What is Kettle Type Distillation Plant – Ruike Petrochemical Equipment

What is Kettle Type Distillation Plant

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batch type kettle distllation machine

kettle distillation (batch distillation) is used for small-scale refining of crude oil and waste engine oil.

Kettle distillation—also known as batch distillation—is a non‑continuous process commonly employed in petrochemical operations for small‑scale or intermittent feedstock treatment.

Kettle distillation operates on a simple principle: raw oil is loaded into a distillation vessel at once, heated to vaporize, and then different fractions are collected in stages.
This process differs significantly from large-scale petrochemical operations’ atmospheric and vacuum continuous distillation methods.

Key Applications in Petrochemical Processing This technology is primarily employed for:

Technical Characteristics When Processing Crude Oil and Waste Motor Oil It is Simple Distillation Range

For Waste Motor Oil: Processing typically begins with settling and filtration to remove mechanical impurities. The batch distillation then separates the waste oil into base oil (heavy fraction) and fuel oil (light fraction). However, this method struggles to thoroughly remove sulfur, nitrogen, and heavy metals.

For Crude Oil: The process is suitable only for small-scale experiments or rudimentary oil refining in remote areas. It cannot achieve the efficient separation of multiple components that atmospheric-vacuum distillation provides.

Rough Product Fractions

  • Separation precision is low, only roughly cutting components by boiling point into “light oil” (similar to gasoline), “heavy oil” (similar to diesel), and residue.
  • Direct fire heating or jacket heating methods often lead to coking of materials at high temperatures, especially when processing high-viscosity waste oils.

Environmental and Safety Concerns

  • Batch operations result in unorganized emissions of volatile organic compounds
  • Small-scale facilities typically lack comprehensive environmental treatment systems

Product Quality When Using Crude Oil or Waste Motor Oil

Products from Crude Oil

Light Fraction (Initial boiling point to 200°C):

  • Similar to gasoline but with low octane rating (approximately 60-70)
  • Contains sulfur, olefins, and other impurities
  • Not suitable for direct use as vehicle fuel

Heavy Fraction (Above 200°C):

  • Similar to diesel but with low cetane number
  • High sulfur content (potentially exceeding 1000ppm)
  • Produces significant pollution when burned

Residue:

  • Contains asphaltenes and high-boiling-point components
  • Potentially usable for road paving or industrial fuel

Products from Waste Motor Oil

Light Fraction:

  • Solvent oil or fuel oil (kerosene-type)
  • Suitable for industrial heating or marine fuel

Heavy Fraction:

  • Regenerated base oil (used for blending low-end lubricants)
  • Contains incompletely decomposed additive residues

Residue:

  • Asphalt-like substance
  • May be used as fuel or treated as hazardous waste

Key Differences from Atmospheric-Vacuum Distillation

Comparison AspectBatch DistillationAtmospheric-Vacuum Distillation
Raw Material AdaptabilityWaste motor oil, small batches of crude oilLarge-scale crude oil (controlled sulfur content and acidity)
Processing CapacitySmall (tens to hundreds of tons daily)Large (thousands to tens of thousands of tons daily)
Core Equipment DifferencesSimple distillation vessel + fractionating columnAtmospheric tower (30-60 theoretical plates) + vacuum tower + heating furnace
Separation DepthRough cutting only (wide boiling range)Precise separation into narrow fractions
Product QualityDoes not meet vehicle fuel standardsCan directly produce gasoline and diesel meeting national standards
Environmental ComplianceProne to waste gas and residue pollutionEquipped with desulfurization, denitrification, and wastewater treatment systems

Process Flow Comparison

Comparison AspectBatch Distillation (Intermittent)Atmospheric-Vacuum Distillation (Continuous)
Process ContinuityBatch operation requiring refeeding and reheatingContinuous feed into the heating furnace and towers, 24-hour operation
Separation PrincipleSimple vaporization-condensationMultiple mass transfers between gas and liquid phases in towers
Automation LevelManual temperature control and fraction switchingAutomated DCS system for temperature, pressure, and flow regulation
Typical Cycle12-48 hours per batchContinuous operation, stopping only for maintenance

While batch distillation can achieve preliminary separation of materials, its low efficiency, pollution issues, and inferior product quality have led the modern petrochemical industry to adopt continuous, intelligent processes like atmospheric-vacuum distillation. These advanced methods ensure more efficient resource utilization and environmentally friendly production.

Understanding these differences is crucial for selecting the appropriate distillation technology for your specific processing needs, whether you’re handling waste oils or processing crude oil in limited quantities.

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