Lube Product Development Process

Vn nh Sn Th Vin K thut Ha hc i hc Bch Khoa H Ni Tel 097.360.4372

Email : tho. vandinhson@hust.edu.vn; thovds@gmail.com Sites : https://sites.google.com/site/vandinhsontho/home
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Typical Commercial Lubricants

Gasoline Engine Oil Diesel Engine Oil Railway & Marine Engine Oil Automatic Transmission Fluid Aviation Engine Oil Jet Engine Oil Turbine Oil Gear oil Greases Compressor Oil Hydraulic Oil
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Technical + Marketing Needs

Establish Targets

New Product Development

Define Initial Formulation Bench-Scale Tests

Time Effort Commitment

Standard Engine Tests Additional Engine Tests

FIELD TESTS PRODUCT INTRODUCTION & MARKETING

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Lubricant Formulation
Base Stock + Additives

Product

Product formulations are designed to meet lubricant performance requirements for specific applications. Basis lubricant functions - Provide lubricating film - Prevent excessive wear - Adhesive - Abrasive - Corrosive Lubricant Users and producers determine product specifications based on operating factors Temperature Load Contaminants Chemical Restrictions
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Lubricant Bench Testing

Lab screening tests to predict performance characteristics: Oxidation resistance Wear Deposit control -- keep engine parts clean Dispersancy -- suspend combustion & oxidation by-products Bench test advantages: Inexpensive; quick Uses small samples Recognized/required by OEMs Bench test disadvantages: Unreliable correlation with engine tests Usually poor for comparing different chemistry. Recognized/required by OEMs

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Lubricant Formulation Definition

Identify base stocks and performance package combination: Base stocks selected for commercial reasons. Additive package from supplier or components to match desired level of performance and physical and chemical (P&C) inspections. Bench study to confirm viscometrics and P&Cs:

Oil Volatility.
Metals content. Foaming. Elastomer Compatibility. Total base & acid numbers (TBN & TAN). Sulfated ash.

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Gasoline Engine Tests

Sequence IID
Engine: 5.7 liter Olds (V-8)

Sequence IIIE
Engine: 3.8 liter Buick (V-6)

Test Length: 32 hours Conditions: Low Speed & Temp Parameters Engine Rust Rated:

Test Length: 64 hours Conditions: High Speed & Temp Parameters Viscosity Increase Rated: (Oxidation) Engine Deposits Cam & lifter Wear
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Standard Engine Testing

Industry tests to define product performance: Engines running in controlled environment. Standard test fuels and running conditions. Highly severe to accelerate oil degradation.

Engine test advantages: Standard test methods. Reference oils to track severity trends.
Engine test disadvantages: Very expensive. Large severity shifts; many variables

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Gasoline Engine Tests (cont d)

Sequence VI
Engine: 3.8 liter Buick (V-6)

Caterpillar 1H2 & 1G2

Engine: 2.2 liter Single SC Cylinder Diesel Test Length: 480 hours Conditions: High Load & Temp Parameters Ring Groove Fill Rated: Piston Deposits

Test Length: 65 hours Conditions: Low load; High & Temp Parameters Fuel Consumption Rated: versus Reference Oil

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Gasoline Engine Tests (cont d)

Sequence VE
Engine: 2.3 liter Ford (4cyl) Engine:

CRC L-38
0.69 liter Labeco lab engine (1cyl) Test Length: 40 hours Conditions: Parameters Rated: High Temp Cu/Pb Bearing Weight Loss Oil Shear Stability Piston Deposits

Test Length: 288 hours Conditions: Parameters Rated: Low Temp Cam & Follower wear Engine Deposits - Sludge - Varnish

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Diesel Engine Tests

Caterpillar 1K
Engine: Single TC Cylinder Diesel Test Length: 252 hours Conditions: Parameters Rated: High Load & Temp Ring Groove Fill Piston Deposits Oil Consumption Engine:

Mack T-7
10.9 liter EM6 Turbocharged (6cyl) Test Length: 40 hours Conditions: Low Speed; High Load Parameters Viscosity Increase Rated: due To Soot loading

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Field Tests & Product Introduction

Field testing provides

Performance documentation in vehicles. Additional information to market product.

