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Oil Purification Technologies: A Historical Perspective

Purificación de los demás aceites,

From the very beginning of early human civilization, people used animal and vegetable oils as lubricants.  As the time went by and people became more sofistcated and with the advent of industry, people started to use petroleum based oils.  Such oils were first applied in 1852 though they did not enjoy wide popularity since they were not as effective as other animal based lubricating substances.

At that time, the industrial production of high quality lubricating oils was in the early stages of development.  Beginning in the 1920s, many producers of lubricating oils started to process base oils to improve their performance characteristics.  The most widespread ways of base oil production include:

  • purification by clays;
  • purification by sulfuric acid;
  • SO2 treatment;
  • treatment by selective solvents;
  • dewaxing by solvents; and
  • purification by adsorbents.

The following is a detailed description of each method of production.

Purification by Clays

Clays were used to adsorb and remove the most harmful components of petroleum oil.  Additionally, they were able to remove aromatic and highly polar compounds that consisted of sulfur and nitrogen.

Sulfuric Acid Refining

Concentrated sulfuric acid was used to create a reaction with the components of base oils that had poor performance characteristics.  Acid turned them into sludge that was then removed.  In general, this technology was effective, but very expensive.

Additionally, there are certain ecological issues connected with the application of sulfuric acid and sludge formation as a means of processing oil.

SO2 Treatment

This kind of processing is an extraction process that is followed by removal of the oil’s components that have poor characteristics with a help of reusable solvent.  The main disadvantage of such a method is the toxicity of a solvent.  This technology therefore, was withdrawn from the market.  It became however, an important step in forming traditional extraction with the help of  selective solvents.

Selective Purification or Extraction by Solvents

Usually, selective solvents are used to remove aromatic hydrocarbons that improve oil’s lubricating capabilities.

Generally speaking, aromatic hydrocarbons are considered to be good solvents, but oil based on them have poor performance characteristics.  This is because such substances are reactive components within a boiling range of natural lubrication.  If they are oxidized, then a chain reaction takes place that reduces the service life of the base oils.

Selective purification is one of the ways to remove unwanted compounds.  It is based on a two phase system where impurities with a solvent and along with a pure oil form two layers.  When these two layers are separated carefully, a layer that consists of unwanted components will be formed, and the other layer will contain purified oil.  This method allows for removing asphaltene substances, resins and aromatic compounds with short side chains.  Additionally it will remove solid hydrocarbons and polycyclic aromatic compounds that speeds up coking and increases the viscosity temperature index.  Extraction by solvents is used mainly after vacuum distillation.

In today’s  modern industry, furfural is used more often and phenol is rarely used because of its toxicity.

Dewaxing by Solvents

Paraffins increase the pour point temperature of oil.  To remove paraffins, oil is mixed with a mixture of two solvents and the resulting solution is cooled down to between -6  to -12ºС.  Paraffin crystals settle down and then may be easily filtered out.  The solvent is then separated from the oil.  At the outlet, we obtain a dewaxed oil that possesses good performance characteristics such as: (1) lower pour point temperature and (2) an increased viscosity index.  The filtered paraffin sludge can be used as a raw material for catalytic hydrocracking or applied to obtain high-stable base oils.

Adsorbent Purification

Adsorbent purification is mainly based on bleaching clays and aluminum silicate (zeolites with non-homogeneous porosity).  When choosing zeolites with the pores of a certain size, it is possible to adsorb selectively such compounds as alkenes, polycyclic arenes, pyrobitumen and resins.

Adsorbent purification allows for oil’s decoloration, therefore, sometimes the term “oil’s decoloration” is used instead of “adsorbent purification.”  When working with oil products that have already been in service, it is advisable to use mobile oil units that are described below.

Oil Filtration: What Should You Know?

Filtración de aceite de transformador

Almost every hydraulic and lubricating system contains some contaminants even at the beginning of its service life.  It may be metal particles originated during production or impurities that penetrated during initial assembly.  Then the number of particles only increases since they may get through vent holes, joinings or during corrective maintenance.

