Base Oil Production Line and Factory Setup

A base oil production line is a complete industrial system designed to transform crude oil fractions into high-quality base oils for lubricant blending under controlled thermal and chemical process conditions. The line produces base oils of different groups depending on the selected refining technology and process configuration.

From an industrial perspective, base oil manufacturing is important because it combines vacuum distillation, solvent extraction or hydroprocessing, dewaxing and hydrofinishing to achieve the required viscosity, volatility, oxidation stability and pour point. The process relies on a defined sequence of unit operations that must be correctly engineered, sized and integrated.

Primary raw materials typically include atmospheric residue or vacuum gas oil fractions from crude oil distillation. The core machinery set consists of vacuum distillation towers, propane deasphalting units, furfural extraction units, MEK/Toluene dewaxing systems and hydrofinishing reactors.

The Industrial Department supports investors who want to establish a new base oil plant as well as existing plant owners who need repair, overhaul, capacity expansion or automation of their current lines. Projects can start from an empty site or from an operating facility that requires technical upgrading.

Whether the goal is a green-field turnkey base oil plant in Iraq, Kurdistan Region, Afghanistan or other regional markets, or the modernization of an existing line in Iran, engineering, machinery supply or manufacturing, installation, commissioning and ongoing technical support can be provided under defined contractual scopes.

Production Line Overview

The base oil production line is engineered as an integrated process system covering distillation, solvent treating or hydroprocessing, dewaxing, finishing and storage. Design capacity is determined during the engineering phase and can typically range from pilot or semi-industrial scales up to higher industrial throughputs, depending on final product mix and market requirements.

Product types include Group I base oils produced by solvent refining and Group II / III base oils produced by hydrocracking and hydroisomerization routes. The overall process flow follows a defined sequence: atmospheric distillation, vacuum distillation, deasphalting, solvent extraction or hydrotreating, dewaxing, hydrofinishing and final storage.

Main machinery groups include vacuum distillation columns, deasphalting towers, extraction units, dewaxing crystallizers and filters, hydrofinishing reactors and associated utility systems. Supporting infrastructure covers electrical power, process water, steam, fuel gas, hydrogen (where applicable) and wastewater handling.

Manpower requirements depend on the degree of automation. Quality control covers incoming feedstock properties, process parameters (temperature, pressure, solvent ratios), finished oil specifications (viscosity, viscosity index, pour point, color, sulfur) and packaging integrity.

Technical Specifications

The following technical data represent typical ranges for an industrial Base Oil production line. Final values are defined during basic and detailed engineering and may vary according to selected technology, level of automation, product portfolio and factory layout. For precise project-specific figures, contact the Industrial Department.

Specification	Description
Product	Base oil (Group I / II / III – depending on process configuration)
Production Capacity	Depending on project capacity and selected equipment sizing (to be determined during engineering phase)
Required Area	5,000–15,000 m² (subject to final layout and capacity)
Electrical Power	380 V three-phase, 500–1,500 kW (depending on equipment selection and automation level)
Water Consumption	50–200 m³/day (process and utility water)
Gas / Fuel	2,000–5,000 m³/h (depending on capacity)
Manpower	30–60 persons per shift (depending on automation)
Main Machines	Vacuum distillation tower, propane deasphalting unit, furfural extraction unit, MEK/Toluene dewaxing unit, hydrofinishing reactor
Storage	Heated storage tanks for finished base oil

All figures are indicative. Detailed utility balances, equipment lists and layout drawings are prepared after process definition and capacity confirmation.

Products

An industrial base oil production line can manufacture a variety of finished products depending on the selected refining technology and feedstock. Typical product families include:

Group I solvent-refined base oils
Group II hydroprocessed base oils
Group III high-viscosity-index base oils
Specialty fractions for further lubricant blending

Variant development (viscosity grades, viscosity index targets, pour-point specifications) is defined during process engineering. Packaging and bulk transfer systems are selected according to target markets and distribution channels.

Raw Materials for Base Oil Factory

Raw material selection and quality control are critical for product quality, process stability and shelf life. The main and auxiliary materials used in a typical industrial formulation are described below.

Main Raw Materials

Crude oil fractions / vacuum gas oil – Primary feedstock. Quality and composition directly influence yield and product properties.
Solvents (furfural, propane, MEK, toluene) – Used in extraction and dewaxing steps where solvent technology is selected.
Hydrogen – Required for hydrofinishing or hydroprocessing routes.
Catalysts – Used in hydroprocessing reactors.

Secondary / Optional Materials

Process water and steam
Fuel gas
Additive packages for finished oil adjustment (where applicable)

Each material has a defined role and a measurable impact on quality attributes. Storage and handling conditions must be controlled to preserve functional properties.