Commercial product generates revenue for Mobil

Follow-up: Monitor performance in field. Modify products to meet new performance requirements.

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Summary

Lubricant product development

Long, expensive process. Must address technical requirements. Gasoline engine oil trends - Reduced phosphorus content. - Enhanced fuel economy. - Lower oil consumption. - Environmentally acceptable products. Diesel engine oil trends: - Improved soot dispersant. - Better wear protection. - Reduced oil consumption. - Alternate fuels.
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Product requirements constantly change

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Engine Test Costs

Gasoline
CRC L-38 $5,200

Diesel
Cat 1K 14,800 Mack T-6 52,200 Mack T-7 11,700 Cummins NTC-400 44,700 Detroit Diesel 6V-53T 43,200

Sequence IID Sequence IIE Sequence VE Cat 1H2 Sequence VI

9,500 13,000 17,500 15,000 9,600

Test Cost For:

API SG API SG/EC-II
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Test Cost For:

60,200 69,800 API CF-4 API CF-4/SG API CF-4/CD-II/SG 128,600 183,600 226,800
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Additional Engine Testing

Supplemental tests to demonstrate superior performance. Enhance marketability of premium products. Common practices: Extend length of standard tests. Run special test methods.

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API Performance Categories since 1970

Established by Tripartite of Organizations SAE (Society of Automotive Engineers) determines the need for new performance standard. ASTM (American Society of Testing & Materials) defines test methods and acceptable performance criteria. API (American Petroleum Institute) develops consumer language and grants product licenses. GASOLINE ENGINE CATERGORIES (Prefix S stands for Service Station) : SA unadditized oil; pre- 1930s SB minimum protection SC designed for 1964 car engines; better wear & deposit control SD ungraded sludge and corrosion protection; 1968 SE improved oxidation control for 1972 engines SF better low temperature sludge & wear protection; 1980 SG improved sludge, wear and deposit control for 1989 engines . SJ now 1996 DIESEL ENGINE CATAGORIES (Prefix C stands for Commercial) CA..CB.CCCD CE modern high performance diesel engine; 1984 CF-4 lower oil consumption, 1990 . CH-4 introduced in 1998 for 4-stroke engines

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API Oil Quality Symbol & Classification

MULTI-GRADE

80-100 VI

115-135 VI VI Improver

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ADDITIVES
What are they? What do they do?

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LUBRICANT ADDITIVES

Chemical Compounds Which are Added to Lube Oil Stocks to Improve Their Performance Properties Supplement or Reinforce Well-Refined, High-Quality Base Stocks No Substitute for Base Oil Quality or Adequate Refining

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LUBRICANT ADDITIVES
Found in a Majority of Lubricants Lubricants Contain 0 to >5 different Additives Concentration are <1 to 20-30% Determining Factors: - Type of Lubricant - Type of Additive

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TYPE OF ADDITIVES
Anti-oxidants Anti-corrosion Agents Detergents Dispersants EP-Antiwear Agents Rust Preventives Anti-squawk Agents Seal Swell Agents Pour Point Depressants Anti-stain Agents Metal Deactivators Emulsifiers Demulsifiers Bactericides VI Improvers Foam Inhibitors Friction Modifiers Anti-chatter

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FACTORS IN OXIDATION

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HOW OXIDATION INHIBITORS WORK

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LUBE OXIDATION INHIBITORS

Sulfur Compounds
Sulfurized Terpense Aromatic Sulfides Sulfurized Olefin Sulfurized Esters Du Pont ST 35 Dibenzyl Disulfide Cracked Wax Sperm Oil

Phosphorus Compounds
Phosphites Santolube 31 (Tri t-Amylphenyl) Phosphates P2S5 + -Pinene P2S5 + Oleyl Alcohol Santolube 394C Santolube 365

Sulfur Phosphorus Compounds

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TYPES OF LUBE OXIDATION INHIBITORS

Metal-Sulfur-Phosphorus Compounds
Zinc Dithiophosphates Santolube 393, 493 Lubrizol 1060, 1360 Oronite 260

Amines
Phenyl Alpha-Naphthylamine Phenyl Beta-Naphthylamine Di-t-Butyl-p-Cresol (DBPC) 2,6-Di-t-Butylphenol (BTBP) PAN PBN Paranol 441 Ethyl 702

