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E-grāmata: Lubricant Blending and Quality Assurance

5.00/5 (2 ratings by Goodreads)
(Pathmaster Marketing Ltd., England)
  • Formāts: 308 pages
  • Izdošanas datums: 25-Oct-2018
  • Izdevniecība: CRC Press
  • ISBN-13: 9780429882586
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Lubricant Blending and Quality AssurancePalielināt
  • Formāts: 308 pages
  • Izdošanas datums: 25-Oct-2018
  • Izdevniecība: CRC Press
  • ISBN-13: 9780429882586
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Many people, including those involved in the manufacturing, marketing and selling of lubricants, believe that blending lubricants is simply a matter of putting one or more base oils and several additives into a tank of some kind and stirring them around to mix them. Blending lubricants that meet customers’ demands requires much more than this. The correct ingredients of the right quality need to be used in precisely controlled quantities. The ingredients need to be tested prior to blending and the finished products need to be tested following blending. The ingredients need to be stored and mixed under carefully controlled conditions. The finished lubricants need to be stored and packaged carefully and then delivered to customers correctly.

This book discusses all of these issues, describes the different types of equipment used to blend lubricants, provides guidance on how best to use this equipment, and offers tips and techniques to help to avoid problems. It focuses on liquid lubricants. Greases are not discussed, as their manufacture involves very different manufacturing procedures compared with those concerned with liquid lubricants.

The book starts with descriptions and discussion of the properties and characteristics of the main types of mineral and synthetic base oils, as well as the properties and characteristics of the main types of additives that are used in lubricant formulations. Criteria and methodologies used to design both new and upgraded blending plants are covered next. The types and operation of the equipment used in lubricant blending plants are described and discussed, together with a chapter on how to avoid problems before, during, and after blending. Testing and analysis of base oils, additives, and blended lubricants are covered in two separate chapters. Procedures for quality control and quality management in lubricant blending plants are also discussed in two separate chapters. Types of packages for lubricants are reviewed, together with methods for filling packages and methods for transporting lubricants in bulk. The storage of lubricants and supply chain management is also covered in depth.

Recenzijas

"The book explains in a comprehensive manner that blending lubricants is a complex business and there must be a strong focus on quality. It also highlights the steps that must be taken in terms of controlling the mixing conditions, analytical checks, packaging, and storage to meet the customer needs. The book is an important reference source of information and advice for all lubricant blenders. I am not aware of another book that provides this information in an easy accessible format."

~Dr. Aubrey Burrows, Consultant at Aubrey Burrows & Associates Ltd.

"Any new recruit or job change candidate looking to take a prominent role associated to the lubricants blending function will find this an immensely valuable source of reference material. However, it does go much wider than that insofar that all functionaries within the company will benefit from the occasional consultation."

~Rod Pesch, LUBE Magazine

"This somewhat smallish book is unique in that it addresses practical matters that of­ten aren't addressed in much tribology and lubrication engineering literature. Further, several chapters serve the surprising pur­pose of providing a concise review for those preparing for certification, including some topics from STLE's Certified Lubrication Spe­cialistrn (CLS) exam, which are somewhat hard to find in books or courses, especially reflecting today's best practices. This little book does all this, as well as most ably cov­ering the very practical titled subject of lu­bricant blending."

Dr. Robert M. Gresham, Tribology & Lubrication Technology "The book explains in a comprehensive manner that blending lubricants is a complex business and there must be a strong focus on quality. It also highlights the steps that must be taken in terms of controlling the mixing conditions, analytical checks, packaging, and storage to meet the customer needs. The book is an important reference source of information and advice for all lubricant blenders. I am not aware of another book that provides this information in an easy accessible format."

~Dr. Aubrey Burrows, Consultant at Aubrey Burrows & Associates Ltd.

"Any new recruit or job change candidate looking to take a prominent role associated to the lubricants blending function will find this an immensely valuable source of reference material. However, it does go much wider than that insofar that all functionaries within the company will benefit from the occasional consultation."

