Many people, including those involved in the manufacturing, marketing and selling of lubricants, believe that blending lubricants is simply a matter of putting one or more base oils and several additives into a tank of some kind and stirring them around to mix them. Blending lubricants that meet customers’ demands requires much more than this. The correct ingredients of the right quality need to be used in precisely controlled quantities. The ingredients need to be tested prior to blending and the finished products need to be tested following blending. The ingredients need to be stored and mixed under carefully controlled conditions. The finished lubricants need to be stored and packaged carefully and then delivered to customers correctly.
This book discusses all of these issues, describes the different types of equipment used to blend lubricants, provides guidance on how best to use this equipment, and offers tips and techniques to help to avoid problems. It focuses on liquid lubricants. Greases are not discussed, as their manufacture involves very different manufacturing procedures compared with those concerned with liquid lubricants.
The book starts with descriptions and discussion of the properties and characteristics of the main types of mineral and synthetic base oils, as well as the properties and characteristics of the main types of additives that are used in lubricant formulations. Criteria and methodologies used to design both new and upgraded blending plants are covered next. The types and operation of the equipment used in lubricant blending plants are described and discussed, together with a chapter on how to avoid problems before, during, and after blending. Testing and analysis of base oils, additives, and blended lubricants are covered in two separate chapters. Procedures for quality control and quality management in lubricant blending plants are also discussed in two separate chapters. Types of packages for lubricants are reviewed, together with methods for filling packages and methods for transporting lubricants in bulk. The storage of lubricants and supply chain management is also covered in depth.
1 Introduction
2 Mineral Oil Base Oils: API Groups I, II and III: Properties and
Characteristics
2.1 Introduction
2.2 Base Oil Nomenclature
2.3 Methods of Manufacturing Base Oils
2.4 Base Oil Composition
2.5 Mineral Base Oil Properties and Characteristics
2.5.1 Overview
2.5.2 Appearance and Colour
2.5.3 Density and Gravity
2.5.4 Viscosity and Viscosity Index.
2.5.5 Pour Point and Cloud Point
2.5.6 Distillation Range
2.5.7 Flash Point
2.5.8 Volatility
2.5.9 Aniline Point
2.5.10 Viscosity Gravity Constant
2.5.11 Refractive Index and Refractivity Intercept
2.5.12 Elemental Contents
2.6 API Base Oil Classifications
2.7 Comparison of Mineral Oil Base Oils
2.7.1 Group I Base Oils
2.7.2 Group II Base Oils
2.7.3 Group III Base Oils
2.7.4 Group I, II and III Base Oils
2.8 Base Oil Interchangeability
2.9 Summary
3 Synthetic Base Oils: API Groups IV and V: Properties and
Characteristics
3.1 Introduction
3.2 Conventional Definitions of Mineral and Synthetic Base Oils
3.3 Types of Synthetic Oils
3.4 Performance Advantages of Synthetic Oils
3.5 Properties and Characteristics of the Main Synthetic Base Oils
3.5.1 Polyalphaolefins
3.5.2 Diesters and Polyol Esters
3.5.3 Polyisobutenes
3.5.4 Polyalkylene Glycols
3.6 End Use Markets for Synthetic Lubricants
3.7 Conclusions
4 Lubricant Additives: Properties and Characteristics
4.1 Review of the Development of Lubricant Additives
4.2 Functions of Lubricant Additives
4.3 Types of Lubricant Additives
4.3.1 Viscosity Index Improvers
4.3.2 Detergents
4.3.3 Dispersants
4.3.4 Pour Point Depressants
4.3.5 Anti-Oxidants (Oxidation Inhibitors)
4.3.6 Anti-Wear Additives
4.3.7 Lubricity Additives
4.3.8 Extreme-Pressure Additives
4.3.9 Bearing Corrosion Inhibitors
4.3.10 Corrosion Inhibitors or Anti-Rust Additives
4.3.11 Metal Passivators
4.3.12 Demulsifiers (Anti-Emulsion Additives)
4.3.13 Emulsifiers
4.3.14 Friction Modifiers
4.3.15 Anti-Foam Additives (Foam Suppressants)
4.3.16 Biocides
4.4 Additive Packages
4.5 Properties of Lubricant Additives
4.6 Effects of Additive Properties on Lubricant Blending
4.7 Summary
5 Lubricant Formulation and Ease of Blending
5.1 Introduction
5.2 The New Product Development Process
5.2.1 Idea Generation
5.2.2 Idea Screening
5.2.3 Idea Evaluation
5.2.4 Agreement Between Marketing and Product
Development Departments
5.2.5 Preliminary Business Analysis
5.2.6 Product Development and Testing
5.2.7 Test Marketing
