Developments in Lubricant Technology E-Book

S. P. Srivastava

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 642

Veröffentlichungsjahr: 2014

Beschreibung

DEVELOPMENTS IN LUBRICANT TECHNOLOGY Examines all stages of Lubricant formulations, production and applications Developments in Lubricant Technology describes the basics of Lubricant formulations and their application in variety of equipment and engines. Divided into twenty chapters, this book provides an introduction to lubricant technology for users, young scientists and engineers desirous of understanding this subject. The book covers all major classes of lubricants including base oils (mineral, chemically modified and synthetic), followed by the description of chemical- additives and their evaluation. A brief chapter on the friction-wear and lubrication has been provided to understand the behaviour of lubricants in equipment. Major industrial oils such as turbine, hydraulic, gear, compressor and metal working fluids have been described. Automotive engine, gear and transmission oils for passenger cars, commercial vehicles, rail-road, marine, natural gas engines and 2T, 4T small engines have been discussed at length with latest specifications and global trends. Various synthetic oils and environmentally friendly products have also been described in the relevant chapters to understand the critical applications of such products in modern equipment and engines. Finally lubricants blending technology, quality control, their storage, handling, re-refining and condition monitoring in equipment have been discussed along with