Base Oil&Additives

BASE OIL AND ADDITIVES
BASIC KNOWLEDGE
PRE-ADVANCE D-FLTS
TRAINING
4 MARCH 2013
Shofwatuzzaki
Lubricants Technical Advisor
Copyright of SHELL INDONESIA 3/4/2013 1

CONTENT
1. BASE OIL
- Composition
- Manufacturing
- Types
2. ADDITIVE
- What is it?
- How does it works?
- How Much?....
Copyright of INSERT COMPANY NAME HERE

BASE OILS AND ADDITIVES
Base oil Additives
+
• Makes up most of the lubricant • Improve base fluid properties
• Determines the fundamental properties of • Protect the base fluid
the lubricant
• Protect equipment
Formulated lubricant

#1
BASE OIL

WHAT IS BASE OIL?
Base oil by source:

• Mineral (Petrol)
• Bio
Base Oil By process:

 Mineral
 Synthetic

WHAT IS BASE OIL?

WHAT IS SATURATES?

SATURATES STRUCTURES

AROMATICS AND POLY-AROMATICS STRUCTURES

QUALITY FEARURES OF LUBE BASE OIL COMPONENTS

API BASE STOCKS CLASIFICATION

BASE OIL CONSTITUTION AND PHYSICAL PROPERTIES

BASE OIL MANUFACTURING

BASE OIL MANUFACTURING

GROUP I BASE OIL

GROUP II & III – KEY MANUFACTURING SCHEME

GROUP I, II, AND III - COMPARISON

SHELL GAS TO LIQUID

GTL - MANUFACTURING

GTL STRUCTURES

#2
ADDITIVES

ADDITIVES
Base Oils + Additives
Anti- Anti- Corrosion Pour point Viscosity

Anti-wear Detergents Index Dispersants
foaming oxidants and Rust depressants Additives
Agents inhibitors Improvers
Extreme
Pressure
Additives
Friction
Modifier

ADDITIVES – IMPROVE THE BASE FLUID
Viscosity Index (VI) improver

 modifies the viscosity („thickness‟) of the base fluid so that it
changes less as the temperature rises
 allows the lubricant to operate over a wider temperature range
Pour point depressant

 keeps the lubricant flowing at low temperatures
Antifoam
 foam reduces the effectiveness of a lubricant
 antifoams reduce/stop foaming when the lubricant is agitated

or aerated
Copyright of INSERT COMPANY NAME HERE 3/4/2013 23
ADDITIVES – PROTECT THE BASE OIL
• Antioxidants
– slow down the breakdown of the base fluid caused by
oxygen (air) and heat
– oxidation is the main cause of lubricant degradation in
service
• Oxidation of the base fluid causes:
– acid formation (corrosion)
– sludges, varnishes (blockages)
• Life of a lubricant in laboratory oxidation tests is Oxidation

often used to give an indication of service life

ADDITIVES – PROTECT THE EQUIPMENT
Rust inhibitor
 inhibits the action of water on
ferrous metals (e.g. mild steel)
Corrosion inhibitor
 protects non-ferrous metals
(e.g. copper)
Anti-wear additive
 forms a protective layer on metal surfaces
to reduce friction and prevent wear when
no lubricant film is present
Extreme pressure additive Roller
bearing wear Gear tooth
 as for anti-wear additive but functioning
wear
only when heavy loads and temperatures
are encountered

VISCOSITY INDEX IMPROVERS
Using a higher VI fluid gives better fluidity especially at lower temperature
and allows the product to be used over a wider temperature range
Hydraulic Oil Hydraulic Oil
ISO VG 32 ISO VG 32
Multigrade Engine Oil VI = 105 VI = 140
77.3 oC
73.4 oC 171.1 oF
164.1 oF
-2.6 oC
27.3 oF -14.6 oC
5.7 oF
10 cSt is the minimum recomended viscosity to

secure lubrication while 1000 cSt is the maximum
recommended viscosity to secure pumpability
VISCOSITY INDEX IMPROVER
Viscosity Modifiers (also known as Viscosity Index Improvers)

• Viscosity modifiers allow lubricants to free-flow at low temperatures but maintain
viscosity grade at high temperatures – some examples below

