region is calculated as 130-160 thousand tons.
In this respect, it is clear that the annual waste mineral oil processing capacity of a re refining plant
6 Balıkesir 259
that will be built either in Istanbul or the neighboring cities within the framework of the project must
be over 50 thousand tons.
7 Sakarya (Adapazarı) 242

After this step, it is necessary to take into consideration several factors that will enable a more
realistic approach to the subject. First of all, for such an investment, Turkey has to think broadly,
beyond national borders due to its logistic location and its relations with regional markets. There are
not many investments in re refining industry in the neighboring countries. the ones that exit are either
low capacity investments or operate with poor technology. In Turkey, re refining of waste mineral
oils by means of advanced industrial processes is open for improvement with the help of correct
government policies. Also, the financial means that the re refining technology provides in the
competitive environment of the International and National mineral oil market cannot be ignored.
As a result, when the findings presented in this chapter are analyzed, it can be observed that the
current waste oil potential in Turkey and the opportunity to improve this potential due to its logistic
location justify the need for a medium scaled re refining plant in Turkey. The life span of such a
plant will be at least 30 years. Moreover, even if decided today, designing the plant construction
works will take 2-2.5 years before the plant starts to operate. Because of these reasons, when the
economy of scale is taken into account alongside with long term factors, it is possible to state as a
strategic projection that the plant should have an annual waste oil processing capacity of 80 million
tons. The activities carried out in line with this projection will be explained in the following parts of
this study.
7.2 CHOOSING THE MOST APPROPRIATE TECHNOLOGY TO BE USED IN THE

PLANT
Today, the processes that use acid-clay method are not preferred anymore because of its incapability
to produce high quality products and its detrimental environmental impacts. Other processes
involving catalytic hydro processing or solvent extraction are technologies that have proven their
validity and are widely employed worldwide.
While making a projection regarding the most appropriate technology to be employed in a waste
mineral oil re refining plant that is to be built in the region stated within the framework of the
project, the only thing that can be stated clearly is that acid-clay technology must not be employed in
the plant. Whether to choose the hydro processing or solvent extraction technology depends
completely on the investor’s strategy regarding the re refining of waste oils.
In order to clarify this subject, it is necessary to examine the main waste oil re refining facilities in
Europe and the technologies they employ (Tablo 7.2.1) As can be followed in the table, out of the 11
waste oil re refining plants, 8 of them use solvent extraction while the other 3 employ catalytic hydro

processing technology. 65% of the base oils produced by re refining waste oils is Group I and 35% is
Group II base oil. Group II oils are produced by means of hydro processing technology while Group
I oils are mostly produced by means of solvent extraction technology.
Table 7.2.1- Waste Oil Re refining Plants in Europe and the Technologies Used
Together with the comparisons of the re refining technologies in Chapter 6, the expectations of the
market also have a leading role in choosing the technology. As it was stated before, the investor’s
strategy in the base oil market will determine the technology to be selected for certain.
In order to carry out more studies within the framework of this project, the following parts of this
study are based on the selection of solvent extraction technology, on which more data is available,
for a re refining plant to be built in Istanbul or neighboring cities.
7.3 PRE-FEASIBILITY STUDY OF THE PLANT
7.3.1 Selection of the Location of the Plant and Size of the Site
Within the scope of the project, the pilot areas projected and assessed for a re refining plant in
Istanbul and the neighboring cities are ; Marmara Ereğlisi (Tekirdağ), Gebze (Kocaeli) and Bandırma
(Balıkesir). This region was chosen upon considering the logistic and geographical location of the
region that will provide feedstock, incentive policies and Organized Industrial Zone facilities and by
carrying out an economic assessment. The location of the pilot areas is displayed in Figure 7.3.1.