Sahi Rasa For Factories raw material

The Supply Chain Department is prepared to support identification, evaluation and supply of the main and auxiliary raw materials required by Base Oil factories. Depending on the contractual scope, services may include supplier identification and evaluation, procurement and purchase coordination, specification control, logistics coordination, supply-chain design for continuous production, ongoing supply arrangements, and supply of materials from Iran for projects located in regional markets.

Registering an order for raw materials for the factory Base Oil
Sahi Rasa Supply Chain Department

Raw-material supply chain support can be examined for industrial projects located in Iran, Iraq, the Kurdistan Region of Iraq (including Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Manufacturing Process

The industrial process follows a defined sequence of unit operations. Each stage has a clear purpose, input materials, equipment and quality impact.

Atmospheric Distillation – Crude oil is separated into fractions; heavy residue proceeds to vacuum distillation.
Vacuum Distillation – Heavy fractions are distilled under vacuum to produce vacuum gas oil and residue cuts suitable for base oil production.
Deasphalting (where used) – Propane deasphalting removes asphaltenes from residual fractions.
Solvent Extraction or Hydrotreating – Aromatic and polar compounds are removed to improve viscosity index and stability.
Dewaxing – MEK/Toluene or catalytic dewaxing reduces pour point by removing wax components.
Hydrofinishing – Final hydrogenation improves color, oxidation stability and removes residual impurities.
Storage – Finished base oil is stored in heated tanks before blending or shipment.

Machinery & Equipment

Each main machine performs a specific function. Support is available for design, manufacturing or procurement, customization, installation, commissioning, repair, overhaul, refurbishment, automation and spare-parts supply according to the agreed project scope.

Vacuum Distillation Tower – Separates heavy feedstock under vacuum. Position: early process stage. Importance: defines the base oil boiling range. Quality impact: improper cut points affect viscosity and volatility. Maintenance: trays, packing, vacuum system and temperature instruments. Sahi Rasa support covers design, procurement, installation, repair and spare parts.
Propane Deasphalting Unit – Removes asphaltenes using propane solvent. Position: after vacuum distillation of residual stocks. Quality impact: residual asphaltenes harm color and stability. Maintenance: solvent recovery system and high-pressure equipment.
Furfural Extraction Unit – Removes aromatics and polar compounds. Position: after deasphalting or on VGO. Quality impact: incomplete extraction lowers viscosity index. Maintenance: extraction towers, solvent recovery and heat exchangers.
Dewaxing Unit (MEK/Toluene) – Crystallizes and filters wax. Position: after extraction. Quality impact: residual wax raises pour point. Maintenance: crystallizers, filters and solvent recovery.
Hydrofinishing Reactor – Final catalytic hydrogenation. Position: last process stage before storage. Quality impact: incomplete finishing leaves color and sulfur issues. Maintenance: catalyst, reactors, compressors and heat exchangers.

Factory Layout & Building Requirements

Typical functional areas include raw-material receiving and storage, main process areas, packaging, quality-control laboratory, utility rooms, maintenance workshop, staff facilities, loading docks and administrative offices. Layout must respect hygienic or safety zoning and process flow. Exact area allocation is determined during the engineering phase according to capacity and product range.

Utilities

Electricity: 380 V three-phase, typically 500–1,500 kW
Water: 50–200 m³/day
Fuel gas: 2,000–5,000 m³/h
Steam and hydrogen systems according to process route
HVAC, flare and drainage according to safety and local regulations

Turnkey Factory Setup

An investor can start from an empty site. Depending on contractual scope, the project can be accompanied through: Idea → Feasibility → Engineering → Factory Design → Machinery → Procurement → Manufacturing → Installation → Commissioning → Training → Raw Material Supply → Packaging → Trial Production → Commercial Production. The objective is an operational factory ready for production.

EPC & PMC

Projects can be executed under EPC (Engineering, Procurement, Construction) or PMC (Project Management Consultancy) approaches. Engineering, machinery supply or manufacturing, installation supervision and commissioning are coordinated within the defined contract boundaries.

Machinery Repair

Existing factories can request inspection, troubleshooting, mechanical and electrical repair, component replacement, spare-parts supply and line maintenance support for the main process equipment.

Machinery Overhaul & Refurbishment

Older equipment can be evaluated for comprehensive overhaul, replacement of worn parts, control-system upgrades, improved reliability and modest capacity or quality improvements where technically feasible.

Capacity Expansion

Capacity of an existing line can often be increased by addressing bottlenecks, upgrading key machines, improving packaging speed, optimizing layout or introducing selective automation.

