MACHAKOS UNIVERSITY

SCHOOL OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHANICAL AND MANUFACTURING ENGINEERING

UNIT CODE: EMM 510

UNIT CODE: ENGINEERING PROJECT II

PROJECT PROPOSAL TITTLE:

DESIGNING AND FABRICATING OF WASTE LUBRICATION OIL BURNER

Presented by:

JACKSON WENGE MUMO: J40-2346-2018

RONALD KIPROP NGOTIO: J40-12251-2017

Supervisor:

Mr. Ngugi

A PROJECT SUBMITTED IN PARTIAL FULFILLMENT OF THE

REQUIREMENTS FOR THE AWARD OF THE DEGREE OF BACHELOR OF
SCIENCE IN MECHANICAL AND MANUFACTURING ENGINEERING OF
MACHAKOS UNIVERSITY

NOVEMBER 2023
 DECLARATION
We hereby declare that this project proposal is our original work and has never been presented
before for any other purpose. The references used here from other journals or materials are
indicated in the references section.

Students:

Name……………………………………………Sign…………………Date………………..

Name……………………………………………Sign…………………Date………………..

Certification by supervisor

I hereby certify that this project has been done under my/our supervision as university
supervisors.

Name……………………………………………Sign…………………Date………………..

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 ABSTRACT

The improper disposal of used lubrication oil poses a significant environmental

hazard and economic burden worldwide. Addressing this issue requires innovative

approaches to repurpose this waste product efficiently and sustainably. This

proposal presents a solution in the form of designing and fabricating an oil burner

that utilizes waste oil as a fuel source for fire production. The motivation behind

this research stems from the urgent need to reduce the environmental impact of

used engine oil, which often ends up contaminating soil and water resources.

Furthermore, this project aims to provide a cost-effective alternative to

conventional fuel sources, especially in regions where access to affordable energy

is limited and in several engineering processes that require the control use of fire

for various purposes including heating, combustion, and material transformation.

The project proposal begins with an extensive review of related literature, focusing

on the properties of used engine oil, its environmental impact, and existing

methods of disposal and recycling. The core of this project proposal involves the

design and fabrication of an oil burner specifically tailored to the unique properties

of used engine oil.

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 ACKNOWLEDGMENT
We would like to thank the Almighty God for the gift of life and protection up to this time.
Special thanks to our immediate supervisor Mr Ngugi, for the guidance and supervision in the
preparation of this proposal.

We would also like to thank the Machakos University particularly the department of Mechanical
and Manufacturing Engineering for their constructive training and the knowledge they have
imparted in us throughout the five years training.

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 Contents
DECLARATION ............................................................................................................................. i
ABSTRACT .................................................................................................................................... ii
ACKNOWLEDGMENT................................................................................................................ iii
Contents ......................................................................................................................................... iv
LIST OF TABLES ......................................................................................................................... vi
LIST OF FIGURES ....................................................................................................................... vi
LIST OF APPENDICES ................................................................................................................ vi
ABBREVIATIONS ....................................................................................................................... vi
NOMENCLATURE ..................................................................................................................... vii
SUBSCRIPTS ............................................................................................................................... vii
CHAPTER ONE ............................................................................................................................. 1
1.2 Problem statement ................................................................................................................. 2
1.3 Objectives .............................................................................................................................. 3
1.3.1 General Objective ........................................................................................................... 3
1.3.2 Specific Objective........................................................................................................... 3
1.4 Research questions: ............................................................................................................... 4
1.5 Justification of the study ....................................................................................................... 4
1.6 Scope ..................................................................................................................................... 5
CHAPTER TWO ............................................................................................................................ 7
2.0 LITERATURE REVIEW ......................................................................................................... 7
2.1 Overview ............................................................................................................................... 7
2.2 Properties of Liquid Fuels in General ................................................................................. 10
2.3 Utilization of Waste Lubrication Oils for Energy Generation ............................................ 12
2.4 Sources of Waste Lubrication Oils...................................................................................... 12
2.5 Uses of Waste Lubrication Oils .......................................................................................... 13
2.6 Burners ................................................................................................................................ 13
2.7 Fuel Combustion Process and Emissions ............................................................................ 13
2.8 Identified Gap ..................................................................................................................... 14
CHAPTER THREE ...................................................................................................................... 15
3.0 METHODOLOGY ................................................................................................................. 15

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 3.1 Background ......................................................................................................................... 15
3.1 Design of the Model ........................................................................................................... 15
3.1.1 Burner Design ............................................................................................................... 16
3.1.2 WLO burner body design ............................................................................................. 18
3.1.3 Waste oil reservoir. ....................................................................................................... 19
3.1.4 Air supply system ......................................................................................................... 19
3.1.5 Atomization technique .................................................................................................. 20
3.2 Fabrication of parts and assembling ................................................................................... 21
3.3 Testing the prototype for functionality................................................................................ 22
3.4 Performance Parameters ...................................................................................................... 22
3.4.1 Fuel Heating Value ....................................................................................................... 22
3.4.1 Combustion of WLO by Volume ................................................................................. 23
3.4.3 Theoretical CO2 Emission Determination at 12% Excess Air ..................................... 23
3.4.4 Theoretical CO Emission Determination at 12% Excess Air ....................................... 24
3.5 The working principle ..................................................................................................... 24
CHAPTER FOUR ......................................................................................................................... 25
4.0 EXPECTED RESULT ............................................................................................................ 25
CHAPTER FIVE .......................................................................................................................... 26
5.0 CONCLUSION AND RECOMMENDATIONS ................................................................... 26
5.1 CONCLUSION ................................................................................................................... 26
5.2 RECOMMENDATION ...................................................................................................... 26
APPENDICES .............................................................................................................................. 27
REFERENCES ............................................................................................................................. 29