Marmara
Ereğlisi
Gebze
Bandırma
Figure 7.3.1- Pilot Areas Selected for the Plant within the Framework of the Project
It is obvious that it is necessary to consider a number of evaluation criteria regarding the pilot areas
selected in order to determine the exact location of the plant. However, in this study, the relation of
the selected pilot areas with feedstock delivery by means of road transportation, one of the evaluation
criteria, was studied.
PETDER statistical data regarding the amount of waste motor oil collected in 2011 from the cities in
the region that will serve as feedstock source was taken as the starting point for this study. According
to 2010 data from the Ministry of Environment and Urban Planning, 18% of the waste oil is
recorded. Based on this data, first the potential annual amount of waste oil generated in the source
region was calculated city-wise as 100% of the potential feedstock of the plant that will be built.
Then, it was projected that the transfer of waste oil to the selected pilot areas will be carried out
completely by means of road transportation and by tankers with a capacity of 20 tons. The number of
trips that will be made to each city for the transportation of the potential annual amount of waste oil
and the cost of this transportation was calculated. This calculation is based on PETDER data in
March 2012, stating the transportation cost as 3.36 TL/km for a 20-ton tanker. The management
costs and the expenses due to toll roads are not included in the unit transportation cost. The total
transportation cost and the cost per ton were calculated by multiplying this data with the number of

trips required for the transfer of potential amount of waste oil and the round trip distance between the
pilot region and the cities. The table below demonstrates the results of the study for each pilot area.
Amount Potential Distance Number Total Transport Cost
Source Region
Collected (ton)Amount (ton) (km) Of Trips (km) Cost ( ¨) (¨/ton)
Marmara 8.467 47.039 Bandırma 2.352 1.376.577 4.625.298 98
1 İstanbul 4.691 26.061 330 1.303 860.017 2.889.656 111
2 Bursa 904 5.022 111 251 55.747 187.309 37
3 Kocaeli (İzmit) 919 5.106 334 255 170.526 572.966 112
4 Tekirdağ 623 3.461 321 173 111.102 373.302 108
5 Çanakkale 459 2.550 166 128 42.330 142.229 56
6 Balıkesir 259 1.439 99 72 14.245 47.863 33
7 Sakarya (Adapazarı) 242 1.344 326 67 43.829 147.265 110
8 Edirne 116 644 582 32 37.507 126.022 196
9 Kırklareli 184 1.022 328 51 33.529 112.657 110
10 Bilecik 49 272 210 14 5.717 19.208 71
11 Yalova 21 117 174 6 2.030 6.821 58
Kuzey Ege 1.973 10.961 548 271.573 912.485 83
12 İzmir 1.465 8.139 254 407 206.728 694.605 85
13 Manisa 223 1.239 141 62 17.468 58.694 47
14 Kütahya 144 800 226 40 18.080 60.749 76
15 Uşak 141 783 374 39 29.297 98.437 126
Batı Karadeniz 741 4.117 206 182.188 612.151 149
16 Zonguldak 514 2.856 461 143 131.641 442.314 155
17 Bolu 100 556 391 28 21.722 72.987 131
18 Düzce 89 494 346 25 17.108 57.482 116
19 Bartın 25 139 568 7 7.889 26.507 191
20 Karabük 13 72 530 4 3.828 12.861 178
Kuzey Batı İç Anadolu 2.370 13.167 658 654.852 2.200.303 167
21 Ankara 2.086 11.589 523 579 606.099 2.036.492 176
22 Eskişehir 284 1.578 309 79 48.753 163.811 104
TOTAL: 13.551 75.283 7.104 3.764 2.485.189 8.350.237 111
Table 7.3.1- Cost Analysis of Waste Oil Transportation to Bandırma from the cities in the source region