Phenols

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DETERGENCY- DISPERSANCY
Detergency Cleaning Action Detergency = Preventing Deposition of Dirt

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MECHANISM OF LACQUER FORMATION

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TYPES OF DETERGENTS

Metallic
- Sulfonates - Phenates - Phosphonates

Non-Metallic (Ashless) - Succinimides Neutral (Normal)

- Contains Stoichiometric Amount of Metal

Basic
- Contains Excess Metal

Overbased (Highly Basic)

- Contains Large Excess of Metal

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ANTI-WEAR AND EXTREME PRESSURE ADDITIVES

1.

HYDRONAMIC (Fluid) Lubrication

Metal-to-Metal Contact Does Not Occur and a Thick Film of Oil is Always Present Between the Lubricated Surfaces. EP Additives Are Not Required.

2.

Boundary Lubrication
Intermetallic Contact at Asperities Occurs. EP Additives are Required and Function by Forming an Adherent Film of Metallic Salts Which Has a Lower Shear Strength Than That of the Metal Surfaces.

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WEAR SURFACE BOUNDARY LUBRICATION

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EXTREME PRESSURE (EP) ADDITIVES

Lead Soaps, Sulfurized Mineral Oil Lead Soaps, Chlorine and Sulfur Compounds, Fatty Oil Phosphorus and Sulfur Compounds, Fatty Oil Sulfur and Chlorine Compounds Sulfur, Chlorine and Phosphorus Compounds Zinc, Sulfur, Phosphorus and Chlorine Compounds

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EXTREME PRESSURE ADDITIVES

Gear Oil Additives

Santopoid S Chlorokerosene Isopropyl Sulfurized Fat (S) Santolube 393 (S, P, Zn)

Industrial Gear Oil Additives

Dibenzyl Disulfide (S) Diphenyl Cresyl Phosphate (P) Oleyl Acid Phosphate (P) Oleic Acid

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ADVANTAGES OF HIGH VISCOSITY INDEX

Low Temperature - Reduce Viscous Drag - Improve Pumpability High Temperature - Reduce Lubricant Consumption - Reduce Wear

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VISCOSITY INDEX IMPROVERS

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MECHANISM OF RUST & CORROSION INHIBITORS

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RUST PREVENTIVE ADDITIVES

Esters
- Dioleyl Malate (DOM) - Octyl Oleyl Malate (OOM)

Nitrogen Compounds
- Long Chain Amines - Long Chain Amides

Phosphorus Compounds Esters of Phosphorus Acids

- Oleyl Phosphoric Acid (RT 28 A) - Amylphenyl Phosphoric Acid (RT 53 A)

Metal Salts
- Aluminum Stearate - Zinc Salt of Primene Succinamic Acid (RT 276 A)

Carbonxylic Acids Alkenyl Succinic Acids

- Primene Succinamic Acid (RT 175)
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POUR POINT DEPRESSANTS

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OILINESS AGENTS

Oiliness Agents Function is to Decrease Friction Form Oriented, Close-Packed, Physically Adsorbed Films at the Oil-Metal Interface Oiliness Agents are Polar Compounds Which Adsorb on Metal Surfaces to Form a Boundary Film Extreme Pressure Agents Function is to Increase Load Carrying Capacity React Chemically with Metals Form Compounds that Prevent Wear and Seizure at the Sliding Interface

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EXAMPLES OF OILINESS AGENTS

Fatty Acids - Oleic Acid - Stearic Acid Oxidized Paraffin Waxes - Sperm Oil Ester of Fatty Acids - Butyl Stearate Chlorinate Fatty Acids Fatty Alcohols, Amines and Nitriles

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FOAMING

Causes problems in Engine Crankcases, Hydraulic Systems, etc.

