Introduction: Turning Waste into Value
In today’s refining and re-refining industries, efficiency and sustainability go hand in hand. One of the most pressing challenges faced by operators is the treatment of slop oil, a complex emulsion of hydrocarbons, solids, and water that accumulates during operations. Traditionally considered waste, slop oil poses both environmental risks and economic loss if not managed properly.
At THERMOPAC, we believe waste is simply untapped value. Our Slop Oil Separation System is engineered to transform this by-product into usable resources, making it an integral part of the re-refining process. By recycling slop oil, we not only recover light hydrocarbons and base oils but also ensure that refiners achieve maximum yield with minimum environmental footprint.
The Objective of the THERMOPAC Separation System
The main goal of the THERMOPAC Separation System is twofold:
- Recycle slop oil into the re-refining process for recovery of valuable fractions such as light hydrocarbons, base oils, and lubricants
- Condition the recovered oil so it complies with refinery standards, making it suitable to be blended with normal crude oil for further downstream processing
This approach closes the loop in refinery operations, ensuring that every drop of oil is put to productive use rather than being discarded as waste.
Step 1: Pre-Treatment – Preparing Slop Oil for Separation
The process begins with pre-treatment, a critical stage that makes slop oil manageable for downstream operations:
- Heating the slop oil reduces viscosity, allowing better flow and separation
- Adding chemical emulsion breakers (demulsifiers) helps destabilize the emulsion of oil, water, and solids, improving separation efficiency
- A three-phase decanter, the core of the system, separates the slop oil into three distinct streams: Oil, Water, and Solids
This recovered oil now meets standard refinery requirements and can either enter the re-refining process alongside used lube oil or be blended with crude oil for further treatment.
Step 2: Advanced Separation – Unlocking Valuable Fractions
After pre-treatment, the recovered oil undergoes further separation to ensure the highest quality output:
- Residual water and gases are removed to prevent contamination and improve oil stability
- Light hydrocarbons such as naphtha and gas oil are separated for recovery and reuse
- Base oils and residue are isolated, preparing them for final refining and polishing
This stage is executed in a self-contained skid, which integrates:
- Flash evaporator
- Thermal oil heat exchanger
- Water/naphtha condenser
- Decanter
- Gas oil evaporator
- Gas oil condenser
By completely dehydrating the feed and removing light hydrocarbons, the system produces a valuable mixture of light and heavy lube oils along with asphaltic residue.
Step 3: Polishing and Recovery – Delivering Quality Oils
The heavier fractions and residues obtained are further treated using THERMOPAC’s thin-film evaporators. This step allows for precise fractionation, producing various cuts of high-quality lube oil. The final polishing ensures that the oils meet the demanding standards required for lubricants, base oil blending, and industrial applications.
The outcome is clear: valuable oils are recovered, refined, and reused, while waste is minimized.
Why Choose the THERMOPAC Separation System?
The advantages of Thermopac’s technology go beyond efficiency:
- Maximum Oil Recovery: Turn slop oil into usable hydrocarbons, base oils, and lubricants
- Compliance with Refinery Standards: Recovered oil is fully compatible with re-refining or blending with crude oil
- Environmental Sustainability: Reduce hazardous waste and lower the carbon footprint of operations
- Operational Reliability: A proven system with robust engineering for continuous, long-term performance
- Cost Savings: Minimize losses by converting slop oil into a revenue-generating resource
Sustainability at the Core
In an era where industries are measured not only by profits but also by their environmental responsibility, Thermopac’s separation system delivers on both fronts. By reclaiming value from slop oil, refiners reduce the burden of waste disposal, conserve natural resources, and move closer to their sustainability targets.
What was once considered a liability becomes an asset, demonstrating how innovation can redefine refinery economics.
Conclusion: The Future of Oil Recovery
The THERMOPAC Slop Oil Separation System represents the future of refinery efficiency and environmental stewardship. By recovering hydrocarbons, base oils, and lubricants from slop oil, our system ensures that no resource is wasted and every operation runs at its highest potential.
At Thermopac, we don’t just design equipment we engineer solutions that deliver reliability, efficiency, and sustainability to industries worldwide.
Are you ready to recover more from your refinery operations?
Contact Thermopac today to learn how our separation systems can redefine your oil recovery strategy.