Short Paper Int. J. on Recent Trends in Engineering and Technology, Vol. 7, No.

3, July 2012

Lubrication Oil Replacement Technology

Rahul Tiwari, Manoj Khatana
Army Institute of Technology, Mechanical, Pune, Maharashtra, India Email: Rahul.tiwari4123@gmail.com Army Institute of Technology, Mechanical, Pune, Maharashtra, India Email: manojkhatana@gmail.com
Abstract. The automobile is a complex integration of many electronics; mechan ical components and chemical compositions (lube oil). One of the most important chemical compositions is the lubrication oil of an automobile. I have tried to propose a cost effective Lube oil replacement unit for passenger cars or heavy duty vehicles. The system will purify the lube oil inside the vehicle and increase the durability of mechanical components. I had experimentally analyzed what are the measures to purify the lube oil inside the vehicle for saving the natural resources. Keywords: contaminated lubrication oil, servo 4T (fresh oil).

I. INTRODUCTION Lubricating oils from petroleum consists essentially of complex mixtures of hydrocarbon molecules. They are mostly composed of isoalkanes having slightly longer Branches and the monocycloalkanes and monoaromatics which have several short branches on the ring. These hydrocarbon molecules generally range From low viscosity oils having molecular weights as low as 250, up to very viscous lubricants with molecular Weight as high as 1000 . The carbon Atoms range from 20 to 34. Lubricating oils are viscous liquid and are used for lubricating moving parts of engines and machines. Grease, which is a semi-solid, also belongs to this group. There are three major classes of lubricating oils, namely: lubricating greases, automotive oils and industrial lubricating oil. When lubricating oils are used in service, they help to protect rubbing surfaces and promote easier motion of connected parts. In the process, they serve as a medium to remove high build up of temperature on the moving surfaces. Further build up of temperature degrade the lubricating oils, thus leading to reduction in properties such as: viscosity, specific gravity, etc. Dirts and metal Parts worn out from the surfaces are deposited into the lubricating oils. With increased time of usage, the lubricating oil loses its lubricating properties as a result of over-reduction of desired properties, and thus must be evacuated and a fresh one replaced. With the large amount of engine oils used, the disposal of lubricating oils has now become a major problem. Many nations are now addressing the problem of environmental pollution posed by waste or used lubricating oils in their countries. For example, about 2 billion gallons of oils are generated annually. This has led industries and governments for find satisfactory solutions that will reduce the contribution of used lubrication oil to pollution and also recover these valuable hydrocarbon resources. In disposing used oil, many people use it as a dust cure; that is, for dust prevention. This 2012 AMAE DOI: 01.IJRTET.7.3.29 8

method of disposal is in many ways unsatisfactory as the lead-bearing dust and run-off, constitute air and water pollution. Another method by which used oil is being disposed is by incineration. This method represents another poor use of such a valuable product, and the Attendant emission of probably carcinogen us products, contribute to environmental pollution. Recycling of used lubricants is now attracting more attention than before. This is partly because of the fear of dwindling of world oil reserves and more as a result of the environment concern which it posses. The following three distinctive reasons explain The interest in the re-cycling of waste lubricating oils: A. The need to conserve crude reserves. B. Minimizing unemployment through the building/construction of used lubricating oil recycling plants. C. The elimination of environmental pollution. II. THE DESCRIPTION The recycling of used lubricants has been practiced to various degrees since the 1930s and particularly during the Second World War when the scarcity of adequate supplies of crude oil during the conflict encouraged the reuse of all types of materials including lubricants. Environmental considerations regarding the conservation of resources have maintained interest in the Concept of recycling up to the present day. The reclamation of spent crankcase oils is now a subject of pressing national interest in some countries. On the other hand, pollution by used lubrication oils is recognized now to account for greater pollution than all oil spills at sea and offshore put together. Some countries have petroleum storage and spent oils represent a precious commodity, which must not be wasted. It was because of this, the conservation of petroleum resources has been declared national policy for several countries and the benefit of wise resource management are obvious. Recent impetus on waste recovery leads to renewed interest in re-distilling to convert this used lubricating oil into useful original lubricating oils. Re-distilling or re-fining is the use of distilling or refining processes on used lubrication oil to produce high quality base stock for lubricants or other petroleum products. The use of this method has increased tremendously in the developed countries, in some countries reaching up to 50% of the countries need for lubricating oil and there are different methods developed by different countries in the western countries, on how to refine used lubricating oil for reuse. The basic principle remains the same and utilizes many of the