Industrial Automation

Typical applications include PLC sequence control, temperature/pressure/flow/level loops, automatic dosing, HMI, data logging, CIP or cleaning automation and optional SCADA integration.

Supply Chain

Factory = Machinery + Raw Materials + Utilities + People + Process + Supply Chain + Market. The Supply Chain Department supports supplier sourcing, procurement, logistics and ongoing material supply for Base Oil projects.

Packaging

Filling, sealing, labeling, coding, cartoning, shrink wrapping and palletizing are integrated according to product format and market requirements.

Branding & Product Development

When required, support can be provided for product development, packaging design, graphic design, industrial design, branding and related marketing preparation.

Market & Country Sections

Engineering, machinery, installation, overhaul and supply-chain support are available for Base Oil projects in Iran, Iraq, Kurdistan Region (Erbil, Sulaymaniyah, Duhok), Baghdad, Basra, Mosul, Afghanistan (Kabul, Herat, Mazar-e-Sharif), Uzbekistan, Turkmenistan, Tajikistan, Syria, Oman, Jordan, Turkey, Armenia and Georgia.

Sahi Rasa Services

Service	Application in This Project
Feasibility Study	Technical and economic assessment of capacity, product mix and investment
Factory Design	Layout, process flow and utility design
Machinery Design / Manufacturing	Specification and coordinated supply or manufacturing of process equipment
Procurement	Sourcing of machinery, components and materials
Installation & Commissioning	Mechanical/electrical installation, start-up and performance testing
Automation	PLC, HMI, process control and optional SCADA
Raw Material Supply	Coordination via Supply Chain Department
Repair / Overhaul / Refurbishment	Restoration and modernization of existing machinery
Capacity Expansion	Engineering and implementation of throughput increases
Staff Training	Operational and basic maintenance training

Why Sahi Rasa

Process engineering, machinery-related capabilities, procurement support, supply-chain coordination, installation, commissioning, training, maintenance support and automation are combined. The practical advantage is a more integrated execution path from concept to an operating production line.

From Empty Land to Production

Typical sequence: Feasibility → Engineering → Factory Design → Equipment Design → Machinery Manufacturing/Procurement → Logistics → Installation → Commissioning → Staff Training → Raw Material Supply → Trial Production → Commercial Production. Operational support for a defined initial period can be examined as a contractual option.

Who Should Contact Sahi Rasa?

Investors – planning a new Base Oil factory or production line
Existing Factory Owners – needing repair, overhaul, refurbishment, modernization, automation or capacity expansion
Industrial Buyers – requiring machinery, spare parts, raw materials or engineering services

Final CTA

If you intend to set up a Base Oil production line or factory, if your existing plant needs repair, overhaul or capacity expansion, if you require new machinery or automation, or if you need coordination of raw-material supply, contact the Industrial Department.

Submit your request for: Factory Setup / Machinery / Repair / Overhaul / Refurbishment / Automation / Capacity Expansion / Raw Materials.

Registering an order for raw materials for the factory Base Oil

FAQ

What is the typical cost of setting up a base oil plant?
Cost depends on capacity, process route (solvent vs hydro), automation level, building and utility scope. A detailed estimate is prepared after process definition.
Which main machines are required?
Vacuum distillation tower, deasphalting unit, extraction or hydrotreating unit, dewaxing system and hydrofinishing reactor.
What production capacity can be designed?
Capacity is determined during the engineering phase according to market demand and investment criteria.
How much space is needed?
Typical process area ranges from approximately 5,000 to 15,000 m², subject to final layout.
What are the main raw materials?
Crude oil fractions or vacuum gas oil, solvents (where used), hydrogen and catalysts.
Can raw materials be supplied?
Yes, via the Supply Chain Department according to project scope.
Is machinery manufacturing or procurement supported?
Design, manufacturing or coordinated procurement according to the agreed scope.
Can existing machines be repaired?
Yes – inspection, troubleshooting, mechanical/electrical repair and spare parts.
Is overhaul or refurbishment possible?
Yes – comprehensive restoration and control upgrades.
Can capacity of an existing line be increased?
Often yes, by addressing bottlenecks and upgrading key equipment.
Are turnkey projects executed?
Turnkey or partial turnkey scopes can be offered under defined contracts.
Are services available in Iraq and Kurdistan Region?
Yes, including Erbil, Sulaymaniyah, Duhok and other locations.
Are services available in Afghanistan?
Yes, including Kabul, Herat and Mazar-e-Sharif.
Can raw materials be supplied from Iran for regional projects?
Yes, coordination of material supply is part of possible supply-chain scope.
Is installation and commissioning included?
They can be included according to the selected contractual package.