LUBRICANTS MANUFACTURE

Lubricants &
Manufacture 1 Petroleum Specialties Company
 MINERAL BASE OIL MANUFACTURE

Lubricants &
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 Lubricants &
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 Lubricants &
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 Lubricants &
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 ESSENTIAL BASEOIL PROPERTIES

OXIDATION STABILITY
CONSISTENCY SATURATES, SULPHUR
NITROGEN

VISCOMETRICS BASESTOCK COMPATIBILITY

VISCOSITY, POUR, VI QUALITY ANILINE POINT
DEMULSIBILITY

APPEARANCE
VOLATILITY SAFETY COLOUR, CLEANLINESS
GCD, NOACK FLASHPOINT CLARITY, ODOUR
TOXICITY

Lubricants &
Manufacture 6 Petroleum Specialties Company
 ATMOSPHERIC DISTILLATION

LPG *
 Crude is transported to
the refinery mainly by ship
or pipeline
NAPTHA

KEROSENE  In an atmospheric
distillation tower liquid
GAS OIL
petroleum gas (LPG),
HEAVY GAS OIL gases and various liquid
CRUDE OIL
petroleum fractions are
produced

 The residue can be used

RESIDUE as a feedstock for base oil
production

Lubricants &
Manufacture 7 Petroleum Specialties Company
 VACUUM DISTILLATION

LIGHT SPINDLE OIL  In the vacuum distillation

tower “base oil cuts” with
HEAVY SPINDLE OIL
various viscosities are
LIGHT LUBEOIL produced

HEAVY LUBE OIL

 The vacuum residue can also
be deasphalted to produce a
BRIGHTSTOCK further base oil cut,
brightstock
RESIDUE
FROM DEASPHALTOR  Asphalt is a by-product and
ATMOSPHERIC RESIDUE is used for roads etc.
DISTILLATION

ASPHALT

Lubricants &
Manufacture 8 Petroleum Specialties Company
 BASE OIL COMPONENTS
VI POUR POINT
N - PARAFFINS VERY HIGH HIGH

IS0 - PARAFFINS HIGH LOW

NAPHTHENES LOW
MODERATE
(CYCLO PARAFFINS)

AROMATICS LOW LOW

BASE OILS ALSO CONTAIN SULPHUR, OXYGEN AND METAL COMPOUNDS

e.g
S

PARAFFINIC BASE OILS CONTAIN 45-60% PARAFFINIC COMPOUNDS

AROMATIC BASE OILS CONTAIN 20-25% AROMATIC COMPOUNDS
NAPHTHENIC BASE OILS CONTAIN 65-75% NAPHTHENIC COMPOUNDS

Lubricants &
Manufacture 9 Petroleum Specialties Company
 WHY DO WE NEED FURTHER
REFINING?
 Mineral base oils after vacuum distillation still contain some
undesirables:

 Large paraffin molecules (wax type) have a high pour point

 Aromatics are considered as carcinogenic and form sludge

 Unsaturates have poor oxidation stability, and form sludge

and varnish

 Nitrogen compounds catalyse oxidation

 However some components are also desirable:

 Sulphur compounds - some are natural anti-oxidants

 Large paraffin molecules - have a high viscosity index

Lubricants &
Manufacture 10 Petroleum Specialties Company
 FURTHER REFINING
PROCESSES
 Aromatics are extracted with certain solvents

 Waxes are removed by solvent dewaxing

 Sulphur, nitrogen compounds and unsaturates are reduced by

hydrogenation

 Further refining is a balance between:

 Reducing the undesirable compounds - basestock quality

 Reducing the desirable compounds - additive treat

 Cost

Lubricants &
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 SOLVENT EXTRACTION
 Each of the particular base oil “cuts”
is mixed with a special solvent WAXY RAFFINATE