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 LIST OF TABLES

Tabe 2.1 : Waste Lubrication Oils Composition……………………………………………….11

LIST OF FIGURES
Figure 2.1: Sources of Waste Lubrication Oils………………………………………………….……………………………12

Figure 3.1 Schematic Illustration of the Designed Burner………………………………………………….…………..16

Figure 3.2 Model Design of the Burner………………………………………………….…………………………………………17

Figure 3.3 Top and side view of the WLO burner body………………………………………………….………………18

Figure 3.4 Air pipe with atomizing nozzles ………………………………………………….…………………………………20

LIST OF APPENDICES
Appendix 1:
BUDGET………………………………………………….………………………………………………….……………………………………..27

Appendix 2: WORK SCHEDULE………………………………………………….…………………………………………………27

ABBREVIATIONS

Abbreviations used meaning

HHV Higher Heating Value

LHV Lower Heating Value

SS Stainless steel

WLO Waste Lubrication Oils

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 LDO Light diesel oil

HFO Heavy fuel oil

CI Compression ignition

NOMENCLATURE
φ Diameter

P Pressure

wt Weight

m˙ Mass Flow Rate

Tm Temperature

f Fuel

SUBSCRIPTS
M Mass

th Theoretical

exp Experimental

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 CHAPTER ONE
1.1 INTRODUCTION

The disposal of used engine oil has long been an environmental challenge, with improper
disposal methods leading to soil and water contamination, air pollution, and adverse health
effects. Simultaneously, the demand for alternative, eco-friendly energy sources is on the rise,
calling for creative solutions to both reduce waste and harness untapped energy resources.

This project proposal seeks to address these critical issues by introducing a groundbreaking
concept: the transformation of waste lubrication oil (WLO)l, often considered a hazardous waste,
into a viable fuel source through the development of a specialized oil burner. By doing so, we
aim to mitigate the environmental impact associated with WLO disposal while simultaneously
providing a sustainable and cost-effective energy solution for a wide range of applications, from
industrial heating to domestic heating and beyond.

In this comprehensive proposal, we will delve into the background and significance of the
project, detailing the environmental implications of WLO mismanagement, the potential benefits
of utilizing it as a fuel source, and the technical challenges we intend to overcome. Moreover, we
will outline the project's objectives, methodology, and anticipated outcomes, shedding light on
the research, development, and implementation phases.

As we embark on this endeavor, we invite stakeholders, investors, and collaborators to join us in

realizing the full potential of repurposing WLO as a valuable energy resource, thereby
contributing to a cleaner, more sustainable future. Together, we can innovate and redefine our
approach to waste management and energy production, setting a new standard for environmental
responsibility and resource utilization.

In the heart of Kenya's industrial and environmental landscape lies a multifaceted challenge - the
management and disposal of WLO. This byproduct of countless engines and machinery, often

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discarded carelessly or left to pollute the environment, poses a significant threat to both the
ecological balance and human health. However, in the face of adversity, innovation and
sustainability often emerge as the guiding stars for engineers and researchers. The endeavor to
mitigate this challenge, by creatively repurposing WLO for fire production through the design
and fabrication of an oil burner, stands as a testament to Kenya's commitment to addressing
environmental concerns while striving for energy efficiency.

Kenya's unique context underscores the importance of such innovative solutions. In a nation that
grapples with limited access to affordable energy sources, the utilization of WLO as a viable fuel
source represents a promising avenue towards energy sustainability. Moreover, in a world
increasingly aware of the dire consequences of improper waste disposal, Kenya's pursuit of
responsible WLO management through recycling and reuse aligns with global efforts to curtail
environmental degradation.

In essence, this project proposal illustrates how engineering ingenuity can transform a
challenging environmental issue into an opportunity for sustainable energy production in the
Kenyan context. It showcases the potential for innovation to bridge the gap between
environmental responsibility and economic development, ultimately contributing to a brighter,
more sustainable future for Kenya and, by extension, the world at large.

1.2 Problem statement

The improper disposal and mismanagement of used WLO Kenya present a pressing
environmental concern, marked by pollution of soil and water resources. Additionally, the high
cost and limited access to conventional energy sources exacerbate the nation's energy challenges.
This dual problem necessitates an innovative and sustainable solution that not only addresses
environmental degradation but also provides an affordable energy alternative.

While used lubrication oil is typically considered a waste product, its potential as a valuable
resource for fire production remains largely untapped in the Kenyan context. The absence of an
efficient and environmentally responsible method for repurposing WLO not only contributes to

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environmental degradation but also denies Kenya an opportunity to harness this resource for
energy generation, thereby reducing its heavy reliance on expensive imported fuels.

Furthermore, the absence of a dedicated system for repurposing WLO perpetuates the negative
environmental impacts associated with its disposal. This includes soil contamination,
groundwater pollution, and adverse effects on local ecosystems and communities. The lack of an
effective solution poses a direct threat to public health and the environment, necessitating
immediate attention.