There have been cases when one liter of a working fluid contained 100 million particles with a size of more than 1 micron.  It has been established that about 80% of breakdowns of hydraulic and lubricating systems are caused by different contaminants that are formed as a result of jamming, bearing vibration, increased/extreme oil temperature or the absence of adequate hydraulic pressure.

It is therefore, necessary to ensure constant oil filtering by a coarse mesh filter and a superfine mesh filter.  The coarse mesh filters are able to retain particles  that are bigger than the size of the existing gaps.  Fine mesh filters remove contaminants with a size up to 5 microns reducing to zero the wear of the working surfaces. The number of unfiltered particles has also a great impact on the wear rate of the equipment.

The modern hydraulic equipment and fluid industry has established international standard ISO4406.  It is the internationally accepted standard used to rate the purity of oils and hydraulic fluids.  According to ISO4406, the amount of particles with a size of more than 5 microns and the amount of the particles with a size of more than 15 microns is determined by measuring 100 millilitres of the working fluid.

Coarse mesh filters usually retain contaminants with a size of more than 25 microns that reduces the service life of friction knots, working in a mode, determined by elastohydrodynamic lubrication.

Service life may be substantially extended by using filters with a filtration fineness of 10 microns.

In addition to removing particiulate matter through filtration, water and moisture must also be removed.  Water penetration should be also prevented since it is a dangerous impurity that can cause corrosion, favors cavitation and accelerates oil’s aging and degradation.  Additionally, water favors the sedimentation of additives, the reduction of lubricating film thickness, and the accelerated wear of the gear pump.

Quality Control and Turbine Oil Purification

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The technical process of turbine oil production consists of derivation of a base component based on distillate fractions of different deposits of oil. Then there is a subsequent removal of asphalt resinous substances, solid paraffins, and sulphur compounds by purification with selective solvents.

At the final stage of production, special additives are added to the purified base components with a set viscosity and flash point to provide the necessary performance characteristics of commercial oils.

There are a wide range of requirements for  turbine oils when operating in turbine equipment.  In particular, they are put into operation only with the permission of the by-product recovery department.

The filling of an oil system is preceded by oil sampling to determine the oil’s acid neutralization number, the content of mechanical impurities, dissolved sludge and water content.  The acid neutralization number should be below the maximum allowable value and the oil should be free of water, mechanical impurities and sludge.

In practice, the purity of turbine oil during operation should meet or be higher than putiry class 11.

If any water is found in the oil or its purity class is 12 or numerically higher, it is necessary to take drastic measures to purify the product.  The monitoring of the condition of mineral turbine oil during operation is performed by oil sampling and analysis. Additionally, oil is regularly checked by eye for obvious things such as sludge and its qualitative characteristics  are  analysed.

If water, sludge and mechanical impurities were detected during a visual inspection, it is necessary to perform an additional analysis.

Purification of turbine oil is performed by special equipment designed and manuafactured by GlobeCore.  Turbine oil purification units in the CMM-MT line are designed to remove mechanical impurities, water and gasses from turbine oil.  The advantages of these units include the possibility to work in several modes simultaneously:

  • filtration;
  • filtration with heating and thermal vacuum purification of the oil; and
  • oil degassing.

Other benefits of GlobeCore oil purification equipment are as follows:

  • purification of oil by thermal vacuum method in one cycle;
  • oil service life extension;
  • stationary (shop facility) or mobile (remote locations);
  • ease of use/automated processing; and
  • spare parts come with all units.

The application of GlobeCore technologies for turbine oil purification allow not only for significant service life extension of the oil, but also for the improvement of operational reliability of turbines and reduced operating costs.

The CMM-C Vacuum Transformer Oil Purification Units

Purificación de aceite de transformadores, , ,

Unfortunately, in today’s industrial market place, the suppliers of insulating and lubricating oils are not able to provide the purity class necessary for trouble free servicing of oil products.  Therefore, bringing the oil’s performance up to required specifications remains an issue.