Source Region
Collected (ton)Amount (km) Of Trips (km) Cost ( ¨) (¨/ton)
Marmara 8.467 47.039 Gebze 2.352 508.781 1.709.505 36
1 İstanbul 4.691 26.061 40 1.303 104.244 350.261 13
2 Bursa 904 5.022 189 251 94.920 318.931 64
3 Kocaeli (İzmit) 919 5.106 51 255 26.038 87.489 17
4 Tekirdağ 623 3.461 167 173 57.801 194.210 56
5 Çanakkale 459 2.550 452 128 115.260 387.274 152
6 Balıkesir 259 1.439 292 72 42.016 141.172 98
8 Edirne 116 644 300 32 19.333 64.960 101
9 Kırklareli 184 1.022 274 51 28.009 94.110 92
10 Bilecik 49 272 197 14 5.363 18.019 66
11 Yalova 21 117 121 6 1.412 4.743 41
Kuzey Ege 1.973 10.961 548 515.873 1.733.333 158
12 İzmir 1.465 8.139 488 407 397.178 1.334.517 164
13 Manisa 223 1.239 474 62 58.723 197.310 159
14 Kütahya 144 800 310 40 24.800 83.328 104
15 Uşak 141 783 449 39 35.172 118.177 151
Batı Karadeniz 741 4.117 206 109.267 367.138 89
16 Zonguldak 514 2.856 284 143 81.098 272.489 95
17 Bolu 100 556 213 28 11.833 39.760 72
18 Düzce 89 494 169 25 8.356 28.077 57
19 Bartın 25 139 391 7 5.431 18.247 131
20 Karabük 13 72 353 4 2.549 8.566 119
21 Ankara 2.086 11.589 426 579 493.687 1.658.787 143
22 Eskişehir 284 1.578 280 79 44.178 148.437 94
TOTAL: 13.551 75.283 6.027 3.764 1.671.786 5.617.199 75
Table 7.3.2- Cost Analysis of Waste Oil Transportation to Gebze from the cities in the source region

Source Region
Collected Amount (ton) (km) Of Trips (km) Cost ( ¨) (¨/ton)
Marmara 8.467 47.039 M. Ereğlisi 2.352 784.439 2.635.715 56
1 İstanbul 4.691 26.061 99 1.303 258.005 866.897 33
2 Bursa 904 5.022 349 251 175.276 588.926 117
3 Kocaeli (İzmit) 919 5.106 167 255 85.263 286.483 56
4 Tekirdağ 623 3.461 38 173 13.152 44.191 13
5 Çanakkale 459 2.550 452 128 115.260 387.274 152
6 Balıkesir 259 1.439 450 72 64.750 217.560 151
8 Edirne 116 644 164 32 10.569 35.511 55
9 Kırklareli 184 1.022 138 51 14.107 47.398 46
10 Bilecik 49 272 351 14 9.555 32.105 118
11 Yalova 21 117 281 6 3.278 11.015 94
Kuzey Ege 1.973 10.961 548 681.628 2.290.271 209
12 İzmir 1.465 8.139 648 407 527.400 1.772.064 218
13 Manisa 223 1.239 564 62 69.873 234.774 190
14 Kütahya 144 800 464 40 37.120 124.723 156
15 Uşak 141 783 603 39 47.235 158.710 203
Batı Karadeniz 741 4.117 206 173.019 581.343 141
16 Zonguldak 514 2.856 439 143 125.359 421.206 148
17 Bolu 100 556 368 28 20.444 68.693 124
18 Düzce 89 494 323 25 15.971 53.661 109
19 Bartın 25 139 546 7 7.583 25.480 183
20 Karabük 13 72 507 4 3.662 12.303 170
21 Ankara 2.086 11.589 580 579 672.156 2.258.443 195
22 Eskişehir 284 1.578 432 79 68.160 229.018 145
TOTAL: 13.551 75.283 8.225 3.764 2.379.402 7.994.790 106
Table 7.3.3- Cost Analysis of Waste Oil Transportation to M.Ereğlisi from the cities in the source region
As can be seen from the tables, according to the cost analysis of the transportation of waste oils from
the cities in the source region to the plant in the pilot area, the mentioned costs for a plant that will be
located in Gebze region (75 TL/ton) will be lower compared to the costs in Bandırma region
(111TL/ton) ve Marmara Ereğlisi region (106 TL/ton). These costs mentioned are the costs for
transportation only and do not include the waste oil supply, sampling and logistics management
costs.
This study is not the only criteria for choosing the location of the plant. It should be regarded merely
as a preliminary assessment to draw the attention of the interested parties within the scope of the
project. There are many other issues, such as the logistic facilities of the area the plant is located,
temporary storage facilities between the source region and the plant, the advantages of building the
plant in an organized industrial zone and land costs, that should be considered for the final decision.
As a result, it is observed that Gebze region stands out among the pilot areas selected, after a
comparison of the waste oil transfer costs from the cities in the source region for a capacity of 80
thousand tons. When the data used in this study regarding capacity and the solvent extraction
technology are analyzed, it is calculated the need for land for the plant, one of the physical
requirements of determining the location, is 26.500m2 .

