GREEN LUBRICANTS CURRENT TRENDS - PowerPoint PPT Presentation

INDIAN SCHOOL OF PETROLEUM

SEMINAR

DR A.K.BHATNAGAR

PETROTECH CHAIR PROFESSOR

INDIAN INSTITUTE OF TECHNOLOGY

NEW DELHI

23RD AUGUST 2003

• BACKGROUND
• GREEN LUBRICANTS DEFINED
• TEST METHODS
• TRENDS- BASE STOCKS, ADDITIVES
• MOTIVATIONAL EFFORTS
• BIOBASED LUBRICANTS
• CONCLUSIONS

iitd

• BEGAN WITH “ SILENT SPRING” NOVEL BY
• RAQUEL CARSON -A HALF FICTION & HALF TRUTH
• DOCUMENTARY.
• CHLORINATED HYDROCARBONS,PARTICULARLY
• DDT & RELATED PESTICIDES WITHDRAWN.
• CHLORINATED SOLVENTS AND MANY POSSIBLE
• TOXIC COMPONENTS OF HYDROCARBONS CAME
• UNDER ATTACK
• RIO AND KYOTO CONFERENCES AND EMERGENCE
• OF SEVERAL NATIONAL ANF INTERNATIONAL NGOs
• ADDED FURTHER IMPETUS
• TODAY HYDROCARBON INDUSTRY IS THE
• TARGET OF ATTACK BY ENVIRONMENTALISTS.

• RESULT
• CLEANING OPERATION AT HEAVY COST STARTED. LUBRICANT
• INDUSTRY WAS ALSO NO EXCEPTION.
• NEW STANDARDS,NEW REQUIREMENTS AND THEREFORE NEW
• PROCESSES, NEW FEED STOCKS EMERGED FOR BASE OILS /
• ADDITIVES
• TOXIC COMPONENTS SUCH AS CHLORINATED PARAFFINS,
• HEAVY METALS, AROMATICS,NITRITES ETC REMOVED
• FROM FINISHED LUBRICANTS.
• DAYS FOR ECO-FRIENDLY FUELS eg. LPG. CNG, ETHANOL,
• BIODIESEL ETC HAVE ALREADY COME.
• DAYS FOR ECOFRIENDLY LUBES
• DONOT APPEAR FAR

• WORLD LUBE OIL CONSUMPTION (1995) 40.0 MMT
• LUBES FOR TOTAL LOST SYSTEM @ 10% 04.0 MMT
• 2 stroke oil
• mould release
• metal working
• greases
• chain lubricant
• miscellaneous
• USED OIL ( NONRECYCLED) 30% 12 MMT
• TOTAL POLLUTING OIL 16 MMT

LUBE OILS ARE OMNIPRESENT

UNCONTROLLED RELEASE IN USA ALONE - 4.7 MMT

Ref : S.Mohanti, envirotech India

• Finished lubricants account for about 1% of total crude oil consumption*

Lubricating Oil

Base oil(80-95%)+Additive Package(05-20%)

*Source : Concawe Report No. 5/96 (Europe)

FRESH OIL

5.3 MMT

PROCESS OIL

O.6 MMT

AUTO LUBE

2.5 MMT

IND. LUBE

1.7 MMT

MARINE OIL

0.5 MMT

TOTAL LOSS

COLLECTABLE USED OIL

2.6 MMT (55%)

AUTO LUBE

1.6 MMT

IND.LUBE

1.O MMT

MARINE OIL

1.O MMT

COLLECTABLE USED OIL

1.5 MMT (32%)

NOT RECORDED

1.1 MMT (23%)

RE-REFINING OF USED OILS

• FIRST INTRODUCED IN 1930’S AND INCREASED
• SIGNIFICANTLY DURING WORLD WAR II
• IN 1980’S MANY ACID/CLAY RE-REFINING PLANTS IN US
• WERE SHUT DOWN DUE TO INCREASED ENVIRONMENTAL
• CONSCIOUSNESS AND ECONOMIC REASONS
• WORLDWIDE AROUND 400 RE-REFINING PLANTS
• TOTAL CAPACITY ~1800 KT/YEAR
• MOST OF THE PLANTS LOCATED IN EAST ASIA,INDIA,CHINA
• & PAKISTAN
• INDIVIDUAL CAPACITY ON AN AVERAGE - 2 KT/YEAR
• MOST OF THE PLANTS BASED ON

ACID CLAY PR.

