Lubricant blending and quality assurance

Content: 1 Introduction2 Mineral Oil Base Oils: API Groups I, II and III: Properties andCharacteristics2.1 Introduction2.2 Base Oil Nomenclature2.3 Methods of Manufacturing Base Oils2.4 Base Oil Composition2.5 Mineral Base Oil Properties and Characteristics2.5.1 Overview2.5.2 Appearance and Colour2.5.3 Density and Gravity2.5.4 Viscosity and Viscosity Index.2.5.5 Pour Point and Cloud Point2.5.6 Distillation Range2.5.7 Flash Point2.5.8 Volatility2.5.9 Aniline Point2.5.10 Viscosity Gravity Constant2.5.11 Refractive Index and Refractivity Intercept2.5.12 Elemental Contents2.6 API Base Oil Classifications2.7 Comparison of Mineral Oil Base Oils2.7.1 Group I Base Oils2.7.2 Group II Base Oils2.7.3 Group III Base Oils2.7.4 Group I, II and III Base Oils2.8 Base Oil Interchangeability2.9 Summary3 Synthetic Base Oils: API Groups IV and V: Properties andCharacteristics3.1 Introduction3.2 Conventional Definitions of Mineral and Synthetic Base Oils3.3 Types of Synthetic Oils3.4 Performance Advantages of Synthetic Oils3.5 Properties and Characteristics of the Main Synthetic Base Oils3.5.1 Polyalphaolefins3.5.2 Diesters and Polyol Esters3.5.3 Polyisobutenes3.5.4 Polyalkylene Glycols3.6 End Use Markets for Synthetic Lubricants3.7 Conclusions4 Lubricant Additives: Properties and Characteristics4.1 Review of the Development of Lubricant Additives4.2 Functions of Lubricant Additives4.3 Types of Lubricant Additives4.3.1 Viscosity Index Improvers4.3.2 Detergents4.3.3 Dispersants4.3.4 Pour Point Depressants4.3.5 Anti-Oxidants (Oxidation Inhibitors)4.3.6 Anti-Wear Additives4.3.7 Lubricity Additives4.3.8 Extreme-Pressure Additives4.3.9 Bearing Corrosion Inhibitors4.3.10 Corrosion Inhibitors or Anti-Rust Additives4.3.11 Metal Passivators4.3.12 Demulsifiers (Anti-Emulsion Additives)4.3.13 Emulsifiers4.3.14 Friction Modifiers4.3.15 Anti-Foam Additives (Foam Suppressants)4.3.16 Biocides4.4 Additive Packages4.5 Properties of Lubricant Additives4.6 Effects of Additive Properties on Lubricant Blending4.7 Summary5 Lubricant Formulation and Ease of Blending5.1 Introduction5.2 The New Product Development Process5.2.1 Idea Generation5.2.2 Idea Screening5.2.3 Idea Evaluation5.2.4 Agreement Between Marketing and ProductDevelopment Departments5.2.5 Preliminary Business Analysis5.2.6 Product Development and Testing5.2.7 Test Marketing5.3 Formulating and Developing a New Automotive Engine Oil5.3.1 The Specification5.3.2 Choice of Base Oil(s)5.3.3 Choice of Viscosity Index Improver5.3.4 Developing the Dispersant/Inhibitor (DI) Package5.3.5 Evaluating and Finalising the Formulation5.4 Formulating and Developing a New Industrial Lubricant5.5 Illustrative Lubricant Formulations5.6 Ease of Blending5.7 Communication and Co-operation Between Formulators andBlenders5.8 Summary6 Lubricant Blending Plant Design: Grassroots Plants and UpgradingExisting Plants6.1 Introduction6.2 Investment in Blending Lubricants6.2.1 Business Aims6.2.2 Blending Plant Conception6.3 Grassroots Blending Plant6.4 Upgrading an Existing Blending Plant6.5 Blending Plant Layout6.6 Designing a Lubricant Blending Plant6.7 Benefits of High Quality Blending Plant Design6.8 Summary7 Lubricant Blending Plant Equipment and Facilities and TheirOperation7.1 Introduction7.2 Lubricant Blending as Part of the Supply Chain7.3 Key Components of a Modern Lubricant Blending Plant7.3.1 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 Vessel7.3.6 Drum Heating Unit (DHU)7.3.7 Pigging Equipment7.4 Blending Operations7.4.1 Batch Blending7.4.2 Automated and In-line Blending7.4.3 Operating a Drum Decanting Unit7.5 Sampling Raw Materials and Blends7.5.1 The Importance of Sampling7.5.2 Sample Bottles7.5.3 Sampling Methods7.6 Automation of Blending7.7 Summary8 Lubricant Blending Issues: Avoiding Problems8.1 Introduction8.2 Sampling Before Blending8.3 Blend Families and Cross Contamination8.4 Temperature Control8.5 Times for Blending8.6 Sampling Blended Lubricants8.7 Slop Oil8.8 Packages, Labels and Labelling8.9 Health, Safety and the Environment8.10 Forklift Trucks8.11 Minimising Operating Expenses8.11 Equipment Maintenance8.12 Cyber-Security8.13 Summary9 Testing and Analysis of Base Oils and Additives in BlendingPlants9.1 Introduction9.2 Tests for Base Oils9.2.1 Colour9.2.2 Boiling Range9.2.3 Density9.2.4 Kinematic Viscosity9.2.5 Viscosity Index9.2.6 Low Temperature Viscosity9.2.7 Pour Point9.2.8 Flash Point9.2.9 Volatility9.2.10 Foaming Properties9.2.11 Demulsibility9.2.12 Acid Number9.2.13 Carbon Residue9.2.14 Water Content9.2.15 Sulphur, Nitrogen and Phosphorous Contents9.2.16 Metals Contents9.2.17 Hydrocarbon Type Analysis9.3 Tests for Additives9.3.1 Metals and Non-Metals Contents9.3.2 Sulphated Ash9.3.3 Infra-Red Spectroscopy9.4 Specifications for Raw Materials9.5 Summary10 Testing and Analysis of Blended Lubricants10.1 Introduction10.2 Laboratory Tests for Lubricants10.2.1 Oxidation Resistance10.2.2 Anti-Oxidant Content10.2.3 Thermal Stability10.2.4 Rust Protection10.2.5 Corrosion Resistance10.2.6 Shear Stability10.2.7 Anti-Wear and Extreme Pressure Tests10.2.8 Metals Contents10.3 Tests for Blending Plant Quality Control of Specific Types ofLubricants10.3.1 Automotive and Industrial Engine Oils10.3.2 Automotive and Industrial Gear Oils10.3.3 Automatic Transmission Fluids10.3.4 Hydraulic Oils10.3.5 Turbine Oils10.3.6 Compressor Oils10.3.7 Metalworking Fluids10.4 Processing and Communication of Test Results10.5 Summary11 Lubricant Product Quality Control11.1 Introduction11.2 Definition of Quality11.3 Meeting Customer Requirements and Quality Control11.4 Procedures for Control of Quality11.4.1 Checking Raw Materials11.4.2 Controlling Quality During Blending11.4.3 Testing Finished Products11.4.4 External Monitoring Systems11.4.5 Component and Formulation Codes11.4.6 Batch Numbering and Traceability11.4.7 Computerised Blend Records11.4.8 Blend Sample Storage and Retention11.5 Resolving Product Quality Problems11.6 Summary12 Lubricant Packaging and Filling12.1 Introduction12.2 Role and Attributes of Packaging12.3 Types of Lubricant Packaging12.3.1 Plastic Bottles12.3.2 Stand-Up Pouches12.3.3 Oil Drums12.3.4 10-Gallon Drums12.3.5 25 Litre (5-Gallon) Drums12.3.6 Grease Drums, Kegs, Pails and Cans12.3.7 Intermediate Bulk Containers (IBCs)12.3.8 Additional Packaging12.4 Reconditioning Drums and IBCs12.5 Recycling Plastic Packaging12.6 Labels for Lubricant Packages12.6.1 The Role of Labels on Packages12.6.2 The Globally Harmonised System (GHS)12.6.3 Types of Lubricant Package Labels12.6.4 Multi-Lingual and Multi-Purpose Labels12.7 Filling Lubricant Packages1 2.7.1 Bottle Filling12.7.2 Drum and IBC Filling12.7.3 Road Tanker, Rail Tank Wagon and ISOTainer Filling12.8 Summary13 Lubricant Storage13.1 Introduction13.2 Storage Vessels and Containers13.2.1 Bulk Storage in Tanks13.2.2 Drum Storage13.2.3 Storage in Intermediate Bulk Containers (IBCs)13.2.4 Plastic Bottles and Tinplate Cans13.3 Lubricant Storage13.3.1 Siting the Lubricants Store13.3.2 Indoor Storage13.3.3 Outdoor Storage13.3.4 Ingress of Moisture13.3.5 Storage of Special Types of Lubricant13.4 Blending Plant Warehouse13.5 Warehouse Management and Automation13.5.1 Warehouse Management Systems13.5.2 Advantages and Disadvantages of WMS13.5.3 WMS Operation13.5.4 Other WMS Functionality and Considerations13.5.5 Implementing WMS13.6 Summary14 Product Quality Management14.1 Introduction14.2 Background to True Total Quality14.3 Lean (Just-in-Time) Manufacturing14.4 Total Quality Management14.5 ISO 900014.6 Implementing TQM14.7 Mapping a TQM Strategy14.8 Supply Chain Management14.9 Enterprise Resource Planning14.10 Summary