Factors in Foaming Viscosity Water Foreign Matter Other Additives Defoamants are Generally Silicone Polymers DCF 200, SAG 47

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LUBRICANT ADDITIVES
Type
Oxidation Inhibitors

Reason for Use

Retard Oxidation of Oil Limit Viscosity Increase Prevent Formation of Sludge

How they work

Inhibit Radical Formation Decompose Peroxides Passivate Metal Surfaces Dispersing Ability

Examples
Phenols Zinc Dithiophosphate Amines Metallic Sulfonates and Phenates Nonmetallic Zinc Dithiophosphates Sulfur, Chlorine, Phosphorus Compounds Polymethacrylates Polyisobutylenes

Detergent-

Keep Sludges Suspended

Dispersant

and Surfaces Clean

Neutralization Action

Extreme Pressure

Prevent Surface Distress

React with Metal Surface

VI Improvers

Reduce Rate of Change of Viscosity with Temperature

Uncoiling of Molecules Prevent Thinning at Higher Temperature

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LUBRICANT ADDITIVES
Type
Antitrust

Reason for Use

Prevent Rusting in Areas Under the Oil

How they work

Polar Compounds Adsorbed on Metal Surfaces

Examples
Nitrogen Compounds Soaps Acids and Esters Wax naphthalene Polymethacrylates

Pour Depressant

Lower the Pour Point

Prevent Wax Crystal Network-Decrease Size of Wax Crystals Adsorbed on Metal Surface

Oiliness Agent Antifoamants

Decrease Friction

Soaps Fatty Acids Silicones

Decrease Foam

Promote Formation of Quick-Breaking Large Bubbles

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Fundamentals of Additives
Additives are blended to critically enhance lubricant performance. Finished lube contains typically 10% additives while lube base stock as a carrier base. Automotive and Marine are the largest market for additives which extend performance and lubricant life. Lubricants are classified by performance and physical & chemical characteristics. Current rating are API SJ (gasoline) and CH-4 (diesel). In parts of Asia, specifically Vietnam, grades as low as SE and CD prevail. Main additive suppliers are Lubrizol, Oronite (ChevronTexaco), Infineum (ExxonMobil & Shell) and Ethyl Corp, which are all present throughout Asia.

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BASE STOCK SHEET

TEST SIGNIFICANCE
-

Viscosity Most Important Measure of Oil Thickness SUS: Saybolt Universal Second cSt : Metric Measurement, Centistokes Viscosity Index Measurement of Oil Sensitivity to Viscosity Change with Temp. Low VI means rapid Viscosity Decrease with Increasing Temp. can be adjusted with Additives Neutralization No. Measurement of Acidity of Base Oil. Generally want Low Acidity CCR Conradson Carbon Residue is a measure of Carbon Residue after Pyrolysis Aniline Point Measurement of Aromatic Level Toluene/Furfural Measures Level of Process Solvents
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SYNTHETIC LUBRICANTS

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Synthetic Lubricants: Fundamental

Synthetics developed for long life and performance under extreme conditions (either very high or very low temperature). Synthetics are very high purity with specific properties and are typical Very High VI with light to medium viscosity. Low demand where oil is expensive, but high demand in some Asias auto markets.

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Synthetic Lubricants
Synthesized Hydrocarbons
- Poly Alpha Olefins (PAOs)* - Alkylated Naphthalenes - Alkylated Benzenes

Organic Esters*

- Dibasic Acid Esters - Polyol Esters

Glycols

- Poly Alkylene Glycol (PAG)*

- Ethylene Oxide - Propylene Oxide

Other Types

- Phosphate Esters*
- Silicate Esters - Silicones - Halogenated Hydrocarbons - Blends ( with Mineral Oils)

* Used in more than 90% of Commercial Synthetic Oil

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Synthetic Lubricants
Typical Properties of Synthetic vs Mineral Oil Lubricants
Poly Alpha Olefins Mineral Oil

Grade Viscosity (Poises) 00F - 300F Viscosity Increase(%) 40 hours, 2100F

10W/50
25 100 10

10W/50
25 300 50

Improved Flow at Low Temperature Improved Oxidation Stability

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Synthetic Lubricants
Relative Properties of Lubricants
Mineral Oil

PAO G G E G E G/E

Alkylated Polyalkylene Esters Naphthalene Glycols

Viscosity Index Pour point Volatility Oxidation Resistance* Hydrolytic Stability Compatibility
(with Oil & Additives)

F P F F G G

G G E G/E F F/G

F G G E E E

G G G F G P/F

P Poor F Fair
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G Good E Excellent