Source : Concawe Report No. 5/96

• RE-REFINING UNITS REGISTERED WITH MOPNG: 69*
• NO ORGANIZED USED OIL COLLECTION SYSTEM
• RE-REFINING PROCESSES
• SIMPLE RECLAMATION,
• ACID/CLAY PROCESS
• QUESTIONABLE ENVIRONMENTALLY
• QUESTIONABLE PRODUCT QUALITY
• ‘IMPORT’ OF USED OIL BY INDIAN RE-REFINING INDUSTRY RAMPANT FROM COUNTRIES WHERE DUE TO STRINGENT ENVIRONMENTAL REGULATIONS WHICH –MAKE LOCAL DISPOSAL OF HAZARDOUS WASTE IN ACCEPTABLE MANNER COMMERCIALLY UNVIABLE

*Source : Indian Express,October 27, 1995, NewDelhi

• REGULATORY PUSH
• CLEAN AIR ACT
• CAFE

• BASE OIL
• LOWER
• VISCOSITY
• HIGHER VI
• LOW PP
• LOW
• VOLATILITY
• ECOFRIEDLY

• CONSUMER DEMAND
• PULL
• WARRANTIES
• EXTENDED DRAIN
• ECOFRIENDLY

• LUBRICANT DESIGN
• FLUIDITY
• OIL CONSUMPTION
• FUEL ECONOMY
• EXTENDED INTERVAL

• ENGINE DESIGN
• CAT CONVERTOR
• LOW FRICTION ENGINE
• AERODYNAMICS

• DESCRIBED IN MANY WAYS
• - GREEN.BIODEGRADABLE,RECYCLABLE,
• NONTOXIC,REUSABLE ETC
• BIODERADABLE PRODUCT WITH LOW OR NO
• TOXICITY HAVING MINIMUM IMPACT ON
• ENVIRONMENT
• THE MAIN DRIVING FORCE IN LAST DECADE,
• MAXIMISING BIODEGRADABILITY AND
• MINIMISING ECOTOXICITY TO REDUCE
• ENVIRONMENTAL IMPACT

• BIODEGRADABILITY IS DEFINED
• “AS SUSCEPTIBILITY OF A SUBSTANCE TO UNDERGO DEGRADATION
• UNDER THE INFLUENCE OF BIOLOGICAL AGENTS SUCH AS BACTERIA,
• FUNGI, YEAST ETC”
• OTHER IMPORTANT CRITERIA ARE
• ECO TOXICITY INCLUDING EFFECTS OF LUBRICANT AND
• ITS PHOTO AND BIODEGRADED PRODUCTS ON LIVING
• ORGANISM
• BIOACCUMULATION POTENTIALS,
• EFFECTS ON EMISSION QUALITY,
• USE OF RENEWABLE RAW MATERIALS
• A FULL LIFE CYCLE ANALYSIS – A PRACTICE TODAY

• ECO TOXICITY INCLUDES EFFECTS OF LUBRICANTS
• AND ITS DEGRADED PRODUCTS ON LIVING ORGANISMS
• A FULL LIFE CYCLE ANALYSIS - A PRACTICE TODAY
• RESEARCH&DEVELOPMENT
• MANUFACTURING
• BLENDING, STORAGE,DISTRIBUTION
• PACKAGING
• MSDS
• IMPACTS DURING USE
• COLLECTION OF USED OILAND PACKAGING
• RECYCLING OR DISPOSAL

