Waste Oil Conversion to Diesel Plant for Refined Oil Solution in Zambia

Scope

Enginerify acted as the Technical & Sustainability Consultant, delivering services across the full project lifecycle: 

1. Feasibility definition & design basis (feed/product envelope, operating philosophy, battery limits)

2. Technology screening & selection with a documented decision matrix

3. BFD and PFD development, stream definition, and equipment tagging

4. 3D diagrams for the complete facility

5. Concept-to-feasibility mass & energy balances, yield model, and utility balance

6. Major equipment preliminary sizing and equipment list (key duties/sizing basis)

7. Facility planning logic, including functional zoning, storage strategy, access/maintenance philosophy, truck movement concept, and expansion strategy

8. HSE/environmental concept integration, preliminary HAZID/risk review, emissions assessment, impact assessment, spill control philosophy, waste handling approach

9. Techno-economic assessment with CAPEX Class-4, OPEX estimate, and scenario/sensitivity review for key drivers

10. Management presentation pack and feasibility summary report with conclusions and recommended next steps

Process for Project Development

Feedstock Assessment & Design Basis

• Waste oil characterization (quality variability, contaminants, water content)

• Definition of product targets (diesel-range fraction)

• Establishment of plant capacity and operating philosophy

• Preparation of Design Basis Memorandum812123

Technology Screening & Selection

• Evaluation of available conversion technologies

• Process route comparison (efficiency, cost, operability)

• Selection of optimized thermal conversion & refining pathway

• Development of decision matrix

Process Conceptualization

• Preparation of Block Flow Diagram (BFD)

• Development of Process Flow Diagrams (PFDs)

• Stream identification and section-wise process definition

• Definition of major processing units

Mass & Energy Balance Development

• Overall and section-wise mass balance

• Product yield modeling

• Utility demand estimation (power, fuel, cooling)

• Energy integration logic

Preliminary Equipment Sizing

• Reactor sizing basis

• Separation and distillation unit sizing

• Storage tank capacity calculation

• Pump and heat exchanger preliminary selection

Facility Planning & Layout Logic

• Functional zoning (receiving, processing, storage, utilities)

• Material handling and truck movement strategy

• Safety separation philosophy

• Expansion planning strategy

• 3D drawing

Environmental & Safety Integration

• Emissions management concept

• Spill containment strategy

• Preliminary hazard identification (HAZID-level review)

• Compliance framework alignment

Techno-Economic Assessment

• CAPEX Class 4 estimate

• OPEX estimation (utilities, labor, maintenance)

• Sensitivity analysis (yield, feed variability, energy pricing)

• Financial viability screening

Management Decision Package

• Executive feasibility report

• Engineering summary documentation

• Investment screening presentation

• Roadmap for FEED and EPC progression

Deliverables

• Design Basis Memorandum (DBM)

• Waste characterization & capacity definition report

• Technology screening & selection matrix

• Process narrative & operating philosophy document

• Block Flow Diagram (BFD)

• Concept-level Process Flow Diagrams (PFDs)

• Overall and section-wise mass balance model (Excel + summary)

• Energy balance & utility demand summary

• Preliminary major equipment sizing calculations

• Major equipment list with capacity & footprint basis

• Utility requirement summary (power, water, fuel, compressed air)

• Functional zoning strategy

• 2D/3D conceptual plot plan (PDF + CAD format)

• Material handling & truck circulation layout concept

• Storage capacity strategy (feed, product, residue)

• Expansion and scalability plan

• Preliminary HAZID / risk identification summary (concept level)

• Environmental & compliance integration note

• CAPEX Class 4 estimate (concept-level)

• OPEX estimate (utilities, manpower, maintenance assumptions)

• Sensitivity and feasibility summary

• Executive summary report

• Management presentation deck