In light of these challenges, the problem statement revolves around the urgent need to develop
and implement a systematic approach to utilize the WLO for fire production in Kenya. This
approach should involve the design and fabrication of an efficient and eco-friendly oil burner
that not only mitigates environmental harm but also provides a sustainable energy source,
contributing to Kenya's economic and environmental well-being. The development and adoption
of such a solution represent a crucial step towards addressing Kenya's waste management and
energy access challenges, aligning with global efforts to achieve sustainable development goals.

1.3 Objectives

1.3.1 General Objective

To design and fabricate a prototype of waste lubrication oil burner

1.3.2 Specific Objective

 To design an efficient and safe waste lubrication oil burner capable of effectively
utilizing used lubrication oil as a fuel source for fire production
 To fabricate an efficient and safe waste lubrication oil burner system capable of
effectively utilizing WLO as a fuel source for fire production using appropriate materials
and components.
 To test the system for functionality.

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 1.4 Research questions:

1. How can we design an oil burner system that efficiently and safely utilizes WLO as a fuel source
for fire production?
2. What materials and components are most suitable for fabricating an efficient and safe oil burner
system capable of utilizing WLO effectively for fire production?
3. What are the key design considerations and safety measures necessary to ensure the successful
fabrication of the oil burner system?
4. How can we test the functionality of the designed and fabricated oil burner system, and what
performance parameters should be evaluated to determine its effectiveness in utilizing WLO for
fire production?
5. Are there any environmental or emissions concerns associated with the combustion of WLO in
the designed system, and how can these be addressed to ensure sustainability and safety?
6. What are the potential applications and industries that can benefit from the implementation of
this oil burner system, and what are the economic and environmental advantages of using WLO
as a fuel source in these contexts?
7. How does the efficiency and performance of the oil burner system compare to traditional heating
systems that use conventional fuels, both in terms of cost-effectiveness and environmental
impact?

8. What modifications or improvements can be made to the system based on the test results to
enhance its efficiency, safety, and reliability in utilizing WLO for fire production

1.5 Justification of the study

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The project proposal holds significant relevance and justification in the Kenyan context for
several compelling reasons:

1. Environmental concern:

 Kenya, like many countries, faces pressing environmental challenges, including the
improper disposal of WLO. The inadequate handling of this hazardous waste poses
serious threats to soil and water quality, air pollution, and public health. Addressing this
issue aligns with Kenya's commitment to environmental sustainability and conservation.
2. Waste management solution
 Kenya's waste management infrastructure is still evolving, and innovative solutions for
waste reduction and reuse are urgently needed. The proposed project offers a sustainable
and eco-friendly approach to managing WLO, reducing the burden on waste disposal
facilities and preventing environmental contamination.
3. Energy sustainability:
 Kenya has a growing demand for energy, both in rural and urban areas. This project
introduces a cost-effective and efficient method for generating heat

1.6 Scope

The scope of the project proposal encompasses the following key components:

1. Design phase:
 The project will involve extensive research and engineering to design an oil burner
system capable of efficiently and safely utilizing WLO as a fuel source for fire
production.
 The design will be based on sound engineering principles and will aim to optimize the
use of materials and components to achieve the desired functionality.
2. Fabrication Phase:
 Following the design phase, the project will proceed to the fabrication stage, where the
designed oil burner system will be physically constructed.

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 Appropriate materials and components will be selected and used in accordance with
industry standards and safety guidelines.
 Fabrication will be conducted with an emphasis on quality control and adherence to
design specifications to ensure the system's safety and efficiency.
3. Testing and validation phase:
 The fabricated oil burner system will undergo rigorous testing to evaluate its functionality
and performance.
 Various parameters, including combustion efficiency, emissions, safety features, and
reliability, will be assessed.
 Testing will be conducted under controlled conditions to simulate real-world applications
and ensure that the system can effectively utilize WLO as a fuel source for fire
production.
4. Environmental impact assessment phase:
 An environmental impact assessment will be conducted to evaluate the system's
sustainability and its contribution to waste reduction through the utilization of WLO.
 An economic analysis will be performed to determine the cost-effectiveness of using this
system compared to traditional heating methods.
 Potential applications and industries that can benefit from the system will be identified
and assessed.
5. Recommendation and future enhancement phase:
 Based on the test results, recommendations will be provided for any necessary
modifications or improvements to enhance the system's efficiency, safety, and reliability.
 Future enhancements and research directions related to the utilization of WLO as a fuel
source will be outlined.

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 CHAPTER TWO

2.0 LITERATURE REVIEW

2.1 Overview

WLO, generated as a result of routine vehicle maintenance and industrial operations, poses a
significant environmental challenge worldwide. The improper disposal of this waste oil can lead
to soil and water contamination, threatening ecosystems and human health. Globally, research
has been dedicated to addressing this issue through the utilization of WLO burners. These
burners provide a sustainable solution by repurposing waste oil as a valuable energy source and
mitigating environmental hazards.

Madhusudan (2017) has collected the rejected products, which has certain properties similar to
petroleum distillates and is a non-renewable energy source. He converted used oil into a valuable
fuel and Paying considerable attention on heat recovery, from WLO by a good means of
environmental sound recycling practice, by designing and fabricating an oil burner which burns
the WLO and delivers the resulted energy for domestic and commercial purposes.

Kazuaki Hashiguchi (2016) has Aimed for the increase in use of combustion technologies for
heavy oil fuel, containing lot of carbon residues and in order to develop burners for heavy oil
with excellent environmental performance, by studying the structures of atomizers and swirles.
He confirmed that the developed structure was attained for reduction of particle size by 38% in a
spray test and that the developed swirler were undamaged even after years of continuous
operation in actual equipment.