 The solvent is removed, taking most

of the aromatics with it SPECIAL
SOLVENT
 Improves MIX

 Viscosity index

 Colour
BASE OIL FEEDSTOCK
 Oxidation stability FROM VACUUM
TOWER

 Lowers the carcinogenicity SOLVENT EXTRACT

 Process oils are produced as a by-

product, used in rubber tyre
manufacture
Lubricants &
Manufacture 12 Petroleum Specialties Company
 SOLVENT DEWAXING
 Oil and solvent are mixed and cooled
to a set temperature

 Large paraffinic molecules precipitate

out as wax, which is filtered off

 Effect DEWAXING
SOLVENT
 Reduces pour point

 Reduces viscosity index (VI)

 By-product is wax
BASE OIL FEEDSTOCK
SOLVENT EXTRACTION
 Used in candle industry
WAX

 Used to form synthetic

basestocks (slack wax
isomerates)
Lubricants &
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 HYDROFINING
 Hydrogen is reacted with the base oil
in the presence of a catalyst under
FINAL
high temperature and high pressure PRODUCT

 Effect
 Improves colour
HYDROGEN
 Converts unsaturates to saturates AND
CATALYST
 Reduces sulphur, nitrogen and
oxygen
 Reduces acidity
 Slightly increases pour point BASE OIL FEEDSTOCK
FROM DEWAXING
 Yields the final base oils PROCESS

 Solvent neutrals of different NAPHTHA

viscosities
 By product naphtha
 Used for fuels
 Used in chemical industry
Lubricants &
Manufacture 14 Petroleum Specialties Company
 THE COMPLETE PROCESS
ATMOSPHERIC
TOWER

EXTRACTION DEWAXING HYDROFINISHING

TOWER UNIT TOWER
VACUUM FINAL
FUEL
(Removes (Removes (Removes N & S PRODUCT
STILL Aromatics) Wax) compounds) BASE OIL
*

CRUDE *
*

RESIDUE *

SOLVENT SOLVENT HYDROGEN

ESSO
SOLVENT
DEASPHALTER
NEUTRAL
RESIDUE SOLVENT WAX NAPTHA
EXTRACT

ASPHALT

* Each cut is sent through different towers separately

Lubricants &
Manufacture 15 Petroleum Specialties Company
 TYPICAL INSPECTION DATA
Process Vacuum Solvent Dewaxing Hydrofining
distillation extraction

Product Distillate Raffinate Dewaxed Oil Base oil

2 -1
KV 100, mm s 5.3 4.7 5.4 5.3
2 -1
KV 40, mm s 34 24 33.5 33.2
VI 81 114 92 92
Colour - - 16 >26
Pour Point, °C 25 30 -12 -12
Sulphur % 0.48 0.13 0.16 0.10
Nitrogen, ppm 520 24 30 26
Aromatics, % 17 8 10 10
Saturates, % 64.9 83.8 80.0 80.0

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 SYNTHETICS

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 TYPES OF SYNTHETICS
 Manufactured by catalytic process, viscosity index >120

 The size of the molecule (related to viscosity) is varied by

the conditions

 Esters  Aviation oils

 Glycols (PAG)  Industrial oils

 Alkyl Benzenes  Refrigeration oils

 Poly alpha olefins (PAO)  Engine oils, industrial

 Slack wax isomerates (SWI)  Engine oils

 Phosphate esters  Industrial - fire resistant fluids

 Silicone fluids  Industrial - heat transfer oils

Lubricants &
Manufacture 18 Petroleum Specialties Company
 “What Can Synthetic
Lubricants Do For You?”

Lubricants &
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 What Are They?