~Rod Pesch, LUBE Magazine

"This somewhat smallish book is unique in that it addresses practical matters that of­ten aren't addressed in much tribology and lubrication engineering literature. Further, several chapters serve the surprising pur­pose of providing a concise review for those preparing for certification, including some topics from STLE's Certified Lubrication Spe­cialistrn (CLS) exam, which are somewhat hard to find in books or courses, especially reflecting today's best practices. This little book does all this, as well as most ably cov­ering the very practical titled subject of lu­bricant blending."

Dr. Robert M. Gresham, Tribology & Lubrication Technology

Preface xv
Author xvii
Chapter 1 Introduction
1(4)
1.1 Purpose
1(1)
1.2 Approach
1(4)
Chapter 2 Mineral Oil Base Oils: API Groups I, II and III: Properties and Characteristics
5(24)
2.1 Introduction
5(1)
2.2 Base Oil Nomenclature
5(1)
2.3 Methods of Manufacturing Base Oils
6(4)
2.4 Base Oil Composition
10(2)
2.5 Mineral Base Oil Properties and Characteristics
12(4)
2.5.1 Overview
12(1)
2.5.2 Appearance and Colour
12(1)
2.5.3 Density and Gravity
12(1)
2.5.4 Viscosity and Viscosity Index
13(1)
2.5.5 Pour Point and Cloud Point
14(1)
2.5.6 Distillation Range
14(1)
2.5.7 Flash Point
14(1)
2.5.8 Volatility
14(1)
2.5.9 Aniline Point
15(1)
2.5.10 Viscosity-Gravity Constant
15(1)
2.5.11 Refractive Index and Refractivity Intercept
15(1)
2.5.12 Elemental Contents
15(1)
2.6 API Base Oil Classifications
16(1)
2.7 Comparison of Mineral Oil Base Oils
17(8)
2.7.1 Group I Base Oils
17(1)
2.7.2 Group II Base Oils
18(2)
2.7.3 Group III Base Oils
20(2)
2.7.4 Group I, II and III Base Oils
22(3)
2.8 Base Oil Interchangeability
25(2)
2.9 Summary
27(1)
References
28(1)
Chapter 3 Synthetic Base Oils; API Groups IV and V: Properties and Characteristics
29(26)
3.1 Introduction
29(1)
3.2 Conventional Definitions of Mineral and Synthetic Base Oils
30(1)
3.3 Types of Synthetic Oils
31(2)
3.4 Performance Advantages of Synthetic Oils
33(1)
3.5 Properties and Characteristics of the Main Synthetic Base Oils
34(17)
3.5.1 Polyalphaolefins
34(3)
3.5.2 Diesters and Polyolesters
37(5)
3.5.3 Polyisobutenes
42(4)
3.5.4 Polyalkylene Glycols
46(5)
3.6 End-Use Markets for Synthetic Lubricants
51(1)
3.7 Conclusions
52(1)
Reference
53(2)
Chapter 4 Lubricant Additives: Properties and Characteristics
55(18)
4.1 Review of the Development of Lubricant Additives
55(3)
4.2 Functions of Lubricant Additives
58(1)
4.3 Types of Lubricant Additives
58(8)
4.3.1 Viscosity Index Improvers
59(1)
4.3.2 Detergents
60(1)
4.3.3 Dispersants
60(1)
4.3.4 Pour Point Depressants
61(1)
4.3.5 Antioxidants (Oxidation Inhibitors)
61(1)
4.3.6 Anti-Wear Additives
62(1)
4.3.7 Lubricity Additives
62(1)
4.3.8 Extreme-Pressure Additives
63(1)
4.3.9 Bearing Corrosion Inhibitors
63(1)
4.3.10 Corrosion Inhibitors or Anti-Rust Additives
63(1)
4.3.11 Metal Passivators
64(1)
4.3.12 Demulsifiers (Anti-Emulsion Additives)
64(1)
4.3.13 Emulsifiers
64(1)
4.3.14 Friction Modifiers
65(1)
4.3.15 Anti-Foam Additives (Foam Suppressants)
66(1)
4.3.16 Biocides
66(1)
4.4 Additive Packages
66(1)
4.5 Properties of Lubricant Additives
67(3)