Viscosity Index may be controlled through base oil type (mineral or
synthetic) or by use of special additives called VISCOSITY INDEX
IMPROVERS (VII)
Polymers (very large molecules) which prevent the oil from thinning out
at high temperatures
 Uncoiling of the polymer counteracts the normal thinning of oil

Ethelyne propylene copolymers,

polymethacryslates
In the Cold
With Heat
Long-chain oil soluble polymers

thicken oil at high temperatures
by swelling action
At high Shear rates VIIs molecules may align themselves with the direction
of flow or tear apart
 Temporary Shear thinning
Shearing Surfaces
 Permanent Shear Thinning
Viscosity
Base Oil Viscosity
Shear Rate
Effect of Shear Rate on Viscosity

POUR POINT DEPRESSANTS
 The pour point of a lubricant is the lowest

temperature at which the lubricant will flow
under standard conditions. A pour point
depressant is an additive which lowers this
temperature
 Wax crystal form when lubricating oil

cooled to low temperatures. This wax
crystals traps the reamaining oil. Pour point
depressants work by interfering with wax
crystallisation processes in lubricants at low
temperatures
 Many pour point depressants are based

on polymethacrylate chemistry

POUR POINT DEPRESSANTS
Aklyalted wax naphthalene,

polymethacrylates, alkylated wax phenol
Without PPD Chrystaline
wax
fibrous network forms
oil
With PPD
Pour Point
unlinked wax crystals form
Despressants
Copyright of SHELL INDONESIA

ANTIFOAM
Almost all lubricating oil systems contain some

air. Air is found in four phases: free air, dissolved
air, entrained air, and foam Foaming
 Foam is a collection of closely packed bubbles Oil surface

surrounded by thin films of oil that float on the
surface of the oil. It is generally cosmetic, but it will
Aeration
be a problem if it makes:
 oil level control impossible,
 spills onto the floor Oil Reservoir
 air locks at high points,
 so extreme that equipment is lubricated with
foam.
Small amounts of foam do not necessarily a

problem unless the system suffers from the
conditions listed above

ANTIFOAM
The mechanism by which antifoam additives work is

simple, as shown on the figure. Antifoamant contacts a
bubble at its film and spreads around the bubble. As it
spreads, the shearing force thins the bubble wall until it
ruptures.
The most common antifoam additive is

based on silicone in the form of
polydimethylpolysiloxane

ANTIOXIDANTS
Antioxidants

ANTIOXIDANTS
Two types of anti-oxidants
PRIMARY anti-oxidants remove radicals
(this dramatically slows down “propagation” reactions)
SECONDARY anti-oxidants remove peroxides
(this dramatically slows down “chain branching” reactions)

ANTIOXIDANTS
No Antioxidants

ANTIOXIDANTS
Primary Antioxidants

ANTIOXIDANTS
Secondary Antioxidants

ANTIOXIDANT
Antioxidants: Synergy of primary and secondary antioxidants

• Primary antioxidants remove radicals BUT produce peroxides
• Their effect is greatly enhanced when combined with secondary
antioxidant to deal with the peroxides
Extent of
No AO
Oxidation Primary AO
Secondary AO
Primary +
Secondary
SYNERGY
Time
ANTIOXIDANT
Antioxidants: When they run out !!

• Viscosity thickening, colour changes, deposits, acid build-up
150
130
110 Oil A
Oil B
90 Oil C
% Vk40 change
70
50
30
10
-10 0 20 40 60 80 100 120
-30
Time on Test (Hours)

DETERGENTS AND DISPERSANTS
ENGINE OIL CAN PREVENT

DEPOSITS AND SLUDGE HARMING THE
ENGINE…BUT HOW?
1. Engine oil contains detergent

molecules that adapt to protect metal 2. Carbon is blocked and
surfaces wrapped up by adaptive
molecules
Solid carbon is blocked and disperse by engine oil

DETERGENTS
Metal Detergents
Base: e.g. CaCO3, MgCO3
Metal: e.g. Ca, Mg, Ba
Soap:
salicylate, sulphonate, phenate
5 nm Base
Soap
FUNCTIONS:
Colloidal dispersion of base, • Neutralize acids
solubilised by metal soap • Keep surfaces clean
• Antioxidant
(salicylate, phenate)