7.3.2 Preliminary Financial Studies
This part of the study includes the preliminary financial studies that will contribute to the feasibility
studies of the plant that is planned to be built in Istanbul and the neighboring cities for the re refining
of waste mineral oils. First of all, it is important to remind some points that this study is based on. It
should be noted that the feasibility study of the plant is based on a capacity of 80 thousand tons and
Avista Oil Solvent Extraction Process that provides the most data among solvent refining
technologies. Also, Green Oil Company that uses Hydroprocessing method has provided PETDER
with preliminary studies that serve as a model in this area to be used within the scope of this project.
However, it was not possible to analyze this data in this report as it could be obtained at the
completion stage of the report. The unit costs used in the feasibility study of the process that was
taken as a model operating in full capacity with an annual capacity of 80 thousand tons are based on
the average prices in 2012. The calculations and projections in this regard were handled one by one
and the results were displayed in a income – expense statement to provide a general assessment
regarding the feasibility of the plant.
Capacity: 80.000 ton / year

Working Time 8.000 hours
3
Natural Gas 0,74 ¨ /m
Electricity 0,23 ¨ /kWh
3
Waste Water Cost 0,92 ¨ /m
3
Utility Water 0,23 ¨ /m
Table 7.3.4- Estimated Operational Data of the Plant
It was projected that the annual waste oil need for the plant will be provided by different suppliers. In
this respect, the refinery delivery prices of the waste oil are varied depending on the waste oil supply
source. It was projected that the authorized institution will transfer the waste oil by only charging the
management and operational costs without profit. The annual waste oil cost of the plant is calculated
below assuming that waste oil will be supplied in mentioned amounts and unit prices. This cost sheet
is based on calculations assuming that the waste oil is received to the refinery at an average price of
350 TL/ton.

Unit Price Amount Collected Waste Oil Cost
(¨/ton) (ton) (¨)
Authorized
220 30.000 6.600.000
Institution
Waste Oil Collection
390 30.000 11.700.000
Unit of the Plant
3rd Party Waste
460 20.000 9.200.000
Collectors
Total: 80.000 27.500.000
Table 7.3.5- Estimated Waste Oil Supply Costs
Based on the product yield projected in the model process, the percentages and amounts of yield to
be produced in full capacity processing 80 thousand tons of waste oil annually are displayed in
Table 7.3.6.
Products Yield (%) Amount (ton)

Volatile Compounds 1 800
Fuels for Heating and Marine 14 11.200
Bottoms Product - Asphalt 15 12.000
Fuel Oil (No.6) 5 4.000
Base Oil 56 44.800
Water 5 4.000
Loss 4 3.200
Total: 100 80.000
Table 7.3.6- Annual Amount of Products Based on Estimated Process Outcome
It was projected that it will be possible for the re refined products to attain a place in the competitive
market by applying a 10-15% discount over the market sale prices of the products with economic
value produced in the model process that this study is based on. In accordance with this evaluation,
the end product sale prices (refinery sale prices without SCT) that constitute the basis for the income
–expense statement are as follows:
Products Market Price ( ¨/ton) Discounted Sale price (¨/ton)

Volatile Compounds 460 400
Fuels for Heating and Marine 1.495 1.300
Bottoms Product
- - Asphalt 977 830
Fuel Oil (No.6) 920 790
Base Oil (SN150) 2.070 1.800
Waste Oil Surplus 150 130
Table 7.3.7- Estimated Sale Prices of the Products