4.6 Effects of Additive Properties on Lubricant Blending
70(2)
4.7 Summary
72(1)
Reference
72(1)
Chapter 5 Lubricant Formulation and Ease of Blending
73(20)
5.1 Introduction
73(1)
5.2 The New Product Development Process
73(5)
5.2.1 Idea Generation
73(2)
5.2.2 Idea Screening
75(1)
5.2.3 Idea Evaluation
76(1)
5.2.4 Agreement Between Marketing and Product Development Departments
76(1)
5.2.5 Preliminary Business Analysis
76(1)
5.2.6 Product Development and Testing
77(1)
5.2.7 Test Marketing
77(1)
5.3 Formulating and Developing a New Automotive Engine Oil
78(6)
5.3.1 The Specification
79(1)
5.3.2 Choice of Base Oil(s)
79(1)
5.3.3 Choice of Viscosity Index Improver
80(1)
5.3.4 Developing the Dispersant Inhibitor Package
81(1)
5.3.5 Evaluating and Finalising the Formulation
82(2)
5.4 Formulating and Developing a New Industrial Lubricant
84(2)
5.5 Illustrative Lubricant Formulations
86(3)
5.6 Ease of Blending
89(1)
5.7 Communication and Cooperation between Formulators and Blenders
90(1)
5.8 Summary
91(2)
Chapter 6 Lubricant Blending Plant Design: Grassroots Plants and Upgrading Existing Plants
93(14)
6.1 Introduction
93(1)
6.2 Investment in Blending Lubricants
93(3)
6.2.1 Business Aims
93(1)
6.2.2 Blending Plant Conception
94(2)
6.3 Grassroots Blending Plant
96(1)
6.4 Upgrading an Existing Blending Plant
97(1)
6.5 Blending Plant Layout
97(3)
6.6 Designing a Lubricant Blending Plant
100(4)
6.7 Benefits of High-Quality Blending Plant Design
104(1)
6.8 Summary
104(1)
Reference
105(2)
Chapter 7 Lubricant Blending Plant Equipment and Facilities and Their Operation
107(32)
7.1 Introduction
107(1)
7.2 Lubricant Blending as Part of the Supply Chain
107(1)
7.3 Key Components of a Modern Lubricant Blending Plant
108(14)
7.3.1 Automatic Batch Blender
108(3)
7.3.2 In-Line Blender
111(3)
7.3.3 Simultaneous Metering Blender
114(2)
7.3.4 Drum Decanting Unit
116(1)
7.3.5 Premix Blending Vessel
117(1)
7.3.6 Drum Heating Unit
117(1)
7.3.7 Pigging Equipment
118(4)
7.4 Blending Operations
122(4)
7.4.1 Batch Blending
122(3)
7.4.2 Automated and In-Line Blending
125(1)
7.4.3 Operating a Drum Decanting Unit
126(1)
7.5 Sampling Raw Materials and Blends
126(4)
7.5.1 Importance of Sampling
126(1)
7.5.2 Sample Bottles
127(1)
7.5.3 Sampling Methods
127(3)
7.6 Automation of Blending
130(7)
7.7 Summary
137(2)
Chapter 8 Lubricant Blending Issues: Avoiding Problems
139(14)
8.1 Introduction
139(1)
8.2 Sampling before Blending
139(1)
8.3 Blend Families and Cross-Contamination
140(1)
8.4 Temperature Control
141(1)
8.5 Times for Blending
141(1)
8.6 Mixing
142(2)
8.7 Sampling Blended Lubricants
144(1)
8.8 Slop Oil
145(1)
8.9 Packages, Labels and Labelling
145(1)
8.10 Health, Safety and the Environment
146(1)
8.11 Forklift Trucks
146(1)
8.12 Minimising Operating Expenses
147(1)
8.13 Equipment Maintenance
148(1)
8.14 Cyber Security
149(2)
8.15 Summary
151(1)
References
151(2)
Chapter 9 Testing and Analysis of Base Oils and Additives in Blending Plants
153(22)
9.1 Introduction
153(1)
9.2 Tests for Base Oils
154(15)
9.2.1 Colour
155(1)
9.2.2 Boiling Range
155(1)
9.2.3 Density
156(1)
9.2.4 Kinematic Viscosity
156(1)
9.2.5 Viscosity Index
157(1)