DISPERSANTS
Steric stabilisation of soot by dispersant
prevents soot particles colliding and attaching

ANTIWEAR AND EXTREME PRESSURE
Boundary layer lubrication

Antiwear and extreme pressure
additives forms protective surface
layers to protect the equipment
 Antiwear additive protects the metal surface from wear under mild boundary
lubrication regime (ex. start up condition, hydraulic pump).
 The most common antiwear additive is Zinc Dialkyl diThiophosphates (ZDTP), while
other antiwear types ofadditive can be Boron compounds, Sulfurized Olefins.
 Vegetable and animal oil has a natural antiwear protection (very weak)
 Extreme pressure additive protects the metal surface from wear under severe
boundary lubrication regime where the lubricant film is very thin and there is
significant metal-to-metal contact (ex. Highly loaded gear).
 The simplest extreme pressure additive is elemental Sulphur (Sulphur Phosphorus),

ANTIWEAR
Anti-wear additives – ZDTP – multiple levels of defence against

wear
Fluid Lubricant Low viscosity fluid
Alkyl Phosphate precipitates High viscosity fluid
100 – 1000 nm
Partially complexed phosphates Increasing
resistance to
penetration
Compacted phosphate matrix

Solid
Solid sulphide/oxide layer Scuffing resistance

Metallic substrate

EXTREME PRESSURE
• React with metal surfaces to form a sacrificial wear layer at high temperature and load
• Reaction layer formation is a four-step process
- Break-in (increased pressure and temperature)

- Physical or chemical adsorption
- Additive-surface reaction
- Sacrificial (controlled) wear of asperities
• Layer has a lower shear strength than the metal
• Prevent metal-to-metal contact
• Prevents welding

EXTREME PRESSURE
EP Protection Requirements as a Function of Load

Straight Oiliness Antiwear Mild EP Strong EP Agent
Mineral Agent Agent Agent (Antiweld)
Oil Added Added (Antiweld) Added
Seizure
R R R
C C C
Load
R: The Point at Which the EP Film-Forming Action of the Additive Starts
C: The Point at Which the Reaction Ceases and the Lubricant's Load-Carrying Ability Diminishes
In severe cases EP additive-surface reaction can lead to corrosion and chemical wear
(especially on yellow metal). Thus the use of EP additives for some application is limited.

FRICTION MODIFIERS
Friction Modifiers

FRICTION MODIFIERS
Friction modifiers forms weak surface

layers on metal surface. It will break and
shear uder normal stress condition

Building Industrial Oils
BASE OILS
ANTI-OXIDANT
HEAT TRANSFER OIL
ANTI-RUST ADDITIVE
TURBINE OIL
E P ADDITIVE ANTI WEAR ADDITIVE
GEAR OIL HYDRAULIC OIL
VI IMPROVER
MULTI-GRADE
HYDRAULIC OIL

HOW MUCH ADDITIVE?…
COMPARATIVE ADDITIVE LEVELS
25 23%
BALANCE COMPOSITION
20
15
12.5%
9.5%
10
7.5%
5%
5
2%
1%
0
Turbine Industrial Way Multigear Tractor Metal SAE
Oil Gear Lubricant Hydraulic Working 10W-30
Oil Oil Automotive

TYPICAL TURBINE OIL COMPOSITION
Base Oil
99%
Antioxidants
R&O Additive
Package < 2%
Rust Inhibitor
Corrosion Inhibitor
Others *
Turbine oil additive package

* Defoamer, demulsifier, AW/EP additives, etc.

Typical Gear Oil Composition
Base Oil – Mineral (Typically Grp I) or Synthetic (PAO or PAG)

98%
Extreme Pressure Additives

Antioxidants
EP/AW Additive
Package < 2%
Rust Inhibitor
Corrosion Inhibitor
Extreme Pressure Additives
Gear Oil additive package

TYPICAL COMPOSITION OF AN ENGINE LUBRICANT
Dispersants
ZDTP
antiwear
Supplementary
additives e.g.
antioxidant,
friction modifier
Additive
package
Detergents
Base fluid Polymers

•Viscosity modifier (“VI Improver”)
•Pour point depressant

Base Oil&Additives

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