Another criteria that needs to be considered regarding costs of a plant with an annual capacity of 80
thousand tons is the investment costs for the on-process and off-process units of the model
technology, the cost of the land that the plant will be located and the know-how costs. Although the
cost of the land varies depending on the area selected, within the framework of this preliminary
study, the average unit value was taken as 600TL/m2 for an area of 26.500 m2 in Gebze/Dilovası
region.
Plant Cost (Capacity: 80.000 ton/year) (¨TL
On Process Units 62.700.000
Off Process Units 15.700.000
Total 78.400.000
2
Land (26.500 m )
Total Land Cost (600 TL¨
/m2) 15.900.000
Table 7.3.8- Estimated Investment Costs

The number of personnel at the plant required to run the model process in this project is estimated as
30. The organizational chart of the plant is given in Figure 7.3.2. The number of shifts in the
operation and production departments is 5 and it was assumed that one foreman will supervise each
shift.

Figure 7.3.2- The Organizational Chart of the Plant for the Model Process
In order to make an income-expense estimation of the plant within the financial study, some
approximations were made. Firstly, the income from the product sales was calculated assuming that
the plant will operate in full capacity. The calculation of the maintenance and repair costs is based on
1% of the cost of the plant and the cost for insurance and other legal dues was calculated as 0.75% .
Other costs include SCT, legal costs arising from the Occupational Health and Safety legislation,
legal representation, marketing and corporate audit costs. Finally, assessments were made based on
available data and an income – expense statement was prepared based on estimated costs and sale
prices. (Table 7.3.9).
- –EXPENSE STATEMENT
INCOME SUM (¨)
Sales
Volatile Compounds 320.000
Fuels for Heating and Marine 14.560.000
Bottoms Product
/ / Asphalt 9.960.000
Fuel Oil (No. 6) 3.160.000
Base Oil (SN 150 ) 80.640.000
Waste Oil Surplus 416.000
109.056.000
OPERATIONAL INCOME (%100 Capacity) 109.056.000
Physical Expenses
Waste Oil -27.500.000
Operational Costs -3.200.000
Procurement and Additional Expenses -428.000
Waste Water Cost -5.000
Waste Disposal Costs -150.000
-31.283.000
GROSS PROFIT 77.773.000
Personnel Expenses
Operational and Administrative Staff -379.000
Shift Staff -401.000
Maintenance Team -67.000
Transportation Team -470.880
-1.317.880
Other Expenses
Maintenance
/ Expenses (% 1 Plant Cost) -784.000
Insurance and Dues(% 0 .75 Plant Cost) -588.000
Laborator y Expenses -60.000
-1.432.000
PROFIT BEFORE TAX AND AMORTIZATION 75.023.120
Amortization
Tankers -216.000
Equipments in the plant -6.270.000
Equipments out of the plant -1.047.000
-7.533.000
GROSS PROFIT BEFORE TAX 67.490.120

Table 7.3.9- Income – Expense Account of the Sample Process
The estimated income – expense statement above projects that the pre-tax gross income of an
investment of 94,5 million TL including the land cost will be 67,5 million TL assuming that the plant
will operate in full capacity. This analysis in this preliminary study does not include the technology
transfer and know-how costs. As is stated in many parts of the report, solvent extraction method was
taken as a model for base oil production in this financial study. Yet, this technology is not developed
/ established in Turkey. Therefore, it is necessary to estimate a cost for the improvement or
purchasing of this technology before the investments.
In this part of the report, it is deemed beneficial to refer to some information obtained from Green
Oil Company that operates with hydro processing method in Greece. The investment cost of this
plant that has an annual capacity of 30 thousand tons is estimated as 27 million € and the annual pre-
tax net profit of such a refinery is estimated to be around 10-11 million €. Although it was not
possible to carry out a detailed analysis in this report as the information regarding the mentioned
company was provided at the completion stage of the report, the information and evaluations
provided by the mentioned company are presented in the Annex of this report.

