Industrial Liquid Filtration Systems

PO Box 527
113 Fairgrounds Drive
Manlius, New York 13104-0527

Tel: (315) 682-8815
Fax: (315) 682-8825
E-mail: info@filtertech.com
Web: www.filtertech.com


CONFIDENTIAL: THE INFORMATION WITHIN THIS LETTER IS FOR THE PROPRIETARY USE OF THE ADDRESSED CUSTOMER AND
FILTERTECH, INC. AND IS NOT TO BE USED OR DISTRIBUTED FOR ANY OTHER PURPOSE WITHOUT WRITTEN PERMISSION FROM FILTERTECH,
INC. MANLIUS, NY
Aluminum Cold Mill Rolling Oil Distillation

By: Mohammed Albedour
FILTERTECH INC.

Abstract

This presentation is mainly about using an effective and simple method of
clarification or refining of the aluminum cold-mill rolling oil. The method uses
vacuum distillation for the used, contaminated or degraded rolling oil to extract the
good base oil plus the additives for reuse in the rolling process, and discharge of the
bottoms for use in heating applications.

The presentation will include a general description of the system main components,
system design and controls, as well as the principle of continuous process vacuum
distillation. Finally, an example showing estimated system cost, anticipated system
operating and maintenance cost verses the investment pay back and savings
expected from a medium size vacuum distillation system will be shown.

Rolling Oil and Contaminants

Rolling oil in this presentation refers to the lubricant oil used in the aluminum cold
rolling process to maintain the product quality and improve the rolls life. This oil is
subjected to the rolling pressure and temperature, resulting in thermal degradation,
increased viscosity, and reduced lubricity. It is also subjected to contamination from
the mills other hydraulic fluids.

Contaminated oil has tremendous negative affect on the product quality and rolls
life and must be refined. The distillation process proved to be the only practical and
most economical way to purify the aluminum rolling oil from all contaminants.

Distillation

Distillation is a liquid-refining or purifying process that uses heat to evaporate the
base oil leaving behind all the other contaminants and then cooling of the vapors,
condensing and collecting them. In the case of aluminum cold rolling, the liquid is
oil.


Page 2

CONFIDENTIAL: THE INFORMATION WITHIN THIS LETTER IS FOR THE PROPRIETARY USE OF THE ADDRESSED CUSTOMER AND
FILTERTECH, INC. AND IS NOT TO BE USED OR DISTRIBUTED FOR ANY OTHER PURPOSE WITHOUT WRITTEN PERMISSION FROM FILTERTECH,
INC. MANLIUS, NY
This method of separation or refining used rolling oil depends on the difference of
the boiling points between the base oil from that of the contaminant. The boiling
point of the base oil must be lower than the contaminants boiling point.

Vacuum Distillation

Distillation under reduced pressure below atmospheric pressure is called vacuum
distillation. The boiling point of the oil will decrease with reduced pressure. The
lower the pressure or the higher the vacuum, the lower the base oil boiling
temperature becomes.

Another major benefit of reduced or lowered boiling point is reducing the heat of
vaporization, which is the amount of energy needed to purify the base liquid, thus
resulting in lower costs to accomplish the oil purification.

Vacuum Distillation Unit (VDU)

The VDU is designed for continuous process even though it can be used as a batch
process but at an increase in energy consumption due to heat up time and heat
losses during down time between batches, especially if the batch time is relatively
short. Operating the VDU as long as possible between shutdowns provides energy-
efficient operation.

The VDU controls allow the used oil to feed into the unit as the processed or purified
oil is produced and pumped out of the unit. This continuous feed and bleed results
in introducing the feed oil into the unit at its optimum operating temperature.
Having the units heater, vessels and piping at the operating temperature and
allowing the system to run for extended periods will yield high recovery efficiency
of the base oil and the valuable additives.

Vacuum Distillation Unit (VDU) Main Components

Water stripper assembly and feed piping loop
Heater assembly, bottoms and feed heating piping loops
Still chamber, recirculation heat loop and bottoms discharge loop
Distillate Receiver and refined oil discharge loop
Vacuum pumps system and process pumps
Electrical controls and essential instruments

Vacuum Distillation Unit (VDU) Operation

The operation consists of the following three cycles:
o Process Cycle
o Cook down Cycle
o Bottoms discharge cycle



Page 3

CONFIDENTIAL: THE INFORMATION WITHIN THIS LETTER IS FOR THE PROPRIETARY USE OF THE ADDRESSED CUSTOMER AND
FILTERTECH, INC. AND IS NOT TO BE USED OR DISTRIBUTED FOR ANY OTHER PURPOSE WITHOUT WRITTEN PERMISSION FROM FILTERTECH,
INC. MANLIUS, NY
Vacuum Distillation Unit (VDU) Cost and Savings Analysis

This analysis shows that the majority of the plants that utilized a VDU realized the
investment pay back in less than a year, actually in some cases within a few months,
and realizing net savings thereafter.

In addition to the financial benefits of refining and reusing the rolling oil is the
benefit of greatly reducing the negative impact on the environment from discarded
oils.