A closed-loop industrial system converting used lubricant feedstock into API-certified base oils and finished lubricant products through six controlled engineering phases, each governed by ASTM methodology and strict quality gate protocols.
EXLUBA's collection network operates under a structured supplier qualification framework. Used lubricants — including automotive crankcases, hydraulic system drains, metalworking fluids, and industrial gear oils — are aggregated from certified industrial sources across the Kingdom of Saudi Arabia.
All incoming feedstock is transported in dedicated, sealed collection vehicles meeting ADR hazardous materials handling standards. Containers are tracked from collection point to facility gate via a documented chain-of-custody system, ensuring full traceability for environmental compliance and feedstock quality assurance purposes.
| Parameter | Acceptance Limit | Action if Exceeded |
|---|---|---|
| Water Content | < 5% v/v | Pre-dehydration required |
| PCB Contamination | < 50 ppm | Reject — hazardous stream |
| Halogen Content | < 1,000 ppm | Segregate for treatment |
| Flash Point | > 40°C | Isolated handling protocol |
| Sediment / Sludge | < 3% w/w | Settlement tank routing |
| Viscosity @ 40°C | 15–350 mm²/s | Blending stream adjustment |
Petrochemical plants, manufacturing complexes, power generation facilities. Scheduled high-volume collection under long-term service agreements.
Typical Batch: 5,000–20,000L per collectionHeavy transport operators, construction fleets, marine equipment. Collected at maintenance intervals per client-specific waste management protocols.
Typical Batch: 500–5,000L per collectionSaudi government facilities, municipalities, and public sector entities. Compliance-driven collection under NCBE-registered service agreements.
Typical Batch: 200–2,000L per collectionEvery incoming batch is assigned a unique batch reference number and subjected to a mandatory intake analysis protocol before it is permitted to enter the re-refining process stream. This laboratory gate prevents off-specification or hazardous feedstock from contaminating production equipment or downstream product quality.
Analysis results determine the optimal processing path: direct distillation, pre-treatment blending, or rejection for specialist hazardous waste handling. The EXLUBA laboratory operates certified test procedures conforming to ASTM International methodology with full batch traceability documentation.
Batch analysis completed within 24 hours of receipt. Results trigger immediate processing routing decisions.
Every test result is linked to a unique batch reference from collection point through to final product COA.
Intake analysis reports available to clients as part of the Certificate of Analysis (COA) package on request.
EXLUBA's re-refining core process employs high-vacuum distillation technology to thermally separate used oil feedstock into discrete hydrocarbon fractions without oxidative degradation. Operating at vacuum pressures of 1–5 mmHg, the system achieves separation temperatures significantly lower than atmospheric boiling points, preserving the integrity of recovered base oil molecular structures.
Pre-treated feedstock enters the distillation column following dehydration and de-asphalting. Fractional cuts are extracted at controlled temperature intervals across the column height. Heavy neutral fractions destined for API Group I production undergo additional clay treatment, while Group II target fractions proceed directly to the catalytic hydrotreating unit.
| Parameter | Operating Range | Control Standard |
|---|---|---|
| Column Operating Pressure | 1–5 mmHg | Vacuum system continuous |
| Feed Preheat Temperature | 180–220°C | Feed furnace PID control |
| Light Neutral Cut Point | 250–300°C | Side-draw controlled |
| Heavy Neutral Cut Point | 300–360°C | Primary product draw |
| Group II Fraction Cut | 360–420°C | Hydrotreater feed |
| Bottom Residue | >420°C | Process fuel recovery |
Distillate fractions targeted for API Group II classification undergo catalytic hydrotreating — a hydrogen-assisted refining process that systematically removes sulphur, nitrogen, oxygen, and residual metal contaminants while saturating aromatic rings to improve oxidation stability and viscosity index. This stage determines final product grade and is the primary quality differentiator between Group I and Group II base oil classifications.