Merai Yash P. (2015) had said that burning of used oil, in kilns and incinerators produces lots of
ash and carcinogens causing environmental pollution. Waste lubricating oil is a product which
cannot be disposed of randomly due to the presence of pollutants. With respect to economic
problems and environmental protection, there is a growing trends in regeneration and reuse of
waste lubricants. By proper recovery methods and refinement process, a lot of valuable product
can be obtained. The objectives of re-refining process is to remove the degraded additives,
contaminants and to restore the properties of the oil identical to the standards provided by SAE.

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Only 1/3rd of the energy is required for manufacturing of re-refined used oil, when compared
with refine crude oil to produce virgin base oil. Therefore, re-refining is considered by many as
their 1st opinion, for conserving resource as well as to minimize the waste and reducing damage
to the environment.

Jiafeng Yao (2014) Geometries were considered to have a great influence, on the spraying
characteristics of atomizers. In his research paper, he studied a “pre filming twin-fluid atomizer”
patented by Sadatomi and Kawahara (2012), in which liquid atomization is performed by
supplying compressed air alone into an internal mixing chamber and by negative pressure the
water is automatically sucked by an orifice. In his experiments, we studied spraying
characteristics influenced by the geometrical parameters, such as orifices of different opening
area ratios and different shapes, porous rings with different porous diameters, and different sizes
of atomizer. Higher spray performance was obtained by a small sized atomizer, with a circular
orifice with an opening area ratio of “0.429” and a porous fiber ring with porosity of “25 µm”.
His present results provides a proper guidance for practical applications with different
requirements of spray characteristics.

M. J. Madu (2014) had made a burner for the atomization and combustion of WLO and kerosene
for the application of foundry. This setup was constructed and tested to reduce the cost. The
nozzle, springs, screws, tank and the fuel hose were the materials used for its construction. He
even carried out some tests, to determine the time taken for some selected materials to melt. The
thermal efficiency of the burner was around 66%. The experiment also resulted that the density
of the mixture, decreases with an increase in the temperature making it easy to mix and use for
combustion.

Shri Kannan C (2014) in this paper the used oil is collected from automobile service stations and
the oil is subjected to dehydration, vacuum distillation followed by solvent extraction. The
solvent used for solvent extraction, was recovered by atmospheric distillation process. Lastly
additives are added in the re-refined oil. The properties of these lubricating oil like density,
viscosity, viscosity index, flash point, fire point, pour point, cloud point and total acid number
were studied and compared with the standards given by the Society of Automotive Engineers.

8
Ihsan Hamawand (2013) had performed recycling of waste engine oils by using acetic acid. This
recycling process was developed which gave him some comparable results, with some of the
conventional methods. This gave the recycled oil, the potential to be reused in car‟ s engines
after adding some required additives. The advantage of using the acetic acid is that it does not
reacts or it only reacts slightly with base oils. The recycling process, takes place at room
temperature. The writer displayed that the base oils and additives are affected slightly by the
acetic acid. By adding 0.8 % vol of acetic acid to the used oil, two layers were separated and a
transparent dark red colored oil with a black dark sludge at the bottom of the container. In this
paper the writer also compared the results with other recycling methods. This comparison
showed that, the recycled oil produced by acetic acid treatment was compared with other
conventional recycling methods. This research has displayed that, WLO can be recycled by using
glacial acetic acid.

Motshumi J. Diphare (2013) The recovery techniques which he discussed, in his paper were
reprocessing, re-refining and incineration of waste lubricating oil. The major objectives of his
paper were to analyze and compare the regenerative technologies, and creating the platform for
government, recovery techniques by private sectors are work in progress.

Nabil M. Abdel-Jabbar (2010) had performed an experimented, and investigated that waste
lubricating oil rerefining adsorbing process, by different adsorbing materials. Adsorbing
materials such as: – oil adsorbent, egg shale powder, date palm kernel powder, and acid activated
date palm kernel powder were used. In his investigation, the adsorption process over fixed
amount of adsorbing materials at ambient conditions. In his process, the adsorption/extraction
process was able to deposit the asphaltic and metallic contaminants to lower values of waste oils.
He also found that, the date palm kernel powder with contact time of 4 hrs, has given the best
conditions for treating the waste oil. The recovered solvent was also reused. He even found that,
the activated bentonite, has the best physical properties followed by the date palm kernel powder.
The carbon residue, ash content, and aspheltene content were decreased up to 68.2%, 72.9%, and
92.3% respectively. His process also decreased the amount of heavy metals present in treated oil.
The solvent recovered from the process was also reused again.

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Udonne J. D. (2010) focused on comparative study of 4 methods for recycling of used
lubrication oils, they are: – 1) Acid/clay treatment, 2) Distillation/clay, 3) Acid treatment and 4)
Activated charcoal/clay treatment methods. The test carried out on the recycled lubrication oil
include:- flash point, pour point, specific gravity, metal contents, viscosity and sulphur contents.
The results from his tests shows that, increase in viscosity from 25.5 for used lube oil to 86.2 for
distillation, 89.10 for acid/clay treatment and 80.5 is for activated/clay treatment.

