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Lubricant Varnish
their formulation chemistries to meet
more demanding specifications. The oil
companies first meet these new demands
by making changes to their lubricant's
base stock. Newer synthetic chemistries
are increasing the energy efficiencies and
solving problems that wouldn't be feasible
with mineral oil base stocks. However,
the biggest change has been the global
adoption of more advanced mineral oil
base stocks. The American Petroleum
Institute classifies different base stocks
into the five different categories outlined
in Table 1.
Group I base oils are manufactured
by solvent extraction, solvent or catalytic
de-waxing, and hydro-finishing processes.
The oils are more polar in nature due to
their remaining soluble impurities. These
Greg Livingstone, David Oakton, polar species lead to a higher solvency than
Fluitec International OilCare Ltd other paraffinic base stocks and a higher
natural oxidative stability compared to
other base stocks.
Lubricating oils are undergoing more changes today than at any Group II base oils are manufactured
Abstract
Efficiency
lubrication system. When the sub-micron Figure 8).
particles agglomerate to multi-micron If, during an 50
sized particles, they are removed through outage, removal of oil
conventional mechanical filtration. degradation products
Agglomeration units have the same from in-service 0
sensitivity to water as electrostatic oil lubricants is required,
cleaners. and the oil can be 25 30
cooled for many days, 35 40
Depth Media Filters (DM) 45 50
all of the technologies 55
Depth media filters can filter will work, with various
Temperature (ºC) 60 65 70
particles down to approximately three degrees of success.
microns in size. However, many of these However, the additional
filters are also constructed with a polar, ability of the ESP Electrostatics Depth Media ESP
cellulose, media. In these cases the polar technology to remove
oil degradation products are attracted the soluble products Figure 8 The relative efficiency of various varnish mitigation technologies
to the polar nature of the media and has distinct advantages. depending on the temperature (°C) of the fluid
adsorb onto the fibres. These units are If the soluble oil
effective at removing smaller amounts degradation products
of polar sub-micron contaminants that are removed before they have the chance plant to achieve optimum life of lubricants
are in suspension. However, if the oil to form varnish deposits then perhaps this along with improved plant reliability.
is heated to above the melting point of is a step closer to a true varnish mitigation When the varnish potential of
the contaminants all of the filtered oil system. a hydraulic oil or lubricant increases
degradation products will melt back into beyond normal values a new generation
solution, re-contaminating the fluid. of contamination control technologies
SUMMARY is required to remove these sub-micron
Electrophysical Separation Lubricant varnish is an emerging contaminants. Electrostatic liquid cleaners
Process (ESP) problem for modern hydraulic and are an effective technology for removing
This patent-pending technology lubricant formulations, increasing sub-micron contaminants in hydraulic
was designed to remove organic soft maintenance, production and energy costs oils. However, the ability to remove even
contaminants from the lubricants. Utilising while decreasing plant reliability. This the oil soluble oil degradation products
a selective absorptive filtration media, the problem has coincided with a dramatic by employing ESP technology can take
unique attribute of this technology is its change in oil formulations, focussing varnish mitigation to a new level.
ability to remove oil degradation products on Group II and III base oils. Varnish is The combination of improved oil
that are both in insoluble and soluble. caused by fluid degradation, the leading analysis and the most appropriate varnish
It does not impact on other additive contributor being oxidation. mitigation system to suit the specific
components in the formulation, nor is A contributing factor in these application should provide valuable
the filter media affected by water or other new deposit problems is that traditional payback in the form of increased oil
contaminants. oil analysis tests have not provided life, greater plant reliability, improved
Most of these technologies work very appropriate warning signs for incipient product quality etc. In selecting the most
well, however their limitations are in their lubricant degradation and the creation appropriate varnish mitigation system a
application. The key is to understand what of degradation products, which cause deep understanding of the lubricant, its
technology is best for what application. varnish. Incorporating oil analysis tests environment and its operating regime
Table 2 lists some variables to consider such as the RULER, which monitors the is required. What may be good for one
when selecting an appropriate varnish depletion of antioxidants, and MPC, which system may not be for the next. As stated
mitigation technology. measures the creation of varnish-forming at the beginning, lubricating oils are
Electrostatic technologies are clearly oil degradation products, has been shown undergoing more changes today than at
superior when attempting to remove to forecast varnish potential earlier than any time in recent memory. Therefore, we
insoluble oil degradation products. When other oil analysis tests. Upgrading routine must change the way we manage these
dealing with R&O oils which produce oil analysis tests to incorporate these lubricants in order to achieve optimum
organic degradation products, temperature technologies will allow a manufacturing performance.