GlobeCore offers trailer mounted transformer oil purification/high vacuum degassing systems designated as the GlobeCore CMM-C line.  These technolgically advanced systems improve the oil’s performance characteristics that have become degraded due to heating and the introductioin of moisture and other unwanted contaminants.  These trailer mounted systems may also used to purify hydraulic fluid, transmission fluid, turbine oil, diesel fuels, industrial oil and other types of oils used in a wide range of industial and commercial applications.

GlobeCore’s thermal vacuum technologies remove water, gasses, and mechanical impurities from oils with a viscosity of no more than 70 cSt at 50ºС. Additionally, they may be used to vacuumize large and small transformers and vacuum fill different equipment under high or low pressure.

The Turkish Delegation Has Visited the GlobeCore Production Facilities

Noticias

On April, 27 the Turkish delegation visited the GlobeCore facilities. The aim of the visit was to check the readiness of the CMM-8.0 unit for commissioning.

General Directorate of State Hydraulic Works was founded in 1954 as a main governmental body in Turkey, responsible for development, planning, regulation and servicing of natural resources. Project management, construction and servicing of hydroelectric power stations are also included in the sphere of its activities.

One of the main parts of the hydroelectric power station is hydro turbine that brings into action generators that produce electric power. Turbine oil is required to lubricate bearings and reduction gears of these turbines. To perform its functions properly, oil should possess such performance characteristics as resistance to thermal oxidation, anticorrosion, antioxidant, antiwear and anti-foam properties.

In the course of operation, turbine oils are exposed to gasses, gaseous products and water that reduces its performance characteristics.

The GlobeCore CMM-8.0 is designed for degassing, dehydration and filtration of turbine oils. If to apply this equipment in time, it can extend the service life of oil, save you money on the new oil purchase.

The Turkish delegation was present during the testing of equipment that proved the readiness of the CMM-8.0 unit for operation.  The signing of the Work Completion Certificate was the logical result of this visit.

We had also a great opportunity to communicate with the employee of Andritz Hydro LTD – Irsad Akaydin. That’s what he said: “We have arrived at the GlobeCore production facilities to test the equipment. Everything was great. I haven’t heard about GlobeCore  technology before that’s why we gained great experience visiting this company. We are also very happy to have visited production shops and got acquainted with the peculiarities of the works carried out”.

Transformer Oil Purification by Bleaching Clay

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During transformer oil purification, not only adsorption, but also other processes such as capillary condensation, chemisorption, flocculation, coagulation have a great impact on the final product.

Very often, so-called Fuller’s earth or Fuller’s Earth filters are used as bleaching clay.  Sorbents, applied for transformer oil reclamation,  should meet the following requirements:

(1) silic acid content in the dry product no less than 32.5%; content of calcium and magnesium no more than 2.2%;

(2) the packed density of grit is no more than 0.65 g/cm3;

(3) the acid number of waste oil should be reduced by 45% per day;

(4) the size of grit grains is 3-7 mm;

(5) no more than 5% of grit grains with the size less than 3 mm;

(6) no other impurities; and

(7) moisture content is no more than 10%;

Bleaching clays may be used both for continuous oil regeneration in transformers with a dehydrating filter breather and for the restoration of oil discharged from power equipment (contact method).

Peculiarities of Transformer Oil Servicing

Filtración de aceite de transformador, ,

Transformer oil is an petroleum product, used to insolate the active parts of transformers under voltage as well as cool and transfer heat during operation.

The performance characteristics of this oil product depend on its chemical composition that is determined from the raw material and methods uesed in its purification.  The commissioning of new electric power transformers requires only fresh oil that has not been previously in service.  Each batch of the product intended for transformer refilling should be certified by the supplier.  But, even fresh new oil delivered to the power facilities should be tested and, if necessary, cleaned of mechanical impurities, moisture and gases before being placed into the transformer.

Performance characteristics of transformer oil are evaluated by the following indicators:

  • dielectric strength;
  • loss tangent;
  • moisture content;
  • gas content; and
  • the presence of mechanical impurities.