Short Paper Int. J. on Recent Trends in Engineering and Technology, Vol. 7, No. 3, July 2012 following basic steps: Removal of water and solid particles by settling. Sulphuric acid treatment to remove gums, greases, etc. Alkaline treatment to neutralize acid. Water washing to remove soap. Clay contacting to bleach the oil and absorb impurities. Striping to drive off moisture and volatile oils. Filtering to remove clay and other solids. Blending to specification. The objective of this research is cantered mostly on obtaining a high quality production of lubricating oil from used lubricating oil by the re-refining of used lubricating oil, thereby reducing environmental pollution and also minimizing importation of lubrication oil. A. Oxidation Oxygen will chemically combine with lubrication oil and its additives to create a variety of oxygenated by-products. Oxidation raises oil acidity, viscosity, and surface deposits, all of which can shorten bearing life. An open container of oil exposed to atmosphere will absorb about 10% Oxygen. Oil additives are usually the first to be impacted by oxidation followed by the base stock. The rate at which oxidation occurs in lubricating oils is primarily dependent on the oil, temperature, moisture content, and lubrication environment. Operating temperature has a tremendous impact on oil oxidation. For every 10oC (18oF) rise the rate of oxidation doubles. Oil operating at 50oC will last 30 times longer that oil operating at 100oC. The presence of oxidation inhibitors will slow the process. However, these will eventually be consumed and the oxidation will continue unabated. B. Moisture Moisture becomes entrained in the oil either directly through contact with frees water or through absorbs ion. Water molecules are polar, that is to say they have positive and negatively charged particles that are readily available for bonding with other molecules. Many of the additives and particulates in lubrication oil are polar as well. Water molecules are attracted, and become attached to these available polar molecules. The amount of moisture that oil can absorb is dependent on the amount of additives, as well as temperature and pressure. Once moisture has attached itself to all of the available polar molecules, the oil can be said to be saturated. Beyond this point water will start to collect as condensation of free water in the bottom of the sump. Free water may enter the sump from leaking heat exchangers, steam from adjacent quench connections, wash downs, and condensation within the bearing housing during temperature cycles Moisture in any form accelerates oxidation. It reacts with and promotes the breakdown of oil additives, and also forms acids. It promotes the localized fatigue of bearing surfaces, and the oxidation of unprotected metal surfaces within the bearing frame, both of which add to the particulate load within the oil. 2012 AMAE DOI: 01.IJRTET.7.3.29 9 Figure two shows the life extension that can be achieved by reducing moisture content. For example, oil with 500 ppm moisture content would experience a 3x life increase if the moisture content were reduced to 65ppm. C. Particulates Particulates not only damage the bearings directly, but indirectly as well. Many particulate molecules are also polar and therefore increase the moisture load carrying capability of the oil. In addition Iron and Copper act as catalysts and react with the oil to form acids.The amount of direct damage that particulates have on the actual bearing surfaces is dependent on the particulate concentration, hardness, size and shape. On the Mohss hardness scale, tool steel is 7.0; unfortunately, dirt, dust, and grinding abrasives, to name a few common contaminants, all have Alumina and Silica with a hardness of 7-9 Mohs. These particles have sharp irregular shapes making them especially abrasive and are often small enough to enter the clearance areas of the bearings. If all is equal in terms of the types of solid contaminants present, then bearing life is certainly dependent on the quantity of solids. This makes particulate counts an acceptable indicator when conducting oil analysis. Mainly the reason for black color is carbon particles. As it is used in engine the following particles may also get mixed with lubrication oil Carbon monoxide Sulphur dioxide Particles of clutch pad Some dust particles present in air while in running condition

