Lubricant Blending and Quality Assurance

This book offers an in-depth understanding of the management and operation of a lubricant blending plant.. It describes the different types of equipment used to blend lubricants, provides guidance on how best to use this equipment, and offers tips to avoid problems.

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