9.2.6 Low-Temperature Viscosity
158(1)
9.2.7 Pour Point
159(1)
9.2.8 Flash Point
160(1)
9.2.9 Volatility
161(1)
9.2.10 Foaming Properties
162(1)
9.2.11 Demulsibility
162(1)
9.2.12 Acid Number
163(1)
9.2.13 Carbon Residue
163(2)
9.2.14 Water Content
165(1)
9.2.15 Sulphur, Nitrogen and Phosphorous Contents
165(2)
9.2.16 Metals Contents
167(1)
9.2.17 Hydrocarbon Type Analysis
168(1)
9.3 Tests for Additives
169(1)
9.3.1 Metals and Non-Metals Contents
169(1)
9.3.2 Sulphated Ash
169(1)
9.3.3 Infrared Spectroscopy
170(1)
9.4 Specifications for Raw Materials
170(3)
9.5 Summary
173(2)
Chapter 10 Testing and Analysis of Blended Lubricants
175(20)
10.1 Introduction
175(1)
10.2 Laboratory Tests for Lubricants
176(13)
10.2.1 Oxidation Resistance
178(1)
10.2.2 Antioxidant Content
179(1)
10.2.3 Thermal Stability
180(1)
10.2.4 Rust Protection
181(1)
10.2.5 Corrosion Resistance
182(1)
10.2.6 Shear Stability
183(3)
10.2.7 Anti-Wear and Extreme-Pressure Tests
186(2)
10.2.8 Metals Contents
188(1)
10.3 Tests for Blending Plant Quality Control of Specific Types of Lubricants
189(4)
10.3.1 Automotive and Industrial Engine Oils
190(1)
10.3.2 Automotive and Industrial Gear Oils
190(1)
10.3.3 Automatic Transmission Fluids
190(1)
10.3.4 Hydraulic Oils
191(1)
10.3.5 Turbine Oils
191(1)
10.3.6 Compressor Oils
192(1)
10.3.7 Metalworking Fluids
192(1)
10.4 Processing and Communication of Test Results
193(1)
10.5 Summary
193(2)
Chapter 11 Lubricant Product Quality Control
195(16)
11.1 Introduction
195(1)
11.2 Definition of Quality
195(2)
11.3 Meeting Customer Requirements and Quality Control
197(1)
11.3.1 Customers
198(1)
11.3.2 Suppliers
198(1)
11.4 Procedures for Control of Quality
198(9)
11.4.1 Checking Raw Materials
199(2)
11.4.2 Controlling Quality during Blending
201(2)
11.4.3 Testing Finished Products
203(1)
11.4.4 External Monitoring Systems
203(1)
11.4.5 Component and Formulation Codes
204(2)
11.4.6 Batch Numbering and Traceability
206(1)
11.4.7 Computerised Blend Records
207(1)
11.4.8 Blend Sample Storage and Retention
207(1)
11.5 Resolving Product Quality Problems
207(2)
11.6 Summary
209(2)
Chapter 12 Lubricant Packaging and Filling
211(26)
12.1 Introduction
211(1)
12.2 Role and Attributes of Packaging
211(2)
12.3 Types of Lubricant Packaging
213(5)
12.3.1 Plastic Bottles
213(1)
12.3.2 Stand-Up Pouches
214(1)
12.3.3 Oil Drums
215(2)
12.3.4 50 L (10-Gallon) Drums
217(1)
12.3.5 25 L (5-Gallon) Drums
217(1)
12.3.6 Grease Drums, Kegs, Pails and Cans
217(1)
12.3.7 Intermediate Bulk Containers
217(1)
12.3.8 Additional Packaging
218(1)
12.4 Reconditioning Drums and IBCs
218(1)
12.5 Recycling Plastic Packaging
219(3)
12.6 Labels for Lubricant Packages
222(6)
12.6.1 Role of Labels on Packages
222(1)
12.6.2 The Globally Harmonised System
223(4)
12.6.3 Types of Lubricant Package Labels
227(1)
12.6.4 Multilingual and Multipurpose Labels
228(1)
12.7 Filling Lubricant Packages
228(8)
12.7.1 Bottle Filling
228(1)
12.7.2 Drum and IBC Filling
229(3)
12.7.3 Road Tanker, Rail Tank Wagon and ISOTainer Filling
232(4)
12.8 Summary
236(1)
Chapter 13 Lubricant Storage
237(18)
13.1 Introduction
237(1)
13.2 Storage Vessels and Containers
237(3)
13.2.1 Bulk Storage in Tanks