Centrifuge processing of transformer oil refers to the classical methods.  Processing by centrifuge forces removes moisture and suspended mechanical particles from the oil.  Centrifugal treatment is applied when refilling power transformers with voltage up to 35 kV or used as a method of pre-treatment.  Long centrifugation is undesirable since it can lead to removal of antioxidant additives that can lead to the premature oxidation of the oil.

Transformer Oil Filtration

Filtration consists of transformer oil being passed through special porous partitions that retain unwanted impurities.

Absorption Treatment of Transformer Oil

The Absorption Treatment of transformer oil absorbs water and other impurities using special substances called “adsorbents.”  Adsorbents may include synthetic zeolites that intended to remove dissolved gasses and moisture from the oil.

Transformer Oil Treatment with Vacuum Units

Vacuum filtration systems provide for preheating of transformer oil up to between 50 to 60 ºС.  Then, the oil is sprayed in the first stage degasser and  flows down in a thin layer along the surface of a series of Rasching Rings.  Simultaneously, the first stage is vacummized by a vacuum pump.   Gas and moisture vapors are pumped through a zeolite cartridge and air filter.  The final drying and degassing of transformer oil is performed in the space of the second stage degasser.  Purified oil comes to the transformer or tank through a fine filter.

GlobeCore was a Co-organizer of a Conference Held in Vietnam

Noticias

In December 2014, GlobeCore, together with Pacific Technology and Equipment Co., Ltd. (PATEK) organized a conference for representatives of the power industry in Vietnam.

The aim of the event was to present the latest developments in the field of purification and regeneration of waste oils.

The representative of GlobeCore, Roman Gluschenko, delivered the report on this topic.  The audience was greatly impressed by the presentation of GlobeCore‘s equipment which was followed by a lively discussion.   Additionally, the laboratory oil regeneration unit was demonstrated to the representatives.

The presentation was so convincing that GlobeCore and the representatives of Vietnam have signed agreements during the meeting in the conference hall.

Here are the photos from the conference:

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The participants of the conference are discussing the issues of purification and regeneration of used oils

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Oil, processed on GlobeCore regeneration laboratory unit

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Contract signature

I-20 Industrial Oil: Filter Prices

Purificación de fluido hidráulico, ,

I-20 industrial oil is used for the lubrication of the most common industrial assemblies and components that do not require oils with special anti-oxidation or anti-corrosion properties.

Buying the oil is not the only expense.  During operation, the oil’s quality must be monitored and the oil should be purified and regenerated when necessary.  The foremost factor in selecting a purification method is the price to quality ratio.

One of the methods of purification that we would like to discuss today are filters and the specifics of their practical use.

Filters have various designs.  Selection of a filter configuration depends on operating conditions and the requirements to maintain the oil’s purity.  Filters are used practically in all stages of production including the storage and transportation of the oil.  Filters are installed in oil storage facilities, oil refineries and in equipment and machinery using oil.

Transportation, storage, and filling of industrial oil I-20 is performed with equal element filters.  This type of filter is of simple design and can be operated in a wide range of operating pressures.  The main drawback of the equal element filters is the need to disconnect them for filter element cleaning or replacement.

In general, oil filters are cylindrical and vary in design of filter element fixture, the number of filter elements, and presence of safety valves.

The need to change the filter arises when the filter becomes contaminated as indicated by the pressure difference on the filter.  This difference is measured by two manometers.

The design of the filter is chosen depending on where the filter will be installed.  Oil refineries usually filter industrial oil before shipping the oil to the customer or wholesale distributor.

Filters used in storage parks must have high throughput.  Their weight and dimensions do not matter much since the filters are stationary.

Along with fabric filter elements, there are also metal mesh, felt or fiberglass filter elements in the oil industry.

The requirements to filters used for oil in stationary oil storage facilities are similar to those installed in oil refineries.

The main problem with a disposable oil filter is the limited service life.  Filter media becomes saturated with contaminants increasing the pressure drop to maximum limits.

Lube oils are filtered mostly through disk filters that can only assure coarse filtration by removing particles larger than 70 microns.

During filtration of thickened oil, the filter’s throughput may be lowered by as much as 30-40% compared to oil without thickeners.