• MASS AWARENESS
• CHANGING PERCEPTIONS
• POLITICAL COMPULSIONS
• IMPROVED LIVING STANDARDS
• PACKAGES OF
• INCENTIVES AND DISINCENTIVES

• IN GERMANY ANY MATERIAL CAPABLE OF SEEPING AWAY
• IS CONSIDERED UNFRIENDLY TO ENVIRONMENT
• MEASURES UNDERTAKEN IN DEVELOPED NATIONS TO
• PROMOTE ECOFRIENDLY PRODUCTS
• LEGAL PROHIBITIONS
• QUASI LEGAL ORDERS
• HUGE SUBSIDIES
• PRESSURE GROUPS
• MANUFACTURER’S OWN INITIATIVES

• THE GERMAN WATER LAW
• THE DRINKING WATER DIRECTIVE
• THE GERMAN GROUND LAW( IN DRAFT)
• THE FEDERAL EMISSION LAW
• THE RECYCLING AND WASTE LAW
• THE CHEMICAL LAW
• THE ENVIRONMENTAL LIABILITY LAW
• GERMAN PARLIA,EMT INITIATIVES
• THE “BLUE ANGEL” ECOSEAL

• GLOBAL ECO NETWORK “GEN”
• EUROPEAN “ECO-LABELS”
• GERMAN “BLUE ANGEL”
• NORDIC COUNTRIES “WHITE SWAN”
• CANADIAN “MAPLE LEAF”
• FRANCE “NF ECOMARK”
• JAPAN “FRIENDLY TO EARTH”
• USA “GREEN SEAL”
• INDIA “EARTHEN PITCHER”

WEN IS AN AVERAGE VALUE OF ACUTE ORAL MAMMALIAN,

FISH AND BACTERIAL TOXICITY VALUES

R511

R50- VERY TOXIC

R51- TOXIC R52- HARMFUL

R53- LONG TERM EFFECT

REF- MOHANTI S, ENVIROTCH 2001

PETROLEUM BASED

SYNTHETICS

SEMISYNTHETICS

WATER BASED

MIXED BASE OILS

RECYCLED

ADDITIVES (0=20%)

NATURE DERIVED

CHEMICALY MODIFIED

SYNTHETIC

SOLVENTS

CHORINATED

NON- CHLORINATED

• CHEMICAL REACTION
• POLYAROMATICS (VI –60 ) TO POLYNAPHTHENE (VI 20 )
• POLYNAPHTHENES (VI 20)
• POLYALKYLMONOCYCLICS (VI 110)
• PARAFFINS WAXES (VI 150 ) TO ISOPARAFFINS (VI 140 )

• IMPROVED SOLVENT REFINING
• HYDROPROCESSING/HYDROCRACKING
• MAX DEWAX
• SELECTIVE CATALYTIC DEWAXING
• WAX HYDROISOMERISATION
• LOW PRESSURE HYDROFINISHING
• GTL TO BASE OIL (GROUP III)

PAO AND GR III ARE COMING CLOSE

• LIGHT VISCOSITY - EASY START,FUEL EFFICIENCY
• LOW VOLATILITY – OIL CONSERVATION
• & REDUCED EMISSIONS
• HIGH VISCOSITY INDEX –BETTER TEMP-VISCOSITY
• RELATIONSHIP
• IMPROVED STABILITY – LONG DRAIN INTERVAL
• REDUCED POUR POINT – LOW TEMP FLUIDITY
• BETTER LUBRICITY – FUEL ECONOMY
• ECOFRIENDLY - SAFE MEETING REGULATIONS

PETROLEUM BASED

SYNTHETICS

SEMISYNTHETICS

WATER BASED

MIXED BASE OILS

RECYCLED/USED OIL

ADDITIVES (0=20%)

NATURE DERIVED

CHEMICALY MODIFIED

SYNTHETIC

SOLVENTS

CHORINATED

NON= CHLORINATED

• Infrastructure for Environment Friendly

re-refining technology

• Import of waste oil – dumping ground
• Base oil quality
• Record of recognized producers and users of re-refined oils in the country and curb on malpractices

USED OILS PRESENT A VARIED AND POORLY DEFINED COCKTAIL OF COMPOUNDS

• IN USE, A LUBRICANT MAY BECOME CONTAMINATED, OR MAY UNDERGO DEGRADATION SO THAT ITS HAZARD TO HEALTH IS INCREASED OR NEW ONES INTRODUCED.

