THE UNIVERSITY OF DODOMA
COLLEGE OF EARTH SCIENCE AND ENGINEERING
DEPARTMENT OF PETROLEUM AND ENERGY ENGINEERING
COURSE NAME: PETROLEUM REFINING AND
PETROCHEMICALS
COURSE CODE: PE 421
NAME OF INSTRUCTOR: MR. AMRAN FAKIH
NATURE OF WORK: GROUP ASSIGNMENT
GROUP MEMBERS
S/N STUDENT’S NAME REG. NUMBER SIGNATURE
01. MARYAM H. AMEIR T/UDOM/2020/09402
02. MALUGU P. JOHN T/UDOM/2020/05795
03 EMMANUEL T. MANENO T/UDOM/2020/05793
04 NURU J. MSANGI T/UDOM/2020/05794
LUBRICATING OIL
Lubricating oil is a type of oil that is used to reduce friction, wear, and heat between moving parts
in various mechanical systems. It is an essential component in the operation and maintenance of a
wide range of machinery, vehicles, and equipment.
Lubricating oils are typically composed of base oils, which are derived from refined petroleum or
synthetic sources. They may also contain various additives, such as anti-wear agents, antioxidants,
detergents, and viscosity modifiers, to enhance the oil's performance characteristics.
The primary function of lubricating oil is to create a thin film between moving parts, such as gears,
bearings, and pistons, to reduce friction and wear. This helps to minimize energy losses, increase
efficiency, and extend the lifespan of the mechanical components. Lubricating oils also help to
dissipate heat generated by friction, preventing overheating and potential damage to the system.
Lubricating oils can be classified based on their base oil composition, viscosity, and intended
applications. Common types include engine oils, gear oils, hydraulic oils, and specialty lubricants
for specific equipment or industries.
The selection of the appropriate lubricating oil depends on factors such as the operating conditions,
temperature range, load, and the specific requirements of the machinery or equipment. Regular oil
changes and maintenance are crucial to ensure the ongoing effectiveness and performance of the
lubricating oil, as well as the overall health and longevity of the mechanical system.
Lubricating oils are more important in engineering applications, from automotive engines and
industrial machinery to aerospace components and renewable energy systems. Proper selection,
application, and maintenance of lubricating oils are essential for optimizing the performance,
efficiency, and reliability of engineered systems.
Large number of natural lubricating oils are produced by blending a small number of lubricating
oil base stocks and additives.
Important properties of lubricating oils include the following;
• Viscosity:
Viscosity is a measure of a fluid's resistance to flow, and it is one of the most critical properties of
lubricating oils. Viscosity affects the oil's ability to create a protective film between moving parts,
which is essential for reducing friction and wear. Appropriate viscosity is important for
maintaining adequate lubrication under varying operating conditions.
• Viscosity Index (VI):
The viscosity index is a measure of how the oil's viscosity changes with temperature. A high
viscosity index indicates that the oil's viscosity is less sensitive to temperature changes, which is
desirable for maintaining consistent lubrication performance across a wide temperature range.
• Pour Point:
The pour point is the lowest temperature at which the oil will still flow or pour. A low pour point
is important to ensure the oil can circulate and provide lubrication at low temperatures, particularly
in cold weather conditions.
• Oxidation Resistance:
Oxidation resistance refers to the oil's ability to resist degradation due to exposure to oxygen, heat,
and other environmental factors. Good oxidation resistance helps maintain the oil's performance
and minimizes the formation of harmful byproducts, such as sludge and varnish.
• Flash Point:
The flash point is the minimum temperature at which the oil can produce enough vapor to ignite
when exposed to an open flame or spark. A high flash point is essential for safety and fire
prevention, particularly in high-temperature applications.
• Boiling Temperature:
The boiling temperature is the temperature at which the oil transitions from a liquid to a gas state.
A high boiling temperature is desirable to ensure the oil can withstand high operating temperatures
without vaporizing and losing its lubricating properties.
• Acidity (Neutralization Number):
The acidity or neutralization number is a measure of the oil's acid content, which can increase due
to oxidation or contamination. A low acidity level is important to prevent corrosion and wear on
the mechanical components.
Undesired Characteristics of Lubricating oils
• High Pour Point:
The pour point is the lowest temperature at which the oil will still flow. A high pour point means
the oil becomes thick and difficult to pump or circulate at low temperatures, which can impair the
oil's ability to provide adequate lubrication.
• Lower Viscosity Index:
The viscosity index (VI) is a measure of how the oil's viscosity changes with temperature. A lower
viscosity index indicates that the oil's viscosity is more sensitive to temperature changes, which
can affect its performance and film-forming ability.
• Poor Oxygen Stability:
Oxygen stability refers to the oil's resistance to oxidation, which can lead to the formation of
harmful byproducts, such as sludge and varnish. Poor oxygen stability means the oil is more
susceptible to oxidation, reducing its lifespan and potentially causing damage to the mechanical
components.
• Poor Color:
The color of the lubricating oil can indicate its condition and quality. A poor or undesirable color,
such as a dark or discolored appearance, may suggest contamination, degradation, or the presence
of impurities in the oil.