S. O. Ogbeide (2009) in his paper he identify a different method for reusing, by adequately
spending oil. He also found that cost of recycling is relatively low, when compared with the
production of crude oil, as there is a reduction in purification stages. The research carried out by
the writer discovered that when 25 liters of oil used and recycled appropriately, 10 liters of
lubricating oil was obtained. Whereas 220 liters of crude oil was required to produce the same 10
liters of oil.

Jennifer M. Granholm (2007) has stated that the requirements for burning used oil depends on
the natural oil, source oil, and physical chemical spec of oil, or has satisfied the required “
product” conditions. She said that „although it looks complicated, the Department of
Environmental Quality supports recycling, which includes burning of used oil when possible,
and research groups were available to discuss regarding the topic.‟ But these businesses requires
an inventory for fuel storage and must have a transport facility for same. This group have also
found some vendors for used oil burning equipment online.

2.2 Properties of Liquid Fuels in General

Liquid fuels like furnace oils, light diesel oil (LDO), kerosene, and diesel among others are
predominantly used in industrial combustion applications [28]. For this combustion to be carried
out effectively and efficiently, various properties of liquid fuels, waste oil lubricant, WLO
included, must be known. Gomez-Rico tested properties of WLO and found the chemical
composition to be as shown in Table 2.1. From the table, it is clear that fuel carbon part of WLO
takes a greater percentage of its composition. This justifies the fact that WLO has high energy
content and can be used comfortably for energy generation. Again, the very harmful parts of it
(nitrogen and sulphur) were in trace quantities and as such were left out in combustion equation

10
even though they still pose great pollution threats. Its lower heating value (LHV) was found to be
48.17 MJ/kg.

Tabe 2.1 : Waste Lubrication Oils Composition

Constituents % weight Chemical Symbol Atomic wt

(g/mole)

Carbon 85.35 C 12

Hydrogen 13.25 H2 2

Oxygen 0.09 O2 32

Nitrogen 0.9 N2 28

Sulphur 0.46 S 32

Water 0 H2O 18

- - CO2 44

- - SO2 64

Ash 0.05 - -

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2.3 Utilization of Waste Lubrication Oils for Energy Generation

There exist many ways by which waste lubrication oils can be utilized. WLO can be reprocessed,
reclaimed and regenerated into base oil to produce base oil with same lubrication quality. One
gallon (3.8 kg) of WLO can be re-refined into 2.3 kg of base lubrication oil. Similarly, WLO can
be reprocessed into fuel for furnaces, or power plants to generate electricity for homes, schools
and businesses . Durrani argues that one liter of WLO contains about 8000 kJ of energy which is
sufficient to light a 100 watts bulb for 24 hours or even to operate a 1000 watts electric water
heater for 2 hours. This implies that waste lubrication oils are potential energy generators for
process heat required in workshops, foundry, hotels and restaurants.

2.4 Sources of Waste Lubrication Oils

Figure 2.1 shows the WLO generated from all engine-run equipment and hydraulic machines.
This indicates that WLO results from many facilities utilized in day-to-day operations and hence
there can never be a shortage of WLO at any given moment.

Figure 2.1: Sources of Waste Lubrication Oils

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2.5 Uses of Waste Lubrication Oils

Currently, WLO are utilized in many areas some of which are not accepted by the United States
Environmental Protection Agency (EPA). Each of the individual application has its own
drawbacks which may render it unappropriate in application. Some of these applications are
discussed as follows:

 WLO can be used as fuel in cement and lime kilns, in brick works and metallurgical
furnaces

 WLO can also be used for co-firing in a boiler where 10 - 25% of it is mixed with heavy
fuel oil (HFO) to serve as a fuel supplement in a boiler

 Heino Vest mixed unrefined WLO in small quantities with diesel fuel and used it in CI
engines

 WLO can be burned in space heaters to heat rooms like garages, workshops, and green
houses among others

 Other applications include using re-refined WLO as fuel in internal combustion engines
(ICEs) without any form of blending.

2.6 Burners

 Gas Fuel Burners : These types of burners use gaseous fuels. In many cases the burner
and heat exchanger are separate and this has posed a number of challenges concerning the
construction of air supply system and the necessity to insulate hot air piping.

 Liquid Fuel Burners : These burners are used to combust liquid fuels ranging from light
kerosene to heavy fuel oil. Most conventional liquid fuel burners are spray types in
design which pose a number of challenges as observed by Jugjai et al

2.7 Fuel Combustion Process and Emissions

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Combustion refers to rapid oxidation of fuel leading to production of heat, light and combustion
products (CO2 and water). Combustion of WLO is similar to burning any other liquid, solid or
gaseous fuel and chemical reactions involved are the same. Oil is a very complex mixture of
compounds containing carbon (over 80%), hydrogen (about 15%) and other elements in small
quantities (e.g O2, CO2, sulphur, water vapor, ash etc.). Carbon and hydrogen in fuel combine
with O2 in air to form CO2 and water vapor respectively releasing 33.85 MJ/kg and 121.1 MJ/kg
of heat respectively. Complete combustion occurs when reaction of fuel and oxidizer is
stoichiometric and all reactants consumed. However, this is difficult to achieve and therefore an
excess amount of air is used to ensure complete or near complete combustion. This air is referred
to as excess air and is expressed as a percent of the required air.

2.8 Identified Gap

The identified gap in this project is the absence of locally fabricated and affordable oil burners
designed specifically for the combustion of WLO. While the concept of utilizing waste oil as a
fuel source has global recognition, there is a scarcity of cost-effective and regionally adapted
solutions in Kenya. The existing burners are often imported, expensive, and may not meet the
unique needs and constraints of Kenyan communities.

