Used-Oil Re-Refining Technologies & Turnkey EPC
Process Configurations: Batch | Semi-Continuous | Continuous
Process & Finishing Technologies: Vacuum Distillation | WFE | Regenerative Clay | Solvent
Balaji Consultants engineers and delivers used lubricating oil re-refining plants from process selection through detailed engineering, equipment supply, site execution and commissioning. Each process configuration is developed around the feedstock, required product quality, plant capacity, utilities and operating objectives.
ENGINEERED AROUND YOUR FEEDSTOCK. NOT A ONE-SIZE-FITS-ALL PLANT.
25+ Years
Re-Refining Engineering Experience
30+ Plants
Re-Refining Installations / Projects
Multiple Technologies
Batch | Semi-Continuous | Continuous
Robust Construction
Engineered for Industrial Operation
Who We Are
Engineering the Process
Delivering the Plant
Balaji Consultants is a specialist used-oil re-refining technology company and supplier of complete re-refining plants. Over more than two decades, we have developed and implemented different re-refining configurations ranging from batch and semi-continuous systems to continuous plants incorporating high-vacuum Wiped-Film Evaporation (WFE), Solvent Extraction and appropriate base-oil finishing technologies.
Our strength lies in understanding the feedstock, selecting the appropriate process route and translating that technology into a complete operating plant through detailed engineering, purpose-designed process equipment and robust industrial construction.
In addition to re-refining, Balaji Consultants undertakes selected lubricant blending, grease manufacturing, crude-oil topping, solvent-processing and related process-plant projects.
Our Core Expertise
Process & Technology
Feedstock evaluation, process selection, process design and integration of the appropriate re-refining and finishing route.
EXPLORE TECHNOLOGIESEngineering & Equipment
FEED, detailed engineering, P&IDs, equipment design, process equipment, piping, instrumentation and automation integration.
ENGINEERING CAPABILITYProject Delivery
Procurement, fabrication, erection coordination, commissioning, operator training, revamps and performance optimisation.
PROJECT DELIVERYOur Engineering Approach
01
UNDERSTAND
Feedstock, product target, capacity, utilities and commercial objectives
02
ENGINEER
Process configuration, FEED, detailed engineering and equipment design
03
DELIVER
Procurement, fabrication, supply and site execution support
04
COMMISSION
Installation support, start-up, performance checks and operator training
05
OPTIMISE
Revamps, debottlenecking, troubleshooting and performance improvement
Concept to Commissioning
ConceptFeed EvaluationProcess SelectionFEEDDetailed EngineeringProcurement & Fabrication Site ExecutionPLC/SCADA IntegrationPre-CommissioningCommissioningOperator TrainingHandover
CommissioningOperator TrainingHandover
The right process starts with the feedstock
Used oil composition can vary significantly with source, collection practice, water content, light hydrocarbons, degradation products, additives, solids and other contaminants. The optimum re-refining configuration therefore depends on what enters the plant and what the client wants to produce.
Balaji evaluates the feedstock, product target, capacity, utilities and project conditions before selecting and integrating the appropriate process stages.
How we select the processActual process configuration, recovery and finished-product properties depend on feedstock characteristics and project design basis.
Feedstock evaluation
Dehydration / light-end removal
Vacuum separation
WFE / lube fraction recovery
Selected finishing route
Regenerative clay
Solvent extraction
Hydrotreating*
Regenerative clay
or
Solvent extraction
or
Hydrotreating*
Finished base-oil / lube fractions
FEATURED PROJECTS
Proven Through Project Execution
Engineering credibility is best demonstrated through operating projects.
Used OilUsed-Oil Re-Refining Plant Kuwait
LOCATION
Kuwait
CAPACITY
50 TPD
PROJECT TYPE
Commissioned Plant
TECHNOLOGY
Used Oil
50 TPD used-oil re-refining plant in Kuwait producing Group I base oils via continuous dehydration, high-vacuum WFE and solvent extraction in continuous commercial operation.
View Case Study
Used Oil50 KLPD Used-Oil Re-Refining Revamp Riyadh, Saudi Arabia
LOCATION
Saudi Arabia
CAPACITY
50 KLPD
PROJECT TYPE
Commissioned Plant
TECHNOLOGY
Used Oil
Brownfield revamp of an existing direct-fired clay-process re-refining facility in Riyadh existing clay vessels retained and repurposed for dehydration, with two Wiped-Film Evaporators added for continuous high-vacuum base-oil recovery.
View Case Study
WFE Systems24 KLPD Semi-Continuous WFE Re-Refining Revamp Bangladesh
LOCATION
Bangladesh
CAPACITY
24 KLPD
PROJECT TYPE
Commissioned Plant
TECHNOLOGY
WFE Systems
Existing batch facility converted to semi-continuous re-refining batch feed-conditioning retained, downstream base-oil recovery converted to continuous WFE operation.
View Case Study
Regenerative Clay10 KLPD Regenerative Clay Treatment Revamp India
LOCATION
India
CAPACITY
10 KLPD
PROJECT TYPE
Commissioned Plant
TECHNOLOGY
Regenerative Clay
Existing 10 KLPD batch clay treatment bottleneck replaced with a semi-continuous regenerative percolation-bed system and on-site thermal adsorbent regeneration unit.
View Case StudyGlobal Presence
Project Experience Across International Markets
Different markets bring different feedstocks, utility conditions, climates, logistics and operating practices. Balaji's international project experience supports practical engineering decisions from design through commissioning.
Product Objective
Engineering Begins With the Product Objective
The required finished product influences the entire process route. Feedstock quality, fractionation strategy and the selected finishing technology determine the achievable product properties and recovery.
LIGHT LUBE FRACTION
MEDIUM LUBE FRACTION
HEAVY LUBE FRACTION
Target viscosity, colour, sulphur, flash point, VI and other properties are established during process design against the agreed feedstock and product requirement.
Automation & Control
Automation for Consistent Plant Operation
Stable re-refining performance depends on controlled temperatures, pressures, vacuum levels, flows and interlocks. Balaji can integrate instrumentation, PLC-based control and HMI/SCADA monitoring according to the selected process configuration and project requirements.
PROCESS MONITORING
ALARMS & INTERLOCKS
HMI / SCADA
TREND & OPERATING VISIBILITY
Technical Resources / Knowledge Centre
Engineering Knowledge for Better Process Decisions
Explore technical resources covering process technology, plant configuration, finishing options and capacity selection for used-oil re-refining projects.
Regenerative Clay vs Solvent Extraction vs Hydrotreating
How to Select the Right Capacity for a Used-Oil Re-Refining Plant
Planning a New Plant, Revamp or Capacity Expansion?
Share your project location, available feedstock, target capacity, required product and site conditions with our engineering team. If you already have a feed-analysis report, send it with your enquiry for a more meaningful preliminary discussion.
Technically prepared? Download Project Enquiry Questionnaire →