• High Cloud Point:
The cloud point is the temperature at which wax crystals begin to form in the oil, causing it to
become cloudy. A high cloud point can impair the oil's ability to flow and circulate, particularly
in cold weather conditions, leading to potential lubrication issues.
• High Organic Acidity:
Organic acidity refers to the presence of acidic compounds in the oil, which can be produced by
oxidation or contamination. High organic acidity can lead to corrosion and wear on metal surfaces,
shortening the lifespan of the mechanical components.
• High Carbon Forming Tendency:
Carbon forming tendency is the propensity of the oil to produce deposits or residues during
operation. High carbon forming tendency can result in the formation of sludge, varnish, and other
contaminants that can clog filters, restrict oil flow, and ultimately impair the performance and
reliability of the mechanical system.
Lube Oil Processing
Lube oil processing involves the transformation of crude oil into various lubricating oils. The
primary goal is to remove impurities and enhance the properties of the oil to meet specific
performance criteria. The steps include:
• Distillation:
Distillation is the first step in the lube oil processing, where the crude oil is separated into different
fractions based on their boiling points. This process involves heating the crude oil and then
condensing the different components as they vaporize at their respective boiling temperatures. The
distillation process allows for the isolation of the lubricating oil fractions, which typically have
higher boiling points compared to other crude oil components, such as gasoline or diesel. The
distillation step helps to remove a significant number of impurities and contaminants present in
the crude oil, laying the foundation for further refining.
• Hydrotreating:
Hydrotreating is a critical step in the lube oil processing, where the oil fractions are treated with
hydrogen gas in the presence of a catalyst. The primary purpose of hydrotreating is to remove
undesirable components, such as sulfur, nitrogen, and other impurities, from the oil. The hydrogen
gas and catalyst work together to break down these impurities, converting them into simpler and
more stable compounds that can be easily removed. Hydrotreating not only removes impurities
but also improves the oil's oxidation stability, color, and other properties, making it better suited
for use as a lubricant.
• Hydrocracking:
Hydrocracking is a more advanced refining process that involves the use of hydrogen and a catalyst
to break down large, complex hydrocarbon molecules into smaller, more desirable ones. The goal
of hydrocracking is to improve the viscosity and thermal stability of the lubricating oil. By
breaking down the larger molecules, the hydrocracking process produces oils with a narrower
range of molecular weights, which can enhance the oil's viscosity characteristics and its ability to
withstand high-temperature conditions. Hydrocracking is particularly useful for producing high-
quality base oils that can be further blended with additives to create specialized lubricating oils for
specific applications.
Propane Deasphalting
Propane deasphalting refers a process used in the petroleum refining industry to separate asphalt
from other heavy hydrocarbon components in crude oil or vacuum residue.
The following are the steps in the propane deasphalting process:
• Mixing:
In this step, the heavy oil feedstock, which contains asphalt and other heavy hydrocarbon
components, is mixed with liquid propane in a contacting vessel. The purpose of this mixing step
is to bring the heavy oil and propane into intimate contact to facilitate the separation process.
• Extraction:
During the extraction step, the liquid propane preferentially dissolves the lighter hydrocarbon
components, leaving behind the heavier asphalt-rich fraction. This is possible because propane has
a higher affinity for the lighter hydrocarbon components compared to the heavier asphalt fraction.
The propane-rich stream containing the dissolved lighter hydrocarbons is known as the extract
stream.
• Separation:
After the extraction step, the propane-rich extract stream and the asphalt-rich raffinate stream (the
heavier fraction left behind) are separated, typically using a fractionation column. The
fractionation column allows for the efficient separation of the two streams based on their
differences in volatility and boiling points.
• Propane recovery:
The final step in the propane deasphalting process is the recovery of the propane from the extract
stream. This is done to recycle the propane back into the process, as it is a valuable and reusable
solvent. The propane recovery is typically achieved through distillation or other separation
techniques to isolate the propane from the dissolved lighter hydrocarbon components.
The main benefits of propane deasphalting include:
• Producing a high-quality, low-sulphur asphalt product
• Increasing the yield of valuable distillate products from the crude oil
• Reducing the amount of heavy residue that would otherwise need to be processed or
disposed of
Viscosity Index Improvement
Viscosity index (VI) improvement involves enhancing the oil's viscosity-temperature behavior by
making it less sensitive to temperature changes.
There are two primary methods:
• Solvent extraction
• Hydrocracking
The primary methods above are explained each as follows
i. Solvent extraction
Solvent extraction involves removing aromatic compounds that negatively affect the viscosity
index. The steps include:
• Dissolution: The lube oil is mixed with a solvent such as furfural or phenol.
• Extraction: Aromatics preferentially dissolve in the solvent that separate from the oil.
• Separation: The solvent-aromatic mixture is separated from the refined oil.
• Recovery: The solvent is recovered and reused those leaves behind the improved oil.
Benefits of solvent extraction
• Improved base oil quality and performance characteristics.
• Ability to produce a range of base oil grades to meet specific application requirements.
