Transform black waste engine and industrial oils into high-value, golden base oil with HK Machine engineering. We design and build turn-key Batch distillation plants from 500 liters to 50,000 liters, providing investors with the fastest Return on Investment (ROI).
Unlike outdated acid-clay processes, our environmentally friendly vacuum technology produces no toxic acid sludge. It conducts complex chemical separation processes safely inside sealed reactors. A typical Batch cycle operates step-by-step as follows:
Before entering the main reactor, the waste oil is pre-heated to around 110-130°C. Trapped rain water, coolants, and light solvents are vaporized and discharged from the system, preventing foaming in the main stage.
The dehydrated oil is transferred to the main reactor and strong vacuum pumps are activated. Lowering the pressure allows the oil to reach its boiling point at 280-360°C without burning or thermal cracking.
Vaporized oil rises through the fractionating column and is extracted as light (SN150) and heavy (SN500) fractions based on molecular weight. It then liquefies back to base oil through water-cooled exchangers.
The distilled oil is clear but is treated with special bleaching earth or silica gel under agitation to completely eliminate burnt odors, unstable sulfur complexes, and dark pigments.
In the final stage, bleaching clay and micron-sized carbon particles are separated using a high-pressure plate filter press. The result is pure, golden-colored, commercially valuable Group I base oil.
Non-condensable emissions are routed through a wet gas scrubber system to meet environmental standards. The remaining heavy residue (bitumen) in the reactor is discharged to be sold for asphalt/waterproofing.
Explore our special page dedicated to portable, compact, containerized mobile waste oil purification machines ranging from 500L to 5,000L capacity.
View Mobile Machine Models →Thanks to the operational flexibility of our Batch system vacuum distillation plants, you can process various waste oils independently without contamination.
The choice of operating system is the most crucial decision in setting up a waste oil refinery. At HK Machine, we strongly advise investors to choose our proven, economic, and flexible Batch systems.
What is a Batch System? A specific volume of waste oil (e.g., 10 tons) is fed into the reactor, processed completely under vacuum to generate base oil, and shut down to discharge the heavy residue. The system is then ready for the next cycle. This is the safest and most profitable method for daily processing demands between 500 liters and 50,000 liters.
1. Low Initial Investment: Requires no expensive PLC configurations, complex software, or countless pressure sensors, resulting in a significantly lower capital cost.
2. Operational Flexibility: You can process black engine oil today, clean the reactor, and process transformer oil tomorrow. The products do not mix, and output quality remains entirely under your control.
3. Easy Operation & Maintenance: Does not require advanced chemical engineering knowledge. Standard operator training is sufficient, and maintenance costs are extremely low.
Continuous flow systems are ideal only for large-scale refinery projects processing over 50,000 liters (50 tons) of a single, uniform raw material continuously 24/7 for months. At smaller capacities, continuous systems pose high risks of clogging and demand excessive investment costs.
Energy represents the largest operational cost in waste oil recycling. We tailor our Batch systems with two different heating infrastructures depending on your region and budget:
We design burner systems based on the most economical fuel source available in your production region:
The plant extracts 6-8% diesel-like light distillate fuel during distillation. You can store and burn this fuel in your own burner, dropping your heating costs to zero.
Ideal for facilities in industrial zones with established gas grids. Natural gas burners guarantee a clean burn with zero soot, smoke, or particulate emissions from the stack.
Recommended for remote locations or African regions without natural gas access, ensuring high combustion efficiency and stable temperature regulation.
While output varies based on raw material quality, here are the average product yields and international ASTM D92 flash point temperatures of the SN base oils produced by our vacuum distillation unit.
Based on processing 10 tons of black waste engine oil.
Minimum temperature resistance of the produced base oils against ignition.
You can inspect the reactor placement, condensation piping, and general design of our industrial waste oil recycling plants in the 3D technical animation video below. Custom projects are prepared for your site layout.
Space and infrastructure requirements vary based on your daily processing volume. You can refer to our standard model matrix below to choose the best configuration:
| DAILY PROCESSING CAPACITY | OPERATIONAL TYPE | HEATING OPTIONS | AUTOMATION LEVEL | MINIMUM REQUIRED AREA |
|---|---|---|---|---|
|
500 Liters (0.5 Ton) View Mobile Version |
Batch System | Burner or Electric Resistances | Manual / Digital Thermostat | 50 - 100 m² |
|
5,000 Liters (5 Tons) View Mobile Version |
Batch System | Burner (Gas/Diesel) or Thermal Oil | Semi-Automatic / Digital Panel | 250 m² Covered Area |
| 10,000 Liters (10 Tons) | Batch System | Thermal Oil or Twin Burner | PLC Control Panel | 400 m² |
| 20,000 Liters (20 Tons) | Batch (Multi-Reactor) | Thermal Oil Boiler System | Advanced PLC Touchscreen | 600 m² |
| 50,000 Liters (50 Tons) | Batch (Multi-Reactor) | Heavy-Duty Thermal Oil Boiler | Full PLC SCADA System | 1,200 m² + Tank Yard |
| Above 50,000 Liters (Continuous) | Continuous Flow System | Thermal Oil or Dedicated Furnace | Advanced SCADA Automation | Project-Specific Custom Engineering |
Based in Nizip Industrial Zone, Gaziantep, Turkey, HK Machine designs and manufactures high-tech Batch waste oil purification and distillation plants. We deliver turn-key solutions domestically and export to Africa, the Middle East, Asia, and Europe. Our engineering is fully compliant with global standards (API, ASME, CE), ensuring highly profitable recycling projects.
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