Oil processing is a critical practice for extending the lifespan of oils and the equipment that depends on them. Regular oil processing not only leads to significant cost savings by reducing the need to purchase new oil but also enhances machinery performance and supports environmental sustainability by minimizing waste. This article explores various techniques of oil processing and the equipment used in these methods.
The Importance of Oil Processing
In industrial applications, oils such as lubricants, transformer oils, and hydraulic fluids can become contaminated over time with water, gases, solid particles, and other impurities. These contaminants degrade the oil’s properties, leading to reduced efficiency, increased wear and tear on equipment, and potential system failures. Implementing effective oil processing methods is crucial to maintain the quality of the oil, ensuring optimal equipment performance and longevity.
Oil Processing Techniques
Several methods are employed in oil processing to remove contaminants and restore oil quality. Each technique targets specific types of impurities and varies in effectiveness, processing time, and equipment requirements.
Sedimentation
Sedimentation is suitable for oil with a low degree of contamination by solid particles and water. The oil is placed in a sedimentation tank for several hours, allowing heavier impurities like sludge, dust, metal particles, and water to settle at the bottom due to gravity. These contaminants are then removed through a drain valve.
- Advantages:
- Simple and cost-effective.
- No need for specialized equipment.
- Disadvantages:
- Limited effectiveness for heavily contaminated oils.
- Long processing time (can exceed 10-20 hours).
- Does not remove dissolved gases or very fine particles.
Filtration
Filtration involves passing the oil through filter media that trap solid particles and impurities. Filters can be stationary, processing oil directly in the system, or filter presses that process oil drained from equipment.
- Advantages:
- Effective at removing solid particles.
- Can be integrated into existing systems.
- Disadvantages:
- Filters require regular maintenance and replacement.
- Potential for oil leaks, leading to oxidation.
- Limited capacity for reclamation.
Coagulation
Coagulation is used when the oil contains a large number of small mechanical impurities. Coagulants are added to the oil, causing small particles to clump together into larger ones that can be more easily removed by sedimentation or filtration.
- Advantages:
- Enhances removal of fine particles.
- Disadvantages:
- Requires careful selection and handling of coagulants.
- Additional processing steps needed.
Evaporation
Evaporation removes moisture from oils by heating the oil to a temperature where water vaporizes. The evaporated moisture is then removed through condensation.
- Advantages:
- Effective at removing water content.
- Disadvantages:
- Energy-intensive due to heating requirements.
- Risk of degrading oil properties if overheated.
Alternative Method: Air dehydration, where warm, dry air is forced through the oil to extract moisture.
Electrostatic Oil Processing
This method uses an electric field generated by special electrodes to remove contaminants. Charged particles in the oil are attracted to electrodes of the opposite charge, while neutral particles are captured by corrugated paper placed between electrodes.
- Advantages:
- Can remove fine particles, including metals.
- Disadvantages:
- Electrodes require frequent cleaning.
- Oil must be pre-dried to reduce water content for efficiency.
- Complex setup and maintenance.
Adsorption Processing
Adsorption utilizes adsorbent materials to remove not only water and mechanical impurities but also acidic components and aging products from the oil. The oil passes through columns filled with adsorbent material, which captures contaminants.
- Advantages:
- Highly effective at restoring oil quality.
- Removes dissolved impurities.
- Disadvantages:
- Adsorbents become saturated and require replacement or reactivation.
- Handling and disposal of used adsorbents.
GlobeCore Solution: Equipment that allows for the reactivation of the adsorbent in parallel with oil processing, enhancing efficiency and reducing downtime.
Vacuum Processing
Vacuum processing involves treating the oil under vacuum conditions to remove dissolved gases and moisture. The oil is heated and exposed to a vacuum, causing volatile contaminants to vaporize and be extracted.
- Advantages:
- Achieves high levels of purification.
- Reduces moisture content to very low levels.
- Disadvantages:
- Requires specialized equipment.
- Energy consumption due to heating and vacuum generation.
GlobeCore’s CMM Units: Designed for vacuum processing of oil, achieving:
- Moisture content by weight below 0.001% (10 ppm).
- Volumetric gas content below 0.1%.
- Solid impurities content below 8 ppm.
- Filtration fineness of 5 μm.
Complex Oil Processing
In practice, oil often contains a mix of different contaminants, necessitating a combination of processing methods. Complex oil processing involves sequentially applying multiple techniques to achieve comprehensive purification. For example:
- Step 1: Sedimentation or filtration to remove large solid particles.
- Step 2: Vacuum processing to eliminate moisture and gases.
- Step 3: Adsorption processing to remove dissolved impurities and aging products.
GlobeCore’s Solution: Producing compact and mobile oil processing plants capable of performing multiple purification steps, customized to the required processing rate.
Equipment for Oil Processing
Choosing the right equipment is critical for effective oil processing. Factors to consider include the type and degree of contamination, processing capacity, and operational requirements.
GlobeCore’s Offerings:
- Customized Oil Processing Plants: Designed to meet specific customer needs, including the addition of features like particle counters or remote control via smartphone or PC.
- Installation and Commissioning Support: Assistance with equipment setup and startup.
- Transformer Maintenance Equipment: Including systems for drying solid insulation, refilling, and evacuation.
Advantages of GlobeCore Equipment:
- Capable of operating with energized transformers using a Transformer Safety System (TSS).
- Easy connection to transformers with quick coupling systems.
- Efficient and reliable purification processes.
Benefits of Regular Oil Processing
- Cost Savings: Reduces the need to purchase new oil, leading to significant financial savings.
- Extended Equipment Life: Prolongs the life of oil-filled equipment by maintaining optimal operating conditions.
- Improved Performance: Enhances the efficiency and reliability of machinery.
- Environmental Impact: Minimizes waste and supports sustainable practices by recycling and reusing oil.
Oil processing is a vital practice for industries reliant on oil-filled equipment. By employing appropriate oil processing methods and utilizing advanced equipment like that offered by GlobeCore, companies can achieve significant cost savings, enhance equipment performance, and contribute to environmental sustainability. Understanding the various processing techniques and selecting the right equipment ensures that oil remains clean and effective, safeguarding the longevity and efficiency of critical machinery.