5.3 Formulating and Developing a New Automotive Engine Oil
5.3.1 The Specification
5.3.2 Choice of Base Oil(s)
5.3.3 Choice of Viscosity Index Improver
5.3.4 Developing the Dispersant/Inhibitor (DI) Package
5.3.5 Evaluating and Finalising the Formulation
5.4 Formulating and Developing a New Industrial Lubricant
5.5 Illustrative Lubricant Formulations
5.6 Ease of Blending
5.7 Communication and Co-operation Between Formulators and
Blenders
5.8 Summary
6 Lubricant Blending Plant Design: Grassroots Plants and Upgrading
Existing Plants
6.1 Introduction
6.2 Investment in Blending Lubricants
6.2.1 Business Aims
6.2.2 Blending Plant Conception
6.3 Grassroots Blending Plant
6.4 Upgrading an Existing Blending Plant
6.5 Blending Plant Layout
6.6 Designing a Lubricant Blending Plant
6.7 Benefits of High Quality Blending Plant Design
6.8 Summary
7 Lubricant Blending Plant Equipment and Facilities and Their
Operation
7.1 Introduction
7.2 Lubricant Blending as Part of the Supply Chain
7.3 Key Components of a Modern Lubricant Blending Plant
7.3.1 Automatic Batch Blender (ABB)
7.3.2 In-Line Blender (ILB)
7.3.3 Simultaneous Metering Blender (SMB)
7.3.4 Drum Decanting Unit (DDU)
7.3.5 Pre-Mix Blending Vessel
7.3.6 Drum Heating Unit (DHU)
7.3.7 Pigging Equipment
7.4 Blending Operations
7.4.1 Batch Blending
7.4.2 Automated and In-line Blending
7.4.3 Operating a Drum Decanting Unit
7.5 Sampling Raw Materials and Blends
7.5.1 The Importance of Sampling
7.5.2 Sample Bottles
7.5.3 Sampling Methods
7.6 Automation of Blending
7.7 Summary
8 Lubricant Blending Issues: Avoiding Problems
8.1 Introduction
8.2 Sampling Before Blending
8.3 Blend Families and Cross Contamination
8.4 Temperature Control
8.5 Times for Blending
8.6 Sampling Blended Lubricants
8.7 Slop Oil
8.8 Packages, Labels and Labelling
8.9 Health, Safety and the Environment
8.10 Forklift Trucks
8.11 Minimising Operating Expenses
8.11 Equipment Maintenance
8.12 Cyber-Security
8.13 Summary
9 Testing and Analysis of Base Oils and Additives in Blending
Plants
9.1 Introduction
9.2 Tests for Base Oils
9.2.1 Colour
9.2.2 Boiling Range
9.2.3 Density
9.2.4 Kinematic Viscosity
9.2.5 Viscosity Index
9.2.6 Low Temperature Viscosity
9.2.7 Pour Point
9.2.8 Flash Point
9.2.9 Volatility
9.2.10 Foaming Properties
9.2.11 Demulsibility
9.2.12 Acid Number
9.2.13 Carbon Residue
9.2.14 Water Content
9.2.15 Sulphur, Nitrogen and Phosphorous Contents
9.2.16 Metals Contents
9.2.17 Hydrocarbon Type Analysis
9.3 Tests for Additives
9.3.1 Metals and Non-Metals Contents
9.3.2 Sulphated Ash
9.3.3 Infra-Red Spectroscopy
9.4 Specifications for Raw Materials
9.5 Summary
10 Testing and Analysis of Blended Lubricants
10.1 Introduction
10.2 Laboratory Tests for Lubricants
10.2.1 Oxidation Resistance
10.2.2 Anti-Oxidant Content
10.2.3 Thermal Stability
10.2.4 Rust Protection
10.2.5 Corrosion Resistance
10.2.6 Shear Stability
10.2.7 Anti-Wear and Extreme Pressure Tests
10.2.8 Metals Contents
10.3 Tests for Blending Plant Quality Control of Specific Types of
Lubricants
10.3.1 Automotive and Industrial Engine Oils
10.3.2 Automotive and Industrial Gear Oils
10.3.3 Automatic Transmission Fluids
10.3.4 Hydraulic Oils
10.3.5 Turbine Oils
10.3.6 Compressor Oils
10.3.7 Metalworking Fluids
10.4 Processing and Communication of Test Results
10.5 Summary
11 Lubricant Product Quality Control
11.1 Introduction
11.2 Definition of Quality
11.3 Meeting Customer Requirements and Quality Control
11.4 Procedures for Control of Quality
11.4.1 Checking Raw Materials
11.4.2 Controlling Quality During Blending
11.4.3 Testing Finished Products
11.4.4 External Monitoring Systems
11.4.5 Component and Formulation Codes
11.4.6 Batch Numbering and Traceability
11.4.7 Computerised Blend Records
11.4.8 Blend Sample Storage and Retention
11.5 Resolving Product Quality Problems
11.6 Summary
12 Lubricant Packaging and Filling
12.1 Introduction
12.2 Role and Attributes of Packaging
12.3 Types of Lubricant Packaging
12.3.1 Plastic Bottles
12.3.2 Stand-Up Pouches
12.3.3 Oil Drums
12.3.4 10-Gallon Drums
12.3.5 25 Litre (5-Gallon) Drums
12.3.6 Grease Drums, Kegs, Pails and Cans
12.3.7 Intermediate Bulk Containers (IBCs)
12.3.8 Additional Packaging
12.4 Reconditioning Drums and IBCs
12.5 Recycling Plastic Packaging
12.6 Labels for Lubricant Packages
12.6.1 The Role of Labels on Packages
12.6.2 The Globally Harmonised System (GHS)
12.6.3 Types of Lubricant Package Labels
12.6.4 Multi-Lingual and Multi-Purpose Labels
12.7 Filling Lubricant Packages
1 2.7.1 Bottle Filling
12.7.2 Drum and IBC Filling
12.7.3 Road Tanker, Rail Tank Wagon and ISOTainer Filling
