Typical Application of Activated Carbon in Industrial Fluid Recovery and Recycling
Activated Carbon is widely used across industries to purify, recover, and reuse various fluids. Below are common real life applications where PAC is effectively implemented:
- Used Engine Oil Treatment
- Slop Oil Purification
- Lubricant Oil Recycling
- Hydraulic Oil Recovery
- Heating Oil Cleaning
- Amine Solution Polishing
- Solvent Purification
- Compressor Oil Reuse
- Gear and Bearing Oil Reprocessing
- Coolant and Quenching Fluid Treatment
- Transformer Oil Clarification
- Cutting and Metalworking Fluid Recovery
- Industrial Waste Oil Blending
Activated Carbon for industrial Waste Oil Treatment
Industrial operations rely on a wide range of fluids such as lubricating oils, heating oils, amines, solvents to keep their systems running efficiently. Over time, these fluids accumulate impurities that reduce their effectiveness and lead to equipment wear, increased maintenance, and unnecessary disposal. In many industries, contaminated fluids are either discarded or collected by reclamation companies, processed, and sold back.
The reclamation process can be done using a proven method of treatment with Activated Carbon. This approach allows industries to clean their used fluids, restore quality, and reuse them again in ongoing operations, reducing costs and environmental impact.
In this article, we’ll explore how Activated Carbon is used to purify industrial fluids, such as waste oil treatment, solvents, and process liquids, and how the solids are separated after treatment.
How to Purify Used Oil and Industrial Fluids On Site?
Pretreatment
Contaminated fluids are first collected in a treatment tank. Large debris, sediments, or sludge are allowed to settle or removed using mechanical strainers. This reduces the load on the treatment system and improves efficiency in later steps.
Water Removal
If the fluid contains free water especially common in slop oil or process liquids. it is gently heated to around 70–80°C and allowed to stand. Heating promotes separation, and standing time allows water to settle at the bottom. Once the water is drained, the temperature can be increased to about 120°C to evaporate any residual moisture.
Acid Addition
Once water is removed and the fluid is cooled to room temperature, acid (92–98%) are slowly added to the fluid while stirring. Acid breaks down emulsified sludge and reacts with contaminants. The typical dosage ranges from 5–7% of the total fluid volume, depending on the contamination level. After acid mixing, the fluid is allowed to stand for up to 12 hours to let the reaction complete and the acid sludge settle.
pH Neutralization
Following acid treatment, the fluid is heated again to around 80°C. Sodium carbonate (Na₂CO₃) or soda ash is added gradually to neutralize the acid content. Stirring continues during this process to ensure even distribution. pH is checked using test paper until the fluid reaches neutral. After that, it is allowed to rest for several hours, and the neutralized sludge is drained.
Powder Activated Carbon Addition and Mixing
After water is removed, Powder Activated Carbon (PAC) is added directly to the heated fluid. The typical dosing range is 0.3% to 0.5% of the fluid volume. The fluid is then stirred or circulated to ensure full contact between the carbon and contaminants.
As mixing continues, a visible change can be seen: the color of the oil begins to improve, and it becomes less dark and more transparent. This indicates that the activated carbon is successfully adsorbing the unwanted contaminants, including color bodies, acids, and organic residues. The Powder Activated Carbon acts like a sponge at the microscopic level removing impurities without chemically altering the fluid.
Holding Time
After mixing, the fluid is allowed to stand so that the PAC has time to complete the adsorption process. Holding time varies based on temperature and fluid type but usually ranges from 1 to 4 hours.
How to Remove the Activated Carbon After Treatment?
After the adsorption is complete, the activated carbon, now carrying the trapped contaminants, remains suspended in the fluid. To complete the purification process, this carbon must be removed before the fluid can be reused.
Separation by Filtration or Centrifuge
The final step involves separating the carbon from the treated fluid. Two standard methods are used:
- Membrane Filtration: The treated fluid is passed through a membrane filtration setup, also known as a belt press system, that uses filter bags or cloth belts. The clean fluid passes through as the press squeezes the mixture, while the activated carbon and other solids remain behind in the filter cake. This method is widely used in plants treating large volumes of oil or high viscosity fluids.
- Centrifuge Filtration: Another method involves using a centrifuge designed for separating solids from liquids. The fluid is spun at high speeds, which forces the heavier sludge (including PAC and adsorbed contaminants) outward while the clean fluid exits from the center. This method is efficient, continuous, and often used in automated or closed loop systems.
Once filtered, the fluid is clean, clear, and ready to be reused in industrial systems.
What is the Purpose of Using Activated Carbon?
The primary goal of using Powder Activated Carbon is to remove dissolved and suspended impurities from contaminated industrial fluids. PAC has a porous structure and extremely large surface area, allowing it to adsorb:
- Organic degradation compounds
- Acids and corrosive molecules
- Varnish, sludge, and fine particles
- Color bodies and foul smelling compounds
By incorporating PAC into the fluid treatment process, industries can achieve the following:
Removal of Impurities
PAC effectively captures sludge, varnish, fuel residues, and chemically reactive by products. It adsorbs dissolved contaminants that cannot be removed by mechanical filtration alone.
Improved Fluid Quality
Treated fluids regain clarity, thermal stability, and appropriate viscosity. This leads to improved system performance, reduced component wear, and extended equipment life.
Environmental Responsibility
Treating and reusing fluids in house reduces the need for fluid disposal and minimizes environmental risk. It supports circular resource use and reduces dependence on fresh fluid procurement.
Operational Cost Savings
By reconditioning fluids rather than replacing them, facilities can significantly reduce their operational and maintenance costs. This is particularly beneficial in industries where large volumes of fluids are consumed or discharged.
Improve Efficiency with Medaad Activated Carbon Solutions
At Medaad Adsorption Chemical, we provide high performance activated carbon solutions for industrial purification applications. Our expertise helps clients reduce waste, cut costs, and protect critical equipment through clean, reconditioned fluids.
Contact us to learn more about how Activated Carbon treatment can support your operations and improve your fluid management strategies.