8 GENERAL ASSESSMENT
Though, within the framework of EU directives and the national regulations, it is considered a
liability to adequately dispose the waste oils that have completed their life span, there are difficulties
regarding the implementation of the current legislation (due to widespread illicit activities in the field
in Turkey) hindering the achievement of expected results. Therefore, the detrimental impacts of the
contaminants in the waste mineral oils on the ecosystem cannot be controlled. The most common
practice in recovery and/or disposal of waste oils in Turkey is the recycling of the waste oils without
advanced refining techniques and recovery of the waste oils as energy by means of combustion as
additional fuel in licensed facilities with an incineration capacity which is s process that enables the
removal of the contaminants in the waste oil. Moreover, unrecorded activities such as reuse of waste
mineral oils as illicit fuel under the name of Number 10 lube, blending with fuel, combustion for
heating purposes in uncontrolled environments, offering to the market as unqualified oil or
inappropriate disposal are also common in the field. All these activities continue to have harmful
effects on the environment and human health more and more.
Although recovery of the waste mineral oils as energy is a preferred method of disposal in Turkey,
processing waste oils by means of appropriate refining technologies in order to regenerate base oil is
an area that is deemed necessary to improve. On the other hand, the “Total Environmental Impacts”
of the processes of energy recovery or base oil regeneration from the waste oils by means of re
refining should be thoroughly analyzed and the benefit / loss analysis for Turkey should be carried
out in order to build waste management strategies accordingly.
When the studies on the subject are analyzed in detail, it is revealed that there are certain cases and
practices in which disposal of waste oils by means of energy recovery proves to be beneficial in
terms of total environmental impacts. Although the regeneration of base oil from the waste oils by
means of advanced re refining technologies is meaningful in terms of feedstock resources, it should
be noted that energy recovery also has several advantages such as high efficiency, low emissions and
low investments.
It is considered beneficial to design projects in accordance with this strategy in Marmara Region
where most of the waste mineral oil in Turkey is generated.
This study, prepared to lead the field, presents a comparative evaluation of the legislation and
technological developments regarding the re refining of the waste mineral oils and the practices in

Turkey. It is observed that Turkey is in actual need of advanced industrial refining technologies in
order to regenerate base oil from the waste oils. For the purpose of fulfilling this need, a preliminary
feasibility study of a re refining plant that will process the waste mineral oils collected from Istanbul
and neighboring cities has been conducted and the results of the study have revealed that the
investment value of a plant with an annual capacity of 80 thousand tons is substantial and feasible as
well as strategically beneficial.
In the studies on the feasibility of the plant, estimations were based on the actual waste oil collection
costs. The relevant data was compiled by the experienced project team members and the plant costs
and other results are believed to be realistic. The financial analyses carried out present the plant as a
profitable investment under projected circumstances. The evaluations in this study do not include
technology transfer (know-how) costs. Although this cost cannot be estimated exactly, it is of utmost
importance that the investor take this issue into consideration. It should never be ignored that the
investments made without ensuring the technology transfer might always pose a risk in terms of the
operational costs.
The estimated capacity of the plant is a capacity value that will enable the waste oil recovery not
only for Istanbul and neighboring cities but also for all the Northwestern Anatolian regions as long as
it is supported with an efficient collection strategy. Operating this capacity value efficiently is in
direct relation to the government policies pertaining to waste oil management. The plant is of great
importance for the recovery of the waste oils as feedstock in Turkey. Any practice that will provide
added value to a petroleum dependent economy should be supported. Contributing to the economy
by processing 80 thousand tons of waste oil annually and reducing the detrimental environmental
impacts in line with this capacity are on one pan of the scale while on the other pan are the
inadequacy of the current legal regulations and lack of practice. This scale is going to determine the
fate of an investment whose feasibility and economic efficiency have been confirmed.
BRIEF CONCLUSION:
 Illegal collection of the waste mineral oils and their consumption as illicit fuel /
unqualified mineral oil in Turkey is the primary obstacle for the potential investments in
this field.
 Recovery of waste oils as energy or re refining as feedstock is an area that should be
“scientifically assessed” in terms of total environmental impacts.

 A capacity of 80.000 ton/year for a re refining plant that will be built in the Marmara
Region seems to be a reasonable projection. The two choices for the technology that will
be used in the plant are solvent extraction and hydro processing. The benefit – loss
analysis of each technology should be carried out carefully. However, the preliminary
feasibility reports of the mentioned facilities provide attractive results in terms of the
potential investment return.