For operation in low temperatures, filters are equipped with jackets with steam or a water inlet for heating.

Transformer Oil Reclamation Methods

Purificación de aceite de transformadores,

Transformer oil serves as the main dielectric liquid insulation in oil-filled equipment.  Among other things things, it is used to increase the dielectric strength of the solid insulation.  Additionally, in power transformers oil is used to cool and transfer heat, and in high voltage breakers, to quench an unwanted or unsafe arc of electricity.

The general condition of oil, and some index values, may indicate if there are some system defects.  When servicing, oil is exposed to such negative impacts as high temperature, moisture, and contact with atmospheric air.  As a result, dielectric fluid attracts and holds unwanted contaminants.  The performance characterists decline and the oil slowly loses its ability to perform its functions.  Additionally, products of transformer oil aging get into the solid cellulose insulation degrading its condition and ability to insulate.  In general, some irreversible processes that happen to the solid insulation may result in premature transformer failure.

Beginning in the 1970s, used oil has usually just been removed and replaced with new oil.   Such an approach however, is now considered to be higly inefficient due to the high cost of new oil, the labor cost associated with the process and because there is always some used oil left in transformer that will contaminate the new oil.  The used oil gets into the new oil and degrades its performance characteristics.  Additionally, the used oil that remains in the solid insulation continues the degradation process of the kraft insulating paper.

Today, oil reclamation is considered to be a reasonable and cost efffective solution to this problem since it restores oil to its original condition and removes the contaminated oil from the core and solid insulation.  If timely performed, oil regeneration will prevent damage done to solid insulation by aggrissive used oil.  This will reduce operating costs since there will be a reduced need to new fresh oil and the cost of disposing of used will have been eliminated.  The GlobeCore Process of oil regeneration greatly increases the service life of the dielectric oil and the transformer.

And this is no great surprise since the majority of oil-filled equipment failure are caused by defects in the liquid and solid insulation.

There are several methods of transformer oil reclamation that include:

  •    zeolite purification;
  •    filter press purification; and
  •    centrifuge cleaning and drying  (purification, clarification methods)

Zeolite purification is based on mass transfer.  As a whole, it is a very difficult process that includes a wide range of subprocesses:

  1.    Absorption  (gas is absorbed by a liquid or solid substance);
  2.    Adsorption  (the components of the substance are absorbed into the surface of the solid substance);
  3.    Crystallization (substance turns into solid state)
  4.    Dissolution (process that is reverse to crystallization);
  5.   Fractionation (separation of mixtures by repeated component exchange between liquid and gaseous phases, usually moving in counterflow to each other)
  6.   Drying (moisture is removed from the substance); and
  7.    Extraction (substances, dissolved in a liquid, are extracted by another liquid which is not or partially mixed with the first one.

Often, it is the adsorption that is used to regenerate transformer oil.  Today, it is considered to be very effective since no sophisticated equipment is required to perform this process.  The process consists in oil being passed through a layer of sorbent.  Moisture, dissolved in insulating liquid is retained on the surface of the sorbent material.  Other substances that have higher adsorption capacity may also serve as sorbents.  Adsorbent does not have any impact on the hydrocarbon composition of the oil and allows for the properties of the insulating liquid to be preserved.

GlobeCore has many years of experience in developing, manufacturing and promoting regeneration equipment for transformer oil, industrial oil, turbine oil, transmission fluids and other types of industral and commercial oils.  GlobeCore has applied several classical approaches for oil treatment, as well as successfully introducing its own developments due to its experienced engineering staff and knowledge of the world wide market needs.

One of the latest GlobeCore developments is transformer oil reclamation, based on an automatic Fuller’s Earth reactivation system that eliminates hzardous waste and greatly reduces labor demand to complete the processing.  First, it provides for considerable cost savings.  Second, application of such technology contributes to environment preservation and protection.

GlobeCore advanced oil processing equipment operate on energized transformers thereby eliminating the need for an alternative energy source when conducting preventive maintenance.  GlobeCore oil processing equipment is able to restore transformer oil to its original new like condition and greatly extend the service life of your electric power transformers.