* with Inhibitors

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Properties of Synthetic Lube Stocks

PAO Specific Gravity @15.60C KV @ 1000C, cSt @ 400C, cSt Viscosity Index Pour Point, 0C Flash Point (open cup), 0C Acid No, mg KOH/g Color ASTM
(1) (2)

Alkylated (1) Naphthalene 0.908 4.7 29 74 -39 222 <0.05 <0.5

ESTER (2) 0.915 5.3 27 133 -57 240 <0.05 <0.5

0.824 5.1 25 138 -57 240 <0.05 <0.5

Mostly Mono Alkylated Naphthalene (Di Alkylated Napthalene has 107 VI, 12.4 cSt KV@1000C) Adipate Ester

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Synthetic Lubricants vs. Mineral Oils

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Performance Benefits over Mineral Oils

Energy Conservation Longer Service Life Greater Flexibility-Design Increased Productivity Lower Maintenance Cost

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Polyalphaolefins by Oligomerization
1-Decene ( C10=) BF3-Propanol or AlCl3

Oligomerization Reaction: C10=C20= + C30= + C40= + C50=

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Esterification of Poly or Dibasic Acid

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Polyalkylene glycols

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Phosphate Esters

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Formulation of Synthetic Lubricants

Composition - PAO (Group IV)

- AN or Ester (Group V) - Additive Package

70-80% 5-10% Balance

Requirement of AN or Ester in PAO Blend:

- Improved Additive Solubility - Improved Deposit Control - Seal Compatibility

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Application of Synthetic Lubricants

PRINCIPLE APPLICATION

SYNTHETIC STOCKS Polyalpha Olefins (PAO) Alkylated Naphthalene (AN) Dibasic Esters Polyol Esters

Automotive & Industrial

Automotive & Aircraft

Industrial

Polyalkylene Glycols Phosphate Esters

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Commercial Polyalphaolefins (PAO)

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Commercial Polyalphaolefins (PAO)

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Commercial Alkylated Naphthalenes (AN)

US Patents 5,177,284 1993 5,602,086 1997 5,629,463 1997

MONO-C16 NAPHTHALENE

DI-C16

NAPHTHALENE

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Naphthalene Alkylation Reaction Pathway

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Oxidation Stability of PAO/AN Blend

RBOT OXIDATION, Minutes

400 300 200 100 0 0 25 50 75 100 Base Stock 0.25 wt% DTBP

wt% AN in PAO
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Molecular Structure Effect on Synthetic Lube Qualities

Alkylated Naphthalene:Hydrotreating Effect

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PETROLEUM WAX

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Petroleum Wax Manufacture

VACUUM DISTILATTION

NEUTRAL DISTILLATES
1 2
FURFURAL SOLVENT EXTRACTION

WAXY RAFFINATES
MEK SOLVENT DEWAXING

DEWAXED OILS
CLAY OR HYDROGEN FINISHING

LUBE BASE STOCKS LN

1

1 2

1 2

LN
2

ATMOS. RESID

FURFURAL
EXTRACT

HN
3 3 3

4 SLACK WAX Or PETROLATUM

BS

Propane De asphalt

DE-ASPHALTED OIL

Deoiled Paraffin Wax

ASPHALTS

MEK Double De-Oiling

Wax Hydrogen Finishing

FOOD GRADE FULLY REFINED WAXES

VACUMM RESID. Deoiled Microwax

DECOLORIZE DEODORIZE

* Tanks Represent Different Viscosity Grades

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Petroleum Wax Definition

PARAFFIN WAX (LN)

Excluded Oil 0.5% Oil Content Maximum 3.2-5.1 cSt @ 1000C 1.0-1.5% Oil Content 5.4-6.8 cSt @ 1000C Readily hold Oil 5% Maximum 14.2-17.5 cSt @ 1000C Substantial Oil Content
(10-30%)

INTERMEDIATE WAX (HN)

MICROCYSTALLINE WAX (BS)

PETROLATUM (BS)

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Petroleum Wax Properties

PARAFFIN WAX
Solid at room temperature Thermoplastic Friable Brittle White to off-white Sharp Melting Point Excellent Barrier for Water, Moisture, Gases Transparent in thin film Dry, non-tacky Inert Low Viscosity (molten) Bland, non-toxic Biodegradable