WLO, generated from vehicle maintenance and industrial operations, is often discarded
haphazardly in Kenya, contributing to environmental pollution. In parallel, there is a pressing
need for accessible and cost-effective energy sources for cooking, heating, and small-scale
industrial processes in Kenya's urban and rural areas. Currently, many households and businesses
rely on expensive and environmentally harmful fuel sources, such as kerosene and charcoal.

The improper disposal of WLO is a pervasive environmental challenge in Kenya, as it is in many

parts of the world. This waste oil poses significant risks to soil and water quality, threatening
ecosystems and public health. Simultaneously, Kenya faces the ongoing challenge of providing
affordable and sustainable energy solutions for various applications. This project proposal aims
to address a specific gap: the lack of affordable and locally fabricated WLO burners for fire
production in Kenya.

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 CHAPTER THREE

3.0 METHODOLOGY

3.1 Background

The problem of coming up with proper and reliable waste oil burners to enable safe combustion
of WLO for process heat generation as well as offer safe disposal solutions has been in existence
for a long time. Due to continued generation of WLO with increasing population, technology and
development, there is a need to seek solution to these problems to avoid health and
environmental problems associated with WLO handling. The methodology used in this project
will be classified into three;

1. The design of waste lubrication oil burner ,

2. Fabrication of parts and assembling
3. Testing the prototype for functionality.

The materials and equipment used in this project include:

 WLO
 Burner components (combustion chamber, nozzles, fuel lines)
 Air supply system

3.1 Design of the Model

The model was designed using Autodesk Inventor software. This design process involved
conceptualization, detailed 3D modeling, material selection, and safety feature integration.
Autodesk Inventor enabled the creation of a digital prototype, which allowed for iterative
improvements and ensured the efficient and safe utilization of WLO for fire production. This
approach not only minimized waste but also contributed to the project's goal of recycling used
oil while generating heat or energy efficiently.

15
Figure 3.1 Schematic Illustration of the Designed Burner

3.1.1 Burner Design

Various review technique and design were studied before concluding the design of the burner.
The basic principle of oil burner is to mix oil and air in a controlled condition for the combustion
and then to deliver the resulted heating energy for further applications. Fig 3.2 shows the
complete design construction of WLO burner. Complete combustion is possible by burner
without any visible smoke only if there is stoichiometric ratio of oil andexcess air

. To design any oil burner the mandatory points that has to be followed are

 Compressed air

 Nozzle position

 Oil feeding

16
 Figure 3.2 Model Design of the Burner

Air pipe with atomizing nozzles

WLO Burner body

Oil reservoir
Blower

Oil return line

17
3.1.2 WLO burner body design

The burner body was designed with the following dimensions:

Top view Side view

Figure 3.3 Top and side view of the WLO burner body

The length, width and height were both set to 30 cm to allow flame to cover most of the
combustion. The air inlet to the burner was set at the middle of the botton of the WLO burner
body turbulent mixing and more air in the burner body and for atomization. The burner body is
to be made of stainless steel (ss) as it is easier to weld, relatively cheap, hard, has good thermal
resistance and finally, corrosion does not effect its performance. This material is cost effective
and ideal for long term operation of the burner. The burner air inlets and air pipe from air supply
blower were joined by a 3/4 inch diameter pipe.

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3.1.3 Waste oil reservoir.
A 3 L capacity container was selected as fuel reservoir for the Setup. It has also to be fitted with
a filter at the top to facilitate Initial filtration of waste when filling the container.

3.1.4 Air supply system

Air supply at the back of a burner introduces a phenomenon called draft which is the flow of
gases through a heat generating equipment. Once combustion occurs, the heated gas leaves
combustion chamber and passes through heat exchangers to the Exhaust stack. Draft can be
natural where combustion air flows into the burner freely Or forced/mechanical where
combustion air is forced into combustion chamber by a Fan. Draft mostly relies on a combination
of both natural and forced means. Air supply to the burner system will achieve through a blower.
A variable flow industrial or hand held blower with levels of flow rate can be used. It has to
have power rating Of 80W, 50 Hz frequency and a maximum flow rate of 3.5 m3/min.

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 3.1.5 Atomization technique
Atomization techniques were employed to achieve fine droplet sizes, enhancing combustion
efficiency. The atomizing nozzles were designed as shown below:

1cm

6cm

Ø = 3mm Ø = 25mm

6cm

1 cm

3cm

Figure 3.4 Air pipe with atomizing

nozzles
Ø =3/4 inch

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 3.2 Fabrication of parts and assembling

Materials and tools:

1. Stainless steel sheet metal(1m×1m)

2. Welding equipment (Arc welding)
3. Cutting tools (angle grinder, or metal shears)
4. Drilling machine
5. Machining tools (lathe, milling machine)
6. WLO reservoir (Plastic container-3liters)
7. WLO delivery system
 stainless steel pipe (3/4 inch diameter)-8m,
 Plastic water tap (1/2 inch diameter)
8. Air intake system
 Industrial air blower -80W
 Elbow pipe fittings (3/4 inch diameter)
 Brass gate valve
 Dual head pipe fitting (3/4 inch diameter)

Procedure:

Cutting and Shaping: Use the cutting tools (angle grinder, plasma cutter, or metal shears) to cut
the sheet metal into the necessary pieces according to the design. This will include the burner
housing, combustion chamber, and other components.