BIBLIOGRAPHY
 Kline & Company, Global Used Oil 2009: Market Analysis and Opportunities Summary of
Key Findings, July 30, 2010.
 Chemical Engineering Partners, [Internet, en son giriş: 23 Mart 2012]

http://www.ceptechnology.com/processtechnology/the-cep-process.aspx
 Audibert, F. “Waste Engine Oils: Rerefining and Energy Recovery”, Elsevier B.V, 2006.
 Puralube-HyLube Process, [Internet, en son giriş: 03 Nisan 2012 ]

http://www.puralube.de/?q=node/23
 Prokop Engineering, [İnternet, en son giriş: 03 Nisan 2012]

http://www.prokop-engineering.cz/hylubeEN.htm
 PETDER, Atık Yağların Yönetimi Projesi 2010 Faaliyet Raporu, İstanbul, 2011.
 PETDER, Atık Yağların Yönetimi Projesi 2011 Faaliyet Raporu, İstanbul, 2012.
 Lubes “n”Greases Europe, Middle East, Africa Magazine: 2010 Base Stock Guide, LNG
Publishing Company Inc. VA, USA.
 Baladincz, J.,Szabó, L., Nagy, G. and Hancsók, J., “Possibilities for processing of used
lubricating oils – part 2”, MOL Scientific Magazine, 2, 68-72, 2010.
 Pelitli, V., Doğan, Ö., Başar, H.Merve, UYUŞUR, B., “Atık Madeni Yağların Geri
Kazanımında Baz Yağ Üretim Teknolojileri”, Sigma Mühendislik ve Fen Bilimleri
Dergisi,29,422-434, 2011.
 IPPC, Draft Reference Document on Best Available Techniques for the Waste Treatments
Industries, European IPPC Bureau, 2003.
 Concawe, Collection and Disposal of Waste Lubricating Oil, Report No: 5/96, November,
1996.
 GEIR, Statistics and questionnaire on used oil collection and utilization in 2006, 2008
Brussels [İnternet, en son giriş: 23 Nisan 2012]
http://www.geir-rerefining.org/documents/WO-questionnaire-EU27-final-022208.pdf

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Selection of the

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Technical Research Report

THIS PROJECT WAS FINANCIALLY SUPPORTED BY 2011 DIRECT OPERATION SUPPORT

Istanbul Development Agency 2011 Direct Operation Support Program

AGREEMENT NO: NAME OF THE PROJECT:

İSTKA/2011/DFD/50 Selection of the Most Appropriate Technology for Waste

PROJECT MANAGER: REPORT TERM:

Designed by Petroleum Industry Association. 15 January 2012 - 15 April 2012

ADDRESS OF THE PROJECT MANAGER:

34384 Şişli - İSTANBUL

FINAL BENEFICIARIES AND/OR TARGET GROUPS:

PETDER-Petroleum Industry Association Page 2/65

1 PROJECT SUMMARY ........................................................................................................................................... 5

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According to calculations, approximately 400-450 thousand tons of mineral oil is consumed in

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Petroleum Industry Association

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2.2 RESTRICTIONS AND EXEMPTIONS

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3.1 WASTE OIL MANAGEMENT IN TURKEY

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3.2 WASTE OIL MANAGEMENT IN OTHER COUNTRIES

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(*) GEIR,2006 Report

(**) U.S. Department of Energy, 2006

(***) Ministry of Environment and Forestry Action Plan

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Type of Fuel Calorific Value (kcal/kg)

Table 4.1.1- Calorific Values of Various Fuels

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4.1 PREPARING FOR RE-USE

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4.3 ENERGY RECOVERY

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5.1 THE ACID / CLAY RE-REFINING METHOD

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Acid Acidic Sledge

Figure 5.1.1- Acid Clay Method Flowchart

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Thin Film Vacuum Distillation

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Chemical Additive Heavy

Waste Oil 100 Thin Film

Figure 5.3.1- Mohawk Process Flow Chart

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Product Recovery and Finishing

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Thermal De-Asphalting TDA

High Pressure Hydro Finishing