TYPICAL PROBLEMS ARE:

• CONTAMINATION WITH ENGINE COMBUSTION PRODUCTS, PARTICULARLY PCAS
• CONTAMINATION WITH BACTERIA AND DECOMPOSING DEAD BACTERIA

Source : Concawe Report No. 5/87

TYPICAL CONTAMINANTS AND SOURCES

• PCA/PAHS OF MINERAL BASE LUBES MAY INCREASE DURING USE
• UPTO TEN- FOLD INCREASE FOR CUTTING OILS AND DIESEL ENGINE OILS
• HUNDRED- FOLD OR MORE FOR GASOLINE ENGINE OILS AND QUENCHING OILS

Source : Concawe Report No. 5/87

Oily sludge

• Classified as hazardous waste

(cat. 10 & 12 of IHWR 1989)

• Significant environment risk
• Contamination of ground water through leaching
• Release of VOCs, odour
• Health hazard due to direct/indirect exposure.
• Pollutants include phenols, HCs, heavy metals like chromium, nickel, cadmium, lead, manganese, zinc, copper etc

Source : Bhattacharya, NEERI, Petrotech-2001

• WASTE OIL CLASSIFIED AS HAZARDOUS WASTE AS PER HW RULES 1989/2000
• ‘BASEL CONVENTION’ 1992
• ON CONTROL OF TRANSBOUNDARY MOVEMENT OF HW,PROHIBITS IMPORT OF WASTE OIL (LISTED IN ‘LIST A’, ANNEX VIII)
• INDIA IS SIGNATORY TO THIS CONVENTION
• HW RULES 1989/2000:PERMISSION TO IMPORT GRANTED BY MOEF UNDER RULES 13(3) AND 14 (3)

RULE 13(3):MOEF MUST SATISFY ITSELF THAT IMPORTER HAS ENVIRONMENT FRIENDLY/APPROPRIATE TECHNOLOGY FOR REPROCESSING...

SLUDGE MANAGEMENT

• STRINGENT REGULATORY MEASURES FOR:
• ZERO HAZARDOUS WASTE REFINERY OPERATIONS
• RECYCLING – THROUGH RE-USE AND/OR AS RAW MATERIALS FOR NEW VALUE ADDED PRODUCTS USING ENVIRONMENTALLY BENIGN PROCESSES
• BIO-REMEDIATION ETC
• BIO-REMEDIATION TECHNOLOGY IMPLEMENTATION INITIATIVES
• TERI – DBT OILZAPPER TECHNOLOGY – LICENSED TO BPCL AND SHRI RAM BIOTECH
• TERI – IOC (R&D) JOINT TECHNOLOGY CALLED OILI VOROUS – S – TRIAL RUNS ORGANIZED IN MATHURA AND BARAUNI REFINERY

• PETROCROPS AS A SOURCE OF FUEL
• -A WELL STUDIED SUBJECT
• BIOBASED PRODUCTS COMMON IN GREASE
• BIOBASED LUBRICANTS
• - A RECENT PHENEMENON
• BEGINNING WITH JOJOBA, A SERIES OF
• VEGETABLE OILS AS POTENTIAL LUBRICANTS
• OR ADDITIVES UNDER STUDY TODAY
• EG. SOYBEAN, PALM.
• COCONUT, SUN FLOWER ETC