D. Oil Chemistry Petroleum products are essentially composed of hydrocarbons, i.e. compounds containing exclusively carbon and hydrogen. The simplest hydrocarbon molecule is methane, CH4. This basic molecule is the main constituent of natural gas. It can be extended with the Addition of more carbon and hydrogen atoms, usually forming into longer chains. Four Carbon atoms in chain forms butane, one of the main constituents of LPG. The atoms may Also form side chains off the main chain, or form into ring structures such as the benzene Ring. Lubricating oils are just extensions of these basic hydrocarbon structures, containing From 20 to 70 carbon atoms per molecule, often in an extremely complex arrangement of Straight chains, side chains and five and six member ring structures. III. COLLECTION OF TEST SAMPLE The test sample of used oils (premium motor oil SAE 40) and (quartz 2000 SAE-40) were collected from oil service station. The used lubrication oil was collected from used oil dumps of car machine. A. Experimental setup for removal of dust particles and water The procedure for the purification of lubrication oil consists of filtration of oil before subjecting to treatment using:

Short Paper Int. J. on Recent Trends in Engineering and Technology, Vol. 7, No. 3, July 2012 acids/clay, distillation/clay, and acid and activated charcoal/ clay treatment methods. The used lubricating oil was filtered to remove impurities such as metal chips, sand, dust particles, micro impurities that are contained in lube base oil. This was done using funnel with a filter paper placed in it, then vacuum pump is connected to filtering flask to which funnel was fixed with the aid of rubber stopper. 2 Litre of used oil were filtered for the two samples collected respectively. For the acid method, the used lubricating oil was stirred thoroughly to promote homogeneity from the stock 450 ml was measured out and transferred to the beaker and 150 ml of gasoline was measured and added to the oil. The lube base oil mixture was transferred to the bucker of the centrifuge and centrifuged at 1500 rpm for minutes. It was then left to settle for another 10 minutes before decanting into a beaker. The decanting liquid mixture was distilled; to remove water, gasoline and any other liquid that may be present. The content in the flask was cooled and treated with 10 ml of concentrated sulphuric acid in a separating funnel with the mixture strongly agitated. It was the allowed to settle for 48 hr after which two layers were formed. The sludge was removed from the bottom of the separating funnel. B. The Basic Steps Performed For Filteration Of Lube Oil The lubricating oils used by vehicle engines have to be replaced at least every 20 000 km. This oil used to be dumped, but now most of it is re-refined and reused. This is done in a Three step process, in which water, solids, lighter oils, dissolved metals, degraded additives Etc. is removed. Step 1 - Dehydration The oil is boiled in a closed container to remove the water that has been mixed into it. Step 2 - Diesel stripping The dehydrated oil is then fed continuously into a vacuum distillation plant for Fractionation. Lighter oils boil off first and are removed, followed by the lubricating oil Itself. Other heavier components do not boil in the conditions used. Step 3 - Lube oil distillation and condensation A liquid extraction process then removes any aromatic components from the oil. By this stage, the oil is identical to refined virgin oil. It is then tested, appropriate Additives are added and the oil is ready to be reused. IV. HEAT TEST The contaminated oil starts boiling at 100 degree celcious , means there is some amount of water present in contaminated oil but if apply same test for 4T servo oil the test gets fails because there is no boiling in case of better quality oil.
T ABLE. I Figure 1. This figure shows how kinematic viscosity decreases with temperatu re

V. CONCLUSION There is 5ml of water in 50ml of contaminated oil Means Contaminated oil of 1litre contains 259.25 ml of water. A. Determination of the Viscosity of lubes Oil As per my consideration change in viscosity can be the early indication of contamination and degradation of oil. The viscosity of a hydrocarbon can be expressed as the number of seconds taken for the Collection of 50ml. of the liquid when flowing under standard conditions through a jet of Standard dimensions. The equipment specified is the Redwood Viscometer.
TABLE II. EFFECT OF TEMPERATURE O N VISCOSITY