1. Welding: Assemble the various components of the burner using welding equipment. Ensure that
all seams and joints are properly welded to prevent leaks and maintain structural integrity. This
includes welding the combustion chamber, and mounting brackets.
2. Drilling: Use the drilling machine to create holes for the air intake to make nozzles. The size and
location of these holes are shown in the design.

21
3. Machining: special fittings will make use machining tools like a lathe or milling machine to
create these parts.
4. Install WLO Delivery System: Attach the fuel delivery system, including pipes, fittings, and
the nozzle, to the burner. Ensure that the connections are tight and secure.
5. Install Air Intake System: Blower for air intake will be installed it the designated location.
Ensure that it can provide the necessary air supply for combustion and atomization.
6. Test and Safety: Before using the burner, thoroughly test it for leaks and proper functionality.
Ensure that all safety precautions are in place, including flame safety devices.

3.3 Testing the prototype for functionality

1. Operational Testing: Fire up the burner and monitor its performance. Make any
necessary adjustments to achieve the desired heat output and efficiency.
2. Maintenance and Monitoring: Regularly inspect and maintain the burner to ensure it
continues to operate safely and efficiently. Monitor WLO levels in the combustion
chamber, combustion, and safety systems.

3.4 Performance Parameters

3.4.1 Fuel Heating Value

Heating value of a fuel refers to the energy released per unit mass or per unit volume of the fuel
when it is completely burnt . This value is also called Calorific value (expressed in MJ/kg) and
can be Higher heating value (HHV) or Lower heating value (LHV) depending on the state of
water molecules in the final combustion products. HHV is achieved when no energy is used to
vaporize the water present in combustion products and as such this water is condensed. HHV
therefore, contains both sensible heat energy and latent heat of vaporization. LHV results when
all the water in combustion products is vaporized by latent heat of vaporization and thus it
contains only the sensible heat energy. Any evaluation involving heating value utilizes LHV.

22
3.4.1 Combustion of WLO by Volume

Combustion by volume is guided by two laws: Dalton‟s Law of partial pressures and Avogadro‟s
Law. Dalton‟s Law states that ‟the total pressure of a mixture of gases equals to the sum of
partial pressures of individual gas constituents‟. Partial pressure of a gas refers to the pressure
that the gas would exert if it occupied the same volume and temperature alone. Avogadro‟s Law
states that ‟1 m3 of any gas at the same pressure (P) and temperature (Tm) contains the same
number of molecules‟. Therefore, the volume of a gas at the same pressure and temperature is
directly proportional to the number of its molecules. It is therefore concluded that the volume of
a kmol of any gas is the same if P and Tm are the same. Combustion reaction of WLO is
expressed by Equation below.

CH1.865O0.0008 + 1.466O2 → CO2 + 0.933H2O

The volume ratio of the reactants and products from the equation is given as

1 : 1.466 → 1 : 0.933

Stoichiometric air required to fully oxidize WLO in the above reaction Equation was calculated
as 6.981 m3 .

3.4.3 Theoretical CO2 Emission Determination at 12% Excess Air

Oil density = 875.9 kg/m3 , combustion takes 5 minutes.

At fuel flow rate of 5.05 kg/hr, oil burnt in 5 minutes is calculated as:

SCair = t.m˙ f

SCair which is the stoichiometric combustion air amount was calculated as 0.4 kg and volume of
oil burnt as 0.00046 m3 . From this value, stoichiometric reaction is balanced as in Equation
below.

0.00046CH1.865O0.0008 + 0.00068O2 → 0.00046CO2 + 0.00045H2O

Volume ratio of the reactants and products from the equation is

23
 0.00046 : 0.00068 → 0.00046 : 0.00045

3.4.4 Theoretical CO Emission Determination at 12% Excess Air

Theoretical CO emission was estimated for each excess air used using Equation . The values
determined were tabulated as will be seen hereafter.

COth = CO2(th) − CO2(exp) − UHC2(exp)

Where COth is theoretical CO emission, CO2(th) refers to theoretical CO2 emission, CO2(exp) is
experimental CO2 emission and UHCexp is experimental UHC emission.

Theoretical unburnt hydrocarbon emission was estimated using Equation

UHCth = CO2(th) − CO2(exp) − COexp

3.5 The working principle

WLO is allowed to flow slowly inside the WLO burner body and the fire is started manually by
dropping a burning paper in the burner . The air is blown over the oil to atomize as well as
oxidize it for combustion. The air pipe with atomizing nozzles has been deigned well to ensure
adequate atomization and complete combustion with the help of the blower.

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 CHAPTER FOUR

4.0 EXPECTED RESULT

The expected result of the project proposal for fabricating a WLO burner is the successful
creation of a functional and efficient oil burner system. This system should meet the design
specifications and safety standards outlined in thi proposal. The key expected outcomes include:

1. Functional Oil Burner: The primary result of the project is the fabrication of a fully functional
WLO burner that is capable of burning waste engine oil efficiently and produce fire.
2. Safety Compliance: The burner should meet or exceed all relevant safety regulations and
standards, ensuring safe operation and minimizing risks associated with oil combustion.
3. Optimal Performance: The burner should demonstrate optimal performance in terms of heat
output, combustion efficiency, and fuel consumption, as specified in the project design.
4. Reliable Components: Each component, including the combustion chamber, fuel delivery
system, air intake system, and exhaust system, should be reliable and work seamlessly together.
5. Operational Testing: The burner should have undergone rigorous testing to verify its
functionality, safety features, and performance. Any issues or inefficiencies should have been
addressed and resolved during testing.
6. Operational Knowledge: We will have gained valuable knowledge and expertise in fabricating
and operating oil burners, which can be used for future projects or maintenance.