Mineral Oil
- Limited By The Properties Of Natural Basestocks
- Contain Impurities Which Reduce Their Lubrication Efficiency

Synthetic Oil
- Tailor Made To Give Optimized Performance
- Provide Maximum Benefit From Pure Basestocks And
Selected Additives
- Provide Design Benefits For Equipment Manufacturers And
Marine Operators

Lubricants &
Manufacture 20 Petroleum Specialties Company
 Differences In Oil Quality - Mineral Oil vs. Synthetic

X X X Mineral

X
x

Synthetic

Base Oil Additives Lubricants

Lubricants &
Manufacture 21 Petroleum Specialties Company
 Base Stock Benefits Versus Mineral Oil

Hand Made Structure

Higher Viscosity Index

Improved Oxidation Resistance

Greater Thermal Stability

Lower Volatility

Energy Savings

Lubricants &
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 Different Types of Synthetics

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 Types Of Synthetic Base Stocks

Poly Alfa Olefin (PAO)

Organic Esters

Other Synthetic Fluids

Lubricants &
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 Viscosity Change with Temperature of SHC vs. Mineral Oil

SHC Increased Protection

Viscosity
cSt Mineral Oil

Viscosity Reference Point

ISO VG

Increased Protection

40
Temperature, °C

Lubricants &
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 Improved Oxidation Stability - SHCs
Synthetic Base Oil Mineral Base Oil
Chemical Structure
Energy Chemical Structure

Energy
Single Bond Double Bond

The mineral oil also contains impurities which are prone to degradation

Lubricants &
Manufacture 26 Petroleum Specialties Company
 Improved Oxidation Stability - SHCs
Synthetic Base Oil Mineral Base Oil
Chemical Structure Chemical Structure
Energy

Energy
Difficult To Break Double Bond More
Strong, Single Bond Prone To Break/Oxidation
The mineral oil also contains impurities which are prone to degradation

Lubricants &
Manufacture 27 Petroleum Specialties Company
 Oxidation Stability of SHCs vs. Mineral Oil
Mobil Oxidation Bench Test

8
Viscosity 0
Mineral Oil
Increase, %
at 100C 6
0

4 SHC
0

2 0 20 40 60 80 100 120
0 Time, Hours

Lubricants &
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 Worm Gear Low Temperature Operability
Power Consumption, kW
3
SHC Mineral Oil

Energy 2
Savings

0
-40 -20 0 20 40
Temperature, C
ISO VG 460 Mineral and Synthetic Gear Oils
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 Frictional Properties
Synthetic
Force Oil

Force
Mineral
Oil

Lubricants &
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 Principles of Traction Coefficient
Frictional Losses

Synthetic Mineral

Tangenta

Lower

Normal
Frictional Losses
Lower Frictional Loss = Increased Machine Efficiency

Lubricants &
Manufacture 31 Petroleum Specialties Company
 Evaporation Loss of SHC vs. Mineral Oil
Evaporation Loss Wt., % @ 6.5 hrs, 204 C
32
28 Mineral Oil

24
Reduction in
Evaporation 20
Effect
16
12 SHC
8
4
0
1 2 3 4 5 6 7 8 9 10 11 12
Viscosity (100C), cSt
Lubricants &
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 Organic Ester

Reaction of Dibasic Acid with an Alcohol

Alcohol + Acid = R - O - C - (CH ) - C - O - R

2n

Ester

Lubricants &
Manufacture 33 Petroleum Specialties Company
 Organic Esters Lubricants
Properties Benefits
• Good Oxidation Stability • Long Oil Life
• Low Temperature • Extended Protection, Ease of
Fluidity Start-Up
• Solvency / Detergency • Reduces Deposit Formation
Characteristics

Note: Not Compatible With All Paints Or Seal Material

Lubricants &
Manufacture 34 Petroleum Specialties Company
 Summary - Synthetic Versus Mineral Oil
SHC Esters
Viscosity-Index ++ +

Low Temperature ++ ++

Oxidation Stability + ++

Hydrolytic Stability = --

Seals/Paints = -
Compatibility

Energy Savings ++ +

Lubricants &
Manufacture 35 Petroleum Specialties Company
 Summary - Synthetic Versus Mineral Oil (cont’d)
SHC Esters
Wear Protection + +

Demulsibility + ++

Rust Protection = --

Compatibility w/ = -
Mineral Oil

Evaporating Rate ++ =

Lubricants &
Manufacture 36 Petroleum Specialties Company