Diameter of cylinder:- 47.625 mm Height of cylinder:- 88.5 mm Diameter of orifice:- 1.2 mm Length of orifice:- 12 mm Kinematic viscosity, V= (At-B)/t Where A= 0.0026 B= 1.176 V1= 1.029 stokes V2= 0.530 stokes V3= 0.409 stokes V4= 0.283 stokes VISCOSITY Vs TEMPERATURE X AXIS TEMPERATURE Y- AXIS VISCOSITY

VI. CHLORINE WATER TEST As per this test I had taken about 20ml of chlorine water and 200ml of used lubrication oil. Material required: 2012 AMAE DOI: 01.IJRTET.7.3. 29 10

Short Paper Int. J. on Recent Trends in Engineering and Technology, Vol. 7, No. 3, July 2012 Chlorine water: - 20ml Used lube oil: - 200ml Thermometer of 350 degree celcious Filter paper: - 5 pieces Mix the chlorine water with used lube oil and wait for 20 minutes ,after 20 minutes the chlorine water get settle down this show the density difference between the oil and chlorine water after this put this mixture on heating equipment and heat until the temperature reaches to 110 degree celcious at this temperature following observation were recorded: As we can see in this experiment the chlorine water has lower boiling point then lube oil, at 100C it tries to escape out of the container with carbon dioxide present in lube oil.
TABLE III. EFFECT OF TEMPERATURE ON CHLORINE

VIII. CONCLUSION In the above paper I had purified the contaminated lubrication oil upto 90% of its original quality. IX. FUTURE WORK I am in process to make retrofit unit for automobiles which will extract the contaminated oil form the vehicle and recycle it. REFRENCES
[1] [2] [3] [4] www.kleanoil.com/products/lubricants_purifier.html http://transformeroilfiltration.weebly.com/ www.astm.org ASTM standard D4684-D8,2008 Leslir R. Rudnick, Lubricant Additives, Chemistry and Application Second Edition, U.S.A. [5] Cutler ET (2009). Conserve Lube Oil: Re-refine Hydrocarbon processing Vol.265, March. [6] Georgel WC, La TGG (1977). Extended Engine Oil Life through New Technology, Seminar paper at the National Petroleum Refiners Association 1977 Annual meeting, Mar 27 29, San Francisco, California. [7] Firas A, Dumitru P (2006). Design aspects of used lubricating oil rerefining, books.google.com.ng/books?isbn= 044452228X, p. 114. Chevron Lubricating oil FM ISO 100. [8] Iarc (1984) Iarc Monographs Risk of chemicals to humans, vol 33, IARC, Lyon, France. [9] Udonne J. D., A comparative study of recycling of used lubrication Oils using distillation, acid and activated charcoal with clay methods, Journal of Petroleum and Gas Engineering Vol. 2 (2), pp. 12-19, February 2011 [10] Art Jones (2010). Lubricating oil through the process of refining used motor oil, www.articlealley.com/article. [11] Scapin MA (2007). Recycling of used lubricating oils by ionizing, linking hub, elservier.com/retrieval/pii/ 30969806X0700182X

VII. RESULT Filter the oil in another container and now you can easily observe the change in colour of lube oil which indicates the less amount of carbon dioxide present in oil. A. Process For Recycling Used Lubrication Oil 1. Pour all collected used oil into a clean, empty saleable container such as plastic milk jug or any specialised oil container such as borosilicate conical flask. 2. Note that used oil is not mixed with any other materials such as antifreeze, paints or other chemicals. 3. Remove the solid impurities from the oil by performing the process of filtration and heating. 4. Sulphuric acid treatment to remove gums, greases. 5. Alkaline treatment to neutralize acid. 6. Water washing to remove soap. 7. Clay contacting to bleach the oil and absorb impurities. 8. Striping to drive off moisture and volatile oils. 9. Filtering to remove clay and other solids. 10. Blending to specification by adding the required additives.

2012 AMAE DOI: 01.IJRTET.7.3. 29

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