WFE SystemsCommissioned
24 KLPD Semi-Continuous WFE Re-Refining Revamp Bangladesh
PROJECT SNAPSHOT
LOCATION
Bangladesh
CAPACITY
24 KLPD
TECHNOLOGY
WFE Systems
PLANT STATUS
Commissioned
BALAJI CONSULTANTS’ ROLE
Process Technology • Revamp Engineering • Modular WFE Systems • Plant Integration • Commissioning
THE CHALLENGE
An existing batch used-oil re-refining facility originally supplied by Balaji Consultants required revamping to improve throughput, operating continuity and base-oil recovery. The existing configuration relied entirely on batch processing, which limited daily output and operating consistency.
OUR SOLUTION
Balaji Consultants developed a semi-continuous revamp configuration that retained the existing batch feed-conditioning section while converting the downstream base-oil recovery section to continuous WFE operation. Two Wiped-Film Evaporators were supplied as modular skids for recovery of separate light and heavy base-oil distillate fractions under high-vacuum conditions. An intermediate buffer tank was installed between the batch front-end and the continuous WFE section to provide steady feed to the downstream equipment.
PROCESS CONFIGURATION
Batch Dehydration & DegassingBuffer / Intermediate TankFeed PreheaterContinuous WFE ProcessingBase-Oil Product Recovery
Inside each WFE, a rotating wiping system distributes the feed as a continuously renewed thin film over the heated evaporation surface. The combination of high vacuum, short residence time and continuous surface renewal permits recovery of valuable lubricating-oil fractions at comparatively lower operating temperatures reducing the risk of thermal cracking, product discolouration and degradation of recoverable base-oil molecules. Two Wiped-Film Evaporators recover separate light and heavy base-oil distillate cuts. The WFE section operates continuously while the feed-conditioning section remains batchwise, giving the arrangement its semi-continuous character.
PROJECT OUTCOME
- Batch-only facility converted to semi-continuous used-oil re-refining
- Continuous WFE base-oil recovery introduced
- Separate light and heavy base-oil distillate cuts recovered
- Improved daily throughput and operating continuity
- Modular skid construction reduced site fabrication and simplified export shipment
- Plant commissioned
SCOPE OF WORK
- Existing-plant assessment & semi-continuous revamp process development
- Semi-continuous configuration design, heat & material balance
- WFE system sizing & modular skid engineering
- Vessel, equipment & piping fabrication; workshop assembly & pre-dispatch testing
- Export packing, delivery to Bangladesh & site integration support
- Pre-commissioning, commissioning & process stabilisation
RELATED TECHNOLOGY
PLANNING A NEW RE-REFINING PLANT OR REVAMPING AN EXISTING ONE?
Balaji Consultants develops process configurations around your feedstock, required product quality, existing infrastructure, capacity and project economics.
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