FFSI’s Plug Flow Reactor – Pioneering Used Lube Oil Recycling

In 2015, FFS International (FFSI) successfully constructed and commissioned a state-of-the-art high temperature and pressure Plug Flow Reactor (PFR) for the supercritical steam processing of used lubricating oils (ULO). As pioneers in advanced oil recycling technologies, we saw the immense potential of supercritical steam processing and managed to build it into the continuous plug flow reactor design. The technology is an improved pre-processor for ULO before hydrogenation to base oil. It aims to replace the likes of wiped-film evaporators, thin film evaporators, and cracking plants,

This article shares the summary of the project, the benefits of the technology, and how we can leverage our expertise to help other companies adopt this transformative solution.

Why Focus on Used Lube Oil Recycling?

Every year, millions of tons of lubricating oil are discarded, posing severe environmental risks and wasting valuable resources. Lubricating oils are always going to be needed where moving parts are involved, so extending the overall lifecycle of each litre is paramount. Traditional methods of oil re-refining often involve energy-intensive processes and the use of harsh chemicals, leaving room for improvement in terms of efficiency and environmental impact. Our vision was to introduce a method that generate better-quality base oil feedstock but also minimized yield losses and improving energy efficiency.

Supercritical steam processing—where water at supercritical conditions (above 374°C and 22.1 MPa) acts as a powerful solvent and reaction medium—proved to be the ideal solution. By integrating this process into a self-scrubbing PFR design, we created a better system capable of delivering improved continuous product.

Building the Plug Flow Reactor

Following results of laboratory testing, we started design work of the industrial PFR in late 2014, construction through 2015 and first product in the beginning of 2016. The entire build was completed to FFSI designs and fully integrated into the partner’s facility, with automation and commissioning also fully completed by us.

Key Features of the FFSI PFR System:

1. Scalability: Modular construction allowed for easy scaling to meet varying processing capacities, from pilot plants to industrial operations. We have built 3 PFRs in total (1 industrial, 2 pilot rigs).
2. Efficiency: An integrated heat recovery system minimized energy consumption, significantly lowering energy costs and circumventing any fluid heat capacity changes.
3. Operability: In-house designed and commissioned automated control system and low maintenance because of continuously cleaned heat exchange surfaces in the reactor from the PIG system.

The build and commissioning obviously came with its challenges ranging from development and design of our own high-pressure valves, building and refining the PIG system, and correcting the flashpoint on the oil product.

All effort culminated in the process that sold every ton of product produced during operation from 2015 up until the collaboration end in 2020 and was a unique selling point of the partner’s business sale.

Achievements and Benefits

Since commissioning, our PFR system delivered outstanding results:

• Stable product with effective ash removal (typically <100ppm metals)
• Increased product yield to 90%+ (increase of by ±30%)
• Eliminated ‘difficult to sell’ bottom products and no need of pre-dehydration or expensive vacuum systems.
• Reduced emissions, with vapour emissions captured and treated in a VOC unit.
• Lower running costs, with consumption est. 200kW/ton product
• No added solvents, only using electricity and water.

Beyond technical success, the project enabled significant cost savings, and the product was successfully proven for use as hydrogenation feedstock to base oil, reducing the dependency on virgin oil resources. Full product specifications and results can be discussed on request.

Partnering for the Future

As global industries pivot toward sustainability, the demand for innovative recycling solutions is growing. Recognising this, we are now expanding our expertise to offer consultation and engineering services to businesses seeking to adopt plug flow reactor systems for used oil processing and the implementation and development of industrial supercritical processing.

Our Services Include:

• Feasibility studies to determine the suitability of PFR technology for specific applications.
• Custom design and engineering of PFR / supercritical systems tailored to client needs.
• Retrofitting and optimization of existing facilities.
• Comprehensive experience, expertise, and technical support for engineering and operational teams.

By partnering with us, companies can harness the proven benefits of PFR technology to meet regulatory requirements, improve operational efficiency, and contribute to a circular economy.

Looking Ahead

The success of our plug flow reactor system underscores the importance of innovation in tackling technical challenges and pioneering innovation. As we move forward, we remain committed to advancing recycling technologies and helping industries transition to more sustainable practices.

If you’re a business looking to enhance your waste oil management strategy, let’s connect. Together, we can utilise state of the art technology to drive profitability and sustainability.

Contact Us

To learn more about our PFR technology and consulting services, reach out to us.