How Much Diesel Can Be Recovered from 1 Ton of Waste Oil?
If you’re planning to invest in a waste oil to diesel machine, one of the first questions you’ll want answered is this:
“How much diesel can I actually get from 1 ton of waste oil?”
This is more than just a number. It’s about understanding how process design, feedstock quality, and system efficiency all come together to define your profitability, performance, and output quality.
Let me break it down based on actual operational data, not guesswork.
Average Diesel Yield Per Ton of Waste Oil
In a well-optimized setup using distillation + catalytic refining technology, you can typically recover:
750–850 liters of diesel from 1 metric ton (1,000 kg) of waste oil.
This range applies to the most commonly used engine oils, hydraulic oils, gear oils, and light industrial lubricants.
The remaining fraction includes:
- Light gases
- Residual carbon black or sludge
- Water and trace impurities
We recover >90% of the hydrocarbons present in the waste oil.
Factors That Affect Diesel Yield
Not all waste oils are created equal. Here are the top five variables that determine your actual
diesel recovery rate
- Feedstock Type & Purity
- Used engine oil with high soot = lower yield
- Industrial lubricants with less ash = higher yield
- Mixed oils with water or antifreeze = needs pretreatment
Pro tip: Pre-filtration and water removal improve yield by 5–10%.
Processing Technology
- Simple pyrolysis = low yield, high impurities
- Distillation + clay or catalytic upgrading = higher diesel fraction
- Machines with advanced temperature control = better fuel recovery
System Efficiency & Heat Recovery
- Higher thermal efficiency = less loss
- Inline heat exchangers and gas recycling boost energy use
- Vacuum distillation reduces cracking loss
Additives & Catalysts Used
- A correct catalyst improves diesel clarity and cetane
- Some formulations increase liquid recovery by up to 8%
Operator Control and Calibration
- Experienced plant operators = more consistent output
- Stable pressure and temperature profiles = cleaner cuts
Diesel Output by Oil Type (Real-World Data)
| Waste Oil Type | Diesel Yield (L/ton) | Purity Level |
| Used Engine Oil | 750–800 | Medium |
| Industrial Hydraulic Oil | 800–850 | High |
| Mixed Waste Lubricants | 720–780 | Varies |
| Pyrolysis Oil (from plastic) | 650–750 | Medium |
All diesel output meets or exceeds the basic standards for off-road and industrial fuel applications. With post-treatment, it can be upgraded to EN590 specs.
Where Does the Rest of the Oil Go?
Every drop is accounted for. From 1 ton of waste oil:
- 75–85% becomes diesel or light fuel oil
- 5–8% becomes non-condensable gas (used to heat the system)
- 8–12% ends as residue/sludge
- 2–5% is water and trace impurities
Our system is designed to recycle energy and minimize waste. Sludge can be processed further or sold to asphalt companies.
Why It Matters: Yield = Profit
Higher yield = faster ROI. Every 50-liter increase in output can significantly raise your monthly revenue. That’s why we help clients:
- Analyze feedstock before purchase
- Choose the right reactor configuration
- Install automation to reduce loss
- Implement filtration and drying systems
We don’t just sell machines — we help you produce more clean fuel, at lower cost, with minimal risk.