• Higher yields of valuable base oil products.
• Reduction in the amount of waste and environmental impacts.
ii. Hydrocracking
Hydrocracking is a catalytic process that breaks down heavy molecules into lighter, more stable
ones that improves the viscosity index.
The steps include:
• Catalytic Reaction:
In this step, the heavy oil feedstock is mixed with hydrogen and then passed over a specialized
catalyst under high pressure and temperature conditions. The role of the catalyst is to facilitate the
breaking down of the large, heavy hydrocarbon molecules into smaller, more desirable ones. The
high pressure and temperature conditions provide the necessary energy for the chemical reactions
to occur, enabling the hydrocracking process. During this catalytic reaction, the heavy molecules
are cracked or broken down into lighter, more stable hydrocarbon compounds.
• Separation:
After the catalytic reaction, the resulting mixture is separated into various fractions using
distillation or other separation techniques. The desired lube base oil fraction, which has the
improved viscosity index and other desirable properties, is collected and isolated from the other
fractions. The separation step ensures that the targeted lube base oil with the desired characteristics
is obtained, while the other fractions can be further processed or used for other purposes.
Components of lube oil fractions which have high viscosity indices are Mononaphthalenes and
Isoparaffins.
Dewaxing
Dewaxing refers to a process to remove waxes from lube oils to improve their low- temperature
properties.
Different steps may be done in dewaxing are as follows;
• Catalytic dewaxing: The oil is passed over a catalyst that selectively cracks and isomerizes
wax molecules into lower melting point compounds.
• Solvent Dewaxing: The oil is mixed with a solvent like methyl ethyl ketone and chilled to
precipitate waxes which are then filtered out.
• Product recovery: Solvent is recovered and recycled and then dewaxed oil is further
processed or blended.
Benefits of the dewaxing process for lubricating oil blending stocks include;
• Improved low-temperature properties
• Enhanced viscosity index
• Higher-quality base oils
Hydro finishing and Finishing by Clay Contacting
Hydro finishing
Hydro finishing is a processing step in the production of high-quality lubricating oils that involves
the treatment of the refined oil with hydrogen under high pressure and temperature conditions.
• Hydrotreating of Dewaxed Lube Oil Stocks:
Hydro finishing involves the hydrotreating of dewaxed lube oil stocks. The purpose of this
hydrotreating step is to remove chemically active compounds that can negatively impact the color
stability of the finished lubricating oils. The dewaxed lube oil stocks have undergone prior
processing steps, such as dewaxing, to remove wax and other undesirable components. The
hydrotreating process specifically targets the removal of these chemically active compounds that
can cause discoloration or instability in the final lubricating oil product.
Most hydrotreating operations in the hydro finishing process utilize cobalt-molybdate catalysts.
These cobalt-molybdate catalysts are highly effective in promoting the chemical reactions
involved in the hydrotreating process. The catalysts help to facilitate the removal of the chemically
active compounds, such as sulfur, nitrogen, and unsaturated hydrocarbons, from the dewaxed lube
oil stocks.
During the hydrotreating process, the dewaxed lube oil stocks are exposed to hydrogen gas under
elevated temperature and pressure conditions. In the presence of the cobalt-molybdate catalysts,
the hydrogen gas interacts with the chemically active compounds, causing them to undergo
hydrogenation, hydrodesulfurization, and other reactions. These reactions result in the
transformation or removal of the undesirable compounds, thereby improving the color stability
and overall quality of the finished lubricating oil.
The hydro finishing process, with its hydrotreating step, is an essential part of the lubricating oil
production process. It helps to ensure that the final lubricating oil product has the desired color
stability, which is crucial for its performance and appearance in engine applications. By removing
the chemically active compounds, the hydro finishing process contributes to the overall stability
and quality of the finished lubricating oils.
Finishing by Clay Contacting
Finishing by Clay Contacting is a processing step in the production of lubricating oils that involves
the treatment of the refined oil with activated clays at elevated temperatures.
• Contacting of Dewaxed Oil with Activated Clays:
This step involves mixing the dewaxed oil, which has undergone previous refining steps, with
activated clays at elevated temperatures. The purpose of this contacting is to improve the stability
of the finished oils when used in engine service. The activated clays have a high surface area and
adsorption capacity, which allows them to interact with and remove certain undesirable
compounds from the oil.
• Removal of Polar Compounds:
During the clay contacting process, the polar compounds present in the oil are selectively absorbed
or adsorbed onto the clay. These polar compounds include aromatic compounds, as well as sulfur
and nitrogen-containing molecules. By removing these polar compounds, the clay contacting step
helps to enhance the stability and performance of the finished lubricating oils.
• Filtration and Disposal of Spent Clay:
After the clay contacting, the spent clay, which now contains the adsorbed polar compounds, is
separated from the oil through filtration. The disposal of the spent clay can be a challenge, as it
may contain hazardous or environmentally sensitive materials that require proper handling and
disposal procedures. Due to the operational and disposal challenges associated with the clay
contacting process, it has been increasingly replaced by alternative finishing methods, such as
hydro finishing.