MICROCRYSTALLINE WAX
Solid at room temperature Thermoplastic Plastic Flexible Yellow to tan Melting over temperature range Excellent Barrier Transparant in thin film Adhesive and tacky Inert Low viscosity (molten) Bland, non-toxic Biodegradable

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Wax Composition
PARAFFIN WAX Melting Point, 0C normal-Paraffin,% Iso-Paraffin,% Monocyclo paraffin,% Polycyclo paraffin,% Aromatic,% Average Carbon no. 53 94.0 2.6 3.4 --24 60 81.9 10.4 7.4 0.3 --30 MICROWAX 80 0-15 15-30 30-35 35-40 --50

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Petroleum Wax Application

Ceramics: Wax emulsion to improve clay Corrugated Board: Water-resistant wax for coating papers Electronics: Special wax for moisture-proof sealing Wood Products: Wax emulsion for wood products Inks: Wax additive for printing inks Packaging: Microwax laminants and hot melt coating of foods Paper Manufacture: wax emulsion for paper sizing, moisture Rubber: Wax for protection of sun checking and tackiness Others: Candles, polishes, dental molding, crayons, cosmetics

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Vietnam Lubricants Overview

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The Market of Vietnam Lubricants

Lubricant Demand Forecast in Vietnam
300000 250000

Metric Ton/yr

200000 150000 100000 50000 0 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010

Year
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Vietnam Lubricant Scenarios

Total lubricant demand in Vietnam is around 160,000 ton in 2003. Principle lube base stock requirement is Group I, imported from Singapore, Thailand, Taiwan and Korea. Anticipated annual growth is between 6-8%. Majority of lubricant consumption has low quality. 90% total demand is from domestic blending and the remaining is imported. Major demand is for Automotive application (70%). Southern Vietnam accounts for 2/3 of total lubricant consumption. Vietnamese companies controls about 45% of total market. International companies has strong position on industrial oil segment.

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Vietnam Specifications for Engine Oil

Minimum Requirement for API SC/CB

Viscosity at 1000C VI Total Base no, mg KOH/g Flash Point, 0C Foaming Tendency, ml Metals, wt% Water, wt%

According to SAE 95 2.4 180 30 0.1 0.03

(ASTM D-445) (ASTM D-2270) (ASTM D-2896) (ASTM D-92) (ASTM D-892-74) (ASTM D-4628-86) (ASTM D-95-83)

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Lube Base Stock Production from Bach Ho Crude

3700C-

NOTE: PetroVietnam Study in 1998 25.0 %

Bach Ho Crude

370-4500C

32.4 %
450-5500C 2

150 SN (13.1 %) Furfural Extraction

2 MEK Dewaxing

450 SN (6.1%) 150 BS (1.9%)

Atmost. Resid

22.6 %
5500C+ 3

Vacuum Resid

19.9 %

EXTRACT 9.4%

WAX 25.5%

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Properties of Lube Base Stocks from Bach Ho

FRACTION FURFURAL RAFFINATE KV @ 400C, cSt KV @1000C, cSt S, ppm N, ppm Saturate, wt% Aromatics- 1 Ring, wt% Aromatics- 2+Ring, wt% 370-4500C 11.36 3.17 370 3 92.9 5.2 2.0 450-5500C 38.24 7.0 483 45 91.6 6.9 1.5

DEWAXED OIL KV @400C, cSt KV @1000C, cSt VI Pour point, 0C ASTM Color
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150 LN 20.26 4.05 96 -9 1.5

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450 HN 86.17 10.0 95 -9 2.0

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Lube Base Stock Production from Bach Ho Crude

Bach Ho Distillates are very waxy Feasibility for the production of Group I lube oil base stocks (only LN and HN) by conventional solvent technology Lube yields are low due to waxy characteristics Lube Base Stocks contain very low S and N Potential for the production of Group III (XHVI with >140 VI) with high yield based on Wax Hydroisomerization Technology

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Possible Lube Production from Dung Quat Refinery

Propylene RFCC Gas Plant LPG Treating Unit (LTU) Propylene Recovery Unit (PRU)