12.8 Summary
13 Lubricant Storage
13.1 Introduction
13.2 Storage Vessels and Containers
13.2.1 Bulk Storage in Tanks
13.2.2 Drum Storage
13.2.3 Storage in Intermediate Bulk Containers (IBCs)
13.2.4 Plastic Bottles and Tinplate Cans
13.3 Lubricant Storage
13.3.1 Siting the Lubricants Store
13.3.2 Indoor Storage
13.3.3 Outdoor Storage
13.3.4 Ingress of Moisture
13.3.5 Storage of Special Types of Lubricant
13.4 Blending Plant Warehouse
13.5 Warehouse Management and Automation
13.5.1 Warehouse Management Systems
13.5.2 Advantages and Disadvantages of WMS
13.5.3 WMS Operation
13.5.4 Other WMS Functionality and Considerations
13.5.5 Implementing WMS
13.6 Summary
14 Product Quality Management
14.1 Introduction
14.2 Background to True Total Quality
14.3 Lean (Just-in-Time) Manufacturing
14.4 Total Quality Management
14.5 ISO 9000
14.6 Implementing TQM
14.7 Mapping a TQM Strategy
14.8 Supply Chain Management
14.9 Enterprise Resource Planning
14.10 Summary
Biography
David Whitby is Chief Executive of Pathmaster Marketing Ltd, a business development consultancy for the international downstream oil, gas and energy industries, which he founded in 1992. Pathmaster Marketing advises clients in the UK, France, Germany, Belgium, Denmark, Poland, the US, Canada, Israel, Saudi Arabia, Iran, South Africa, Brazil, Singapore, Malaysia and Australia on business planning, business strategy, market development and technology commercialisation. Specialist sectors include lubricants, fuels, new energies and speciality chemicals.
An Australian by birth, David began his career with British Petroleum, as a process chemist at the Kwinana refinery in Western Australia. He worked for BP for 22 years in a number of management positions, including Marketing and Business Development Manager at Kalsep (an advanced separations company), Business Manager at BP Ventures, Project Leader for Industrial Lubricants at BP Research and Marketing Services Officer at Duckhams Oils.
David was Programme Director for Lubricants Courses at the Oxford Princeton Programme (formerly the College of Petroleum and Energy Studies in Oxford), where he was responsible for planning the overall lubricants course programme and delivering several training courses each year. He ran the Advanced Lubrication Training Programme for the UK Lubricants Association (formerly the British Lubricants Federation.). He has written numerous papers and articles on lubricants and has chaired and lectured to international conferences and directed over 100 training lubricants courses in the UK, Canada, Germany, France, Belgium, Denmark, Switzerland, Poland, the Czech Republic, Hungary, Russia, Saudi Arabia, Jordan, Bahrain, Cyprus, Argentina, Brazil, South Africa, Singapore, Malaysia, Thailand and Australia. He also writes the bi-monthly "Worldwide" column for the US Society of Tribologists and Lubrication Engineers "Tribology and Lubrication Technology" magazine and is a contributor to "Lubes ‘n’ Greases" magazine.
"The book explains in a comprehensive manner that blending lubricants is a complex business and there must be a strong focus on quality. It also highlights the steps that must be taken in terms of controlling the mixing conditions, analytical checks, packaging, and storage to meet the customer needs. The book is an important reference source of information and advice for all lubricant blenders. I am not aware of another book that provides this information in an easy accessible format."
~Dr. Aubrey Burrows, Consultant at Aubrey Burrows & Associates Ltd.
"Any new recruit or job change candidate looking to take a prominent role associated to the lubricants blending function will find this an immensely valuable source of reference material. However, it does go much wider than that insofar that all functionaries within the company will benefit from the occasional consultation."
~Rod Pesch, LUBE Magazine
"This somewhat smallish book is unique in that it addresses practical matters that often aren't addressed in much tribology and lubrication engineering literature. Further, several chapters serve the surprising purpose of providing a concise review for those preparing for certification, including some topics from STLE's Certified Lubrication Specialistrn (CLS) exam, which are somewhat hard to find in books or courses, especially reflecting today's best practices. This little book does all this, as well as most ably covering the very practical titled subject of lubricant blending."
Dr. Robert M. Gresham, Tribology & Lubrication Technology