25
 CHAPTER FIVE

5.0 CONCLUSION AND RECOMMENDATIONS

5.1 CONCLUSION

In conclusion, the project proposal for fabricating a WLO burner holds significant promise for
achieving the goal of creating a safe, efficient, and compliant waste oil combustion system.
Through design, welding, machining, and rigorous testing, we anticipate producing a functional
burner that not only meets or exceeds safety and environmental regulations but also demonstrates
optimal performance. The successful execution of this project will not only yield a reliable oil
burner but will also equip the team with valuable expertise in this domain, facilitating future
projects and contributing to sustainable waste oil disposal solutions. We look forward to
realizing these objectives and delivering a high-quality, dependable burner system that addresses
both practical heating needs and environmental considerations.

5.2 RECOMMENDATION

We strongly recommend the approval and initiation of the proposed project for fabricating the
burner. This project aligns with our goals of sustainability and resource utilization by
repurposing waste engine oil for a practical heating solution. The comprehensive approach
outlined in the proposal, covering design, welding, machining, and rigorous testing, ensures that
the end result will be a safe, efficient, and compliant burner system. By supporting this project,
we not only address environmental concerns related to waste oil disposal but also gain valuable
knowledge and expertise in the field. This investment promises long-term benefits, not only in
terms of operational heating solutions but also in advancing our commitment to responsible
resource management and innovation in waste utilization.

26
 APPENDICES
Appendix 1

BUDGET

No. component Specifications Quantity Unit price Total Price

(Kes) (Kes)
1 Stainless steel pipe ¾” 4meters 500 2000
2 9. Stainless steel sheet 1m*1m, 1 piece 800 800
metal

3 Dual head pipe fitting ¾” 1 piece 400 400

4 Elbow pipe fitting ¾” 1 piece 400 400
5 Brass gate valve ¾” 1 piece 1000 1000
6 Plastic water tap ½” 1 piece 500 500
8 Blower 220VAC, 1 piece 5000 5000
80W, 50Hz
Miscellaneous 2000

TOTAL 12100

Appendix 2

WORK SCHEDULE

TASK Start date End date Status

DECRIPTION
Brainstorming and 10/10/2022 20/10/2022 complete
coming up with the
proposal
Writing and submission 22/10/2022 22/11/2022 Complete
of report proposal

27
Design and drawing 18/09/2023 25/09/2023 Complete
Contacting supervisor 2/10/2023 4/10/2023 Pending
Purchase of component 4/10/2023 6/10/2023 Pending
Metal cutting and 9/10/2023 13/10/2023 Pending
machining

First presentation 16/10/2023 18/10/2023 Pending

Welding of components 19/10/2023 19/10/2023 Pending
Fitting all the 20/10/2023 20/10/2023 Pending
components in place
Safety features 23/10/2023 23/10/2023 Pending
installation and
operational check
Final adjustments 24/10/2023 24/10/2023 Pending
Test run 25/10/2023 25/10/2023 Pending
Presentation 30/10/2023 30/10/2023 Pending

28
REFERENCES
1. Burning Used Oil By Michigan Department Of Environmental Quality Jennifer M.
Granholm, Governor www.michigan.gov
2. An Investigation To The Recycling Of Spent Engine Oil S. O. Ogbeide* Department Of
Mechanical Engineering, Ambrose Alli University, P.M.B 14, Ekpoma, Edo State,
Nigeria.Received 22 June 2009;Accepted 24 February 2010.J.
3. Waste Lubricating Oil Treatment by Adsorption Process Using Different Adsorbents
Nabil M. Abdel-Jabbar, Essam A.H. Al Zubaidy, and Mehrab Mehrvar
4. A Comparison of Waste Lubricating Oil Treatment Techniques Motshumi J. Diphare,
Edison Muzenda, Tsietsi J. Pilusa and Mansoor Mollagee.
5. Recycling Of Waste Engine Oils Using A New Washing Agent Ihsan Hamawand , Talal
Yusaf ,and Sardasht Rafat Faculty of Engineering and Surveying, National Centre for
Engineering in Agriculture, University of Southern Queensland, Toowoomba 4350,
QLD, Australia.
6. Studies on Reuse of Re-Refined Used Automotive Lubricating Oil Shri Kannan C,
Mohan Kumar KS, Sakeer Hussain M, Deepa Priya N and Saravanan K Department of
Chemical Engineering, Kongu Engineering College, Perundurai , Tamilnadu, INDIA.
7. Design, Construction and Testing Of a Burner That Uses an Admixture of used engine
oil and Kerosene for Foundry Application. M. J. Madu, I. S. Aji, B. Martins Graduate
Assistant, Department of Mechanical Engineering, University of Maiduguri, Borno state
8. Re-refining of used lubricating oil. Merai Yash P. International Journal of Scientific &
Engineering Research, Volume 6, Issue 3, March-2015 [11] Mitsubishi Heavy Industries
Technical Review Vol. 53 No.4 Development of Environmentally-Friendly Heavy Oil
Fired Burner.
9. Design and Fabrication of Oil Burner, Based on waste lubrication oil as a Sustainable
Source of Energy. Madhusudan S, Vismay K G, Gururaja

29