Re-refined and virgin API-certified base oils serve as the foundation for EXLUBA's finished lubricant product range. Each formulation is developed against a target performance specification — API service category, viscosity grade, and application profile — and executed through a closed-tank, metered-dosing blending system.
Additive packages are sourced from qualified international suppliers and pre-approved through EXLUBA's additive qualification protocol before incorporation into production blends. Dosing ratios are controlled gravimetrically with batch-level verification against the approved blend sheet prior to product release.
Measured quantity of certified base oil loaded to heated blending vessel. Temperature maintained at 60–70°C to reduce viscosity for efficient mixing.
Gravimetric metering · ±0.1% toleranceVII addition controls the viscosity-temperature relationship of the finished product, achieving the target multi-grade viscosity classification (e.g., 5W-40, 10W-40).
Shear stability index verified: ASTM D6278Maintains engine cleanliness by suspending soot and combustion deposits in the oil film. Overbased detergent provides acid-neutralising reserve (TBN contribution).
TBN target: ASTM D2896 per grade specificationZinc dialkyldithiophosphate (ZDDP) provides primary antiwear and antioxidant function. EP additives activate under boundary lubrication conditions in gear and hydraulic applications.
4-Ball Wear Scar: ASTM D4172 per gradeDual antioxidant system provides primary and secondary oxidation protection, extending the service life of the lubricant under high-temperature operating conditions.
Oxidation stability: ASTM D943 / RBOT D2272Completed blend is sampled and submitted for full laboratory analysis before packaging authorisation is issued. Viscosity, TBN, flash point, and colour must match the approved product specification.
COA issuance upon analytical sign-offEXLUBA's quality system embeds laboratory checkpoints at each stage of the processing chain — not solely at product release. This multi-gate approach catches process deviations early, minimises waste, and ensures the integrity of every batch from feedstock intake through to final product COA issuance.
| Test / Parameter | G1 Intake |
G2 Pre-Dist |
G3 Distillate |
G4 Post-HT |
G5 Blend |
G6 Release |
|---|---|---|---|---|---|---|
| Water Content ASTM D95 | ● | ● | ||||
| Flash Point ASTM D93 | ● | ● | ● | |||
| Kinematic Viscosity ASTM D445 | ● | ● | ● | ● | ● | |
| Viscosity Index ASTM D2270 | ● | ● | ● | |||
| Colour ASTM ASTM D1500 | ○ | ● | ● | |||
| Sulphur Content ASTM D4294 | ● | ● | ||||
| Metal ICP Screen ASTM D5185 | ● | ● | ● | |||
| Pour Point ASTM D97 | ○ | ● | ● | |||
| Total Base Number ASTM D2896 | ● | ● | ||||
| PCB Contamination IEC 61619 | ● | |||||
| ● Required checkpoint ○ Conditional checkpoint Empty cell = not applicable at this gate | ||||||
EXLUBA's re-refining process generates quantifiable environmental benefits relative to virgin crude-derived lubricant production. Every ton of used oil processed through the EXLUBA facility displaces an equivalent volume of primary crude extraction, reducing the total lifecycle carbon intensity of the lubricant supply chain.
Process by-products — including light hydrocarbon cuts and recovered sludge fractions — are directed to controlled energy recovery systems rather than landfill or uncontrolled disposal. The facility operates under Saudi NCBE environmental compliance protocols with documented waste stream tracking.
90% of incoming used oil feedstock is converted into saleable base oil fractions or recovered by-products. The remaining 10% is directed to controlled energy recovery, achieving near-zero waste-to-landfill performance.
Re-refining used lubricating oil requires approximately 60–70% less energy than processing crude oil to equivalent base oil specification, resulting in a measurable carbon intensity reduction per unit of output produced.
12,000 metric tons of used industrial lubricants processed annually through the closed-loop EXLUBA facility — displacing equivalent primary crude extraction volume from the regional lubricant supply chain.
Detailed engineering documentation, laboratory protocol specifications, and quality system overviews available to qualified industrial partners and procurement teams on request.