237(1)
13.2.2 Drum Storage
238(1)
13.2.3 Storage in Intermediate Bulk Containers
239(1)
13.2.4 Plastic Bottles and Tin-Plate Cans
239(1)
13.3 Lubricant Storage
240(2)
13.3.1 Siting the Lubricants Store
240(1)
13.3.2 Indoor Storage
240(1)
13.3.3 Outdoor Storage
241(1)
13.3.4 Ingress of Moisture
242(1)
13.3.5 Storage of Special Types of Lubricant
242(1)
13.4 Blending Plant Warehouse
242(2)
13.5 Warehouse Management and Automation
244(9)
13.5.1 Warehouse Management Systems
244(3)
13.5.2 Advantages and Disadvantages of WMS
247(1)
13.5.3 WMS Operation
248(2)
13.5.4 Other WMS Functionality and Considerations
250(2)
13.5.5 Implementing WMS
252(1)
13.6 Summary
253(2)
Chapter 14 Product Quality Management
255(22)
14.1 Introduction
255(1)
14.2 Background to True Total Quality
255(1)
14.3 Lean (Just-in-Time) Manufacturing
256(3)
14.4 Total Quality Management
259(5)
14.5 ISO 9000
264(2)
14.6 Implementing TQM
266(3)
14.7 Mapping a TQM Strategy
269(2)
14.8 Supply Chain Management
271(3)
14.9 Enterprise Resource Planning
274(1)
14.10 Summary
275(1)
References
275(2)
Glossary 277(4)
Index 281
David Whitby is Chief Executive of Pathmaster Marketing Ltd, a business development consultancy for the international downstream oil, gas and energy industries, which he founded in 1992. Pathmaster Marketing advises clients in the UK, France, Germany, Belgium, Denmark, Poland, the US, Canada, Israel, Saudi Arabia, Iran, South Africa, Brazil, Singapore, Malaysia and Australia on business planning, business strategy, market development and technology commercialisation. Specialist sectors include lubricants, fuels, new energies and speciality chemicals.

An Australian by birth, David began his career with British Petroleum, as a process chemist at the Kwinana refinery in Western Australia. He worked for BP for 22 years in a number of management positions, including Marketing and Business Development Manager at Kalsep (an advanced separations company), Business Manager at BP Ventures, Project Leader for Industrial Lubricants at BP Research and Marketing Services Officer at Duckhams Oils.

David was Programme Director for Lubricants Courses at the Oxford Princeton Programme (formerly the College of Petroleum and Energy Studies in Oxford), where he was responsible for planning the overall lubricants course programme and delivering several training courses each year. He ran the Advanced Lubrication Training Programme for the UK Lubricants Association (formerly the British Lubricants Federation.). He has written numerous papers and articles on lubricants and has chaired and lectured to international conferences and directed over 100 training lubricants courses in the UK, Canada, Germany, France, Belgium, Denmark, Switzerland, Poland, the Czech Republic, Hungary, Russia, Saudi Arabia, Jordan, Bahrain, Cyprus, Argentina, Brazil, South Africa, Singapore, Malaysia, Thailand and Australia. He also writes the bi-monthly "Worldwide" column for the US Society of Tribologists and Lubrication Engineers "Tribology and Lubrication Technology" magazine and is a contributor to "Lubes n Greases" magazine.
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