• GOVERNMENT INITIATIVES –
• COUNTRY SPECIFIC
• USA- SOY OIL
• EUROPE- RAPE SEED OIL
• MALAYASIA - PALM
• INDIA JATROPA CURCUS ??
• SOY BEAN PRODUCTIN IN USA 2.7 BILLION BUSHELS
• -HALF OF WORLDS TOTAL PRODUCTION
• SOYOIL POTENTIALS - 3.6 BILLION GALLONS /YEAR
• AVAILABLE AT COMPETETIVE COST 0.15 / LBS
• GMO TECHNOLOGY IS FURTHER ENCOURAGING
• ITS USE AS INDUSTRIAL LUBRICANT

• MANDATES
• FEDERAL EXECUTIVE ORDER13134 ,1999
• “DEVELOPING & PROMOTING BIOBASED
• PRODUCTS & BIOENERGY” TO
• TRIPLE THE USE BY 2010
• IOWA STATE SENATE FILE 2185 GIVING
• PURCHASE PREFERENCE TO ALL
• BIOBASED LUBES & GREASE
• “LEAD BY EXAMPLE”

• RESOLUTION (JUNE 16, 19940
• PROMOTE USE OF BIOLUBRICANTS AND
• HYDTAULIC FLUID
• RESOLUTION (28TH NOV.1995
• REVISED 1999)
• REPORT ON USE OF RAPIDLY
• BIODEGRADABLE LUBES
• REGULATION(JUNE 2000)
• PROGRAMME TO SUPPORT SUBSTITUTION
• OF MINERAL OIL WITH BIOBASED OILS

• DUE TO PUBLIC CRAZE FOR GREEN
• PRODUCTS, MANY COMPANIES NOW OFFER
• BIOBASED LUBES
• SOLD AS THE TOP OF SHELF, PRESTIGE
• PRODUCTS FOR A NISCHE BUT GROWING
• MARKET
• USE ECOSEALS FOR PRODUCT
• DIFFERENTIATION

REF BHATIA VK IIP(D) JUNE 2000

SOURCE :SAE 941758

OXIDATIVE STABILITY V/S PERCENT

OLEIC IN VEGETABLE OILS

SOURCE : EUROGREASE, P 21, JULY 2000

CHANGES IN VEGETABLE OIL VISCOSITIES

IN ASTM D-2271 (1000HRS @1000 PSI @78OC

CHANGES IN VISCOSITIES AS PER ASTM D-2271 OF

FORMULATED FLUIDS (1000HRS @1000 PSI @78OC)

* Measured @ 40oC

• POSITIVE SIDE
• BETTER VISCOSITY-TEMP RELATIONSHIP
• BETTER LUBRICITY
• ECO FRIENDLY
• BETTER VOLATILITY CHARACTERSTICS
• SURPLUS AVAILABILITY IN SOME COUNTRIES
• NEGATIVE SIDE
• OXIATION,HYDROLYTIC AND THERMAL
• STABILITY
• HIGH PERFORMANCE ADDITIVES

GMO MAY PROVIDE THE ANSWER

PETROLEUM BASED

SYNTHETICS

SEMISYNTHETICS

WATER BASED

MIXED BASE OILS

RECYCLED

ADDITIVES (0=20%)

NATURE DERIVED

CHEMICALY MODIFIED

SYNTHETIC

SOLVENTS

CHORINATED

NON-CHLORINATED

DETERGENT

DISPERSANT

EMULSIFIER

DEMULSIFIER

EXTREME PRESSURE

FOAM INHIBITOR

DYE

SEAL SWELL AGENT

FRICTION MODIFIER

OXIDATION INHIBITOR

POUR POINT DEPRESSANT

RUST & CORROSION INHIBITOR

BIOCIDES

COUPLERS

EMULSIFIERS

FOAM INHIBITORS

FRICTION MODIFIER

PPD

VISCOSITY MODIFIERS

CHEMICALLY ACTIVE

ANTIWEAR AGENT

DETERGENT

DISPERSANT

E P AGENT

OXIDATIOJN INHIBITOR

RUST AND CORROSION INHIBITOR

• CURRENTLY USED ADDITIVES
• ARE NOT BIODEGRADABLE GENERALLY
• COULD BE TOXIC Eg,NITRITES,HEAVY METALS,
• CHLORINATED PARAFFINS ,BIOCIDES,
• PHOSPHATES ETC
• BIOBASED ADDITIVES
• SULFURISED VEGETABLE OILS AS EP/AW
• SPECIAL ASHLESS SULPHONATES, SUCCINATES AS
• CORROSION INHIBITOR
• SPECIAL ANTIOXIDANTS

ADDITIVES FOR BIOBASED LUBES IS A WEAK LINK

• NAPHTHENIC (LVI)
• HVI
• TOXICANT FREE
• XHVI
• SYNTHETICS
• BIODEGRADABLE
• ECOFRIENDLY
• BIOBASED

• LIGHTER VISCOSITY - EASY START & FUEL EFFICIENCY
• LOW VOLATILITY – OIL CONSERVATION
• & REDUCED EMISSIONS
• HIGH VISCOSITY INDEX – BETTER TEMP-VISCOSITY
• RELATIONSHIP
• IMPROVED STABILITY – LONG DRAIN INTERVAL
• REDUCED POUR POINT – LOW TEMP FLUIDITY
• BETTER LUBRICITY – FUEL ECONOMY
• ECOFRIENDLY - SAFE MEETING REGULATIONS

DEMAND 1.0 MMT

SUPPLY

SR 0.63 MMT

GR II 0.14 MMT

DEFICIT 0.33 MMT

BIODEGRADABLE OIL BASED ON VEGETABLE OILS

CAN PLAY A COMPLIMENTARY ROLE

• INDIAN DEMAND FOR LUBES BY 2005
• WILL BE ABOUT 1,6 MMT
• RECYCLE INDUSTRY IS VIRTUALLY
• NON FUNCTIONAL
• COUNTRY’S WATER WAYS, AIR QUALITY
• HEAVILY POLLUTED
• PROMOTIONAL EFFORTS FOR BIOBASED,
• ALCOHOL,BIODIESELARE ALREADY ON.
• BIOBASED LUBRICANTS CAN BE COPROMOTED.
• IT OFFERS NO CONFLICT WITH EXISTING
• PRACTICE AS SUBSTANTIAL QUANTITY
• . OF BASE OILS ARE STILL IMPORTED.
• A COMPLIMENTARY ROLE IS FORESEEN

• NEW MACHINE’S REQUIREMENTS AND
• ENVIRONMENTAL PRESSURES HAVE
• FORCED SINIFICANT CHANGES IN LUBRICANT
• AND ADDITIVE TECHNOLOGY
• TOTAL LIFECYCLE ANALYSIS FOR A
• NEW PRODUCT HAS BECOME NECESSARY
• FOR GREEN LUBRICANT BIODEGRADABILITY
• IS ONE OF MANY OTHER REQUIREMENTS
• GROUP III BASE OILS ARE COMING CLOSER
• TO PAO BUT IN TERMS OF BIODEGRADABILITY
• THEYARE NO MATCH FOR BIOBASED
• LUBRICANTS

• GENETICALLY MODIFIED VEGETABLE OILS
• WITH HIGH OLEIC CONTENT HAVE GIVEN
• MATCHING PERFORMANCE WITH MINERAL
• OIL BASED PRODUCTS
• POSSIBLE BIOREMEDIATION OF ACIDIC SLUDGE
• BY IOC/TERI SCIENTISTS HAS OPENED A NEW
• APPROACH TO REVITALISE THE RECYCLING
• INDUSTRY
• BIOBASED LUBRICANT INDUSTRY IS PICKINGUP
• USA AND EUROPE. IT MAKES A GOOD SENSE IN
• INDIA TOO AS IT IS EXPECTED TO PLAY
• A COMPLIMENTARY ROLE.

THINKING GREEN IS “SATWIK”

EATING GREEN IS “HEALTHY”

GREENING OF ENERGY IS “FUTURE”

THE “FUTURE” WHICH IS FOR US,

FOR OUR CHILDREN AND HUMANITY

THANK YOU