to base oils using re-refining processes. The remainder is either burned or landfilled. With a conversion rate of just ~20% from used oil to re-refined base oils, there’s still plenty of runway to reduce waste in the value chain4
.
Positive signs of change In recent years, regulations and structures have been put in place which have resulted in more waste oil being recycled. This includes better collection processes, more collaboration between stakeholders, as well as more focus by the industry on sustainability. A growing market has been the result. Recent analysis by Polaris Market Research5
, highlights that the
global automotive oil recycling market size was valued at USD 45.8 billion in 2022 and is predicted to reach USD 83.5 billion by 2032, an impressive 7%/year forecasted growth rate.
However, the focus to date has been on transforming used motor oil into re-refined Group I or Group II base oils.
The challenge with Group III Due to the complex nature of Group III base oils, they need more intensive re-refining compared to their Group I and Group II counterparts. Consequently, this can make the process cost intensive, and many organisations are struggling to develop a workable business case to produce re-refined Group III base oils at scale.
The options
The good news is that there is light at the end of the tunnel. Companies (such as ReGen III) have developed re-refining processes that not only deliver on sustainability, but also base oil quality and the business case.
Re-refining often uses processes such as distillation and hydro-processing, both of which are commonplace in existing refineries. However, the secret to the success of producing high-quality re-refined Group III base oil is in the sauce, or in this case, the process.
And different companies are getting a range of results from their proprietary processes in terms of yield and base oil quality.
ReGen III’s solution The ReGen™ process has been specifically designed for Group III production at industry-leading yields and throughput, all while achieving high-quality products. Independent laboratory tests using re-refined Group III base oils produced from the ReGenTM
process
surpassed the American Petroleum Institute (API) targets for viscosity index, sulphur, and saturates, and exceeded industry benchmarks for volatility, colour, and cold crank. When mixed with additives, these re-refined base oils can create high-quality finished lubricants that may also reduce the need for viscosity modifiers or other costly additives.
ReGen III is advancing a 5,600 bpd used motor oil feedstock re-refinery in the US Gulf Coast, which will employ ReGen III’s patented ReGenTM
technology to
Figure 1: High-Quality Group III RRBO – How ReGen III’s Group III RRBO compares to API guidelines.
produce Group III base oils, Group II+ base oils, and other products. Both FEL-2 and Value Engineering have been completed and various feedstock
4 5
Used Oil Management and beneficial Reuse Options to Address Section 1: Energy Savings from Lubricating Oil Public Law 115-345” (available at
energy.gov). 2024 value based on 2008 – 2018 growth rates and data, extrapolated from 2018. Automotive Oil Recycling Market Size, Share Global Analysis Report, 2023-2032
24
LUBE MAGAZINE NO.191 FEBRUARY 2026
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