LPG

Crude Distillation Unit (CDU)

Naphtha Hydrotreating Unit (NHT)

Catalytic Reforming Unit (CCR)

Unleaded Gasoline
Kerosene

CRUDE OILS

Kerosene Treating Unit (KTU)

Jet Fuel Auto Diesel

Industrial Diesel
Residue Fluid Catalytic Cracking Unit (RFCC) RFCC Naphtha Treating Unit (NTU)

Fuel Oil

Vacuum Tower

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MEK DEWAXING Unit

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Recycle of Used Lubricants

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Global Views of Used Lubricants

Stronger effort in other countries to re-refining used lubricants to produce new lube base stocks 20-60% Re-refining effort in Canada, France, England, Italy, India Only 10% Re-refining in the United States (90% used lubricants as low-quality fuels): - Demand of 2.4 billion gallons of lubricants in 2002
- Generation of 1.4 billion gallons for used lubricants (50%) - Recovery of 1.0 billion gallons of used lubricants (70%) - Re-refining of 100 million gallons to produce 60-70 million gallons of lube base stocks

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Vietnam Used Lubricants

Potential of 110,000 ton/yr Used Lubricants in 2003 (assuming 70% of 160,000 T/yr of total demand) Recovery of approximately 50% (55,000 ton/yr) used lubricants although no available statistics

Current use of used lubricants in Vietnam: - Simple Re-refining in very small scale by individuals to produce low quality new lubricants, selling to boat engines, agriculture engines, small industrial engines - Lubricant for duc be tong, duc ngoi - Fuels for manufacture of ceramics, bricks, etc - Sold and export to Southern China

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Used Lubricants Issues

Barriers to Profitable Used Oil Refining

High Capital Costs High Operating Costs Environmental Treatment Problems Large Collection Costs Hydrotreating Oil

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Composition of Used Lubricants

Lube oil base stocks Additives Soluble and In-soluble Contaminants: - Water - Other hydrocarbons (fuels) - Oxidized products - Acid products - Sludges - Heavy metals, nitrogen, chlorines - Particulates such as Dirts and other solids

CHALLENGE ---- REMOVAL OF 1. ADDITIVES 2. CONTAMINANTS

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Options for Used Lubricants

Recycling by Re-refining to new lube base stocks (usually Neutral stocks) Burning as fuels Road oiling to suppress dirts in gravel roads Cutting stock for asphalt production (some)

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Used Lubricants Re-Refining Technology

Conventional Acid/Clay Treatment & Distillation Solvent Extraction Technology & Distillation Hydroprocessing (HDT) & Distillation Combination of Several Processes

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Conventional Acid/Clay Treatment

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KTI Process-Conventional Hydroprocessing

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PROP Technology- Complex Process

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IFP Selecto-Propane Technology

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Typical Hydroprocessing Process for Used Lubricants

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INTERLINE PROCESS Based on Propane Extraction Technology

Water, vol % Fuel, vol % Lube Base Oil, vol % Asphalt Flux, vol %

5% 3% 74% 18%

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Performance of Interline Process Technology

1. Used Oil 2. First Phase Oil (after contaminants have been removed via the Interline Process) 3. Residue/Residuum 4. Light Neutral Base Oil (directly from the distillation column without a finishing step) 5. Light Neutral Base Oil (following clay polishing) 6. Heavy Neutral Base Oil (directly from the distillation column without a finishing step) 7. Asphalt Flux/Modifier (Residuum mixed with Tower Bottoms)
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Interline Commercial Plants

SALT LAKE CITY UNITED STATES 1995 27,000 T/yr 24,000 gallon/day SEOUL, KOREA 1997 27,000 T/yr ENGLAND 1996 27,000 T/yr

Others: AUSTRALIA (1997, 27,000 T/Yr SPAIN (2000, 27,000 T/yr)

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EVERGREEN Oil Re-Refining Facility (800 b/d) in Newark, CA

Pre-Treatment Water and Light Fraction Removal Fuel Oil Fraction Removal Separation of Lube by Distillation Conversion of Lube Distillate through Hydrotreatment to Base Stock Splitting of Base Stock into Desired Cuts through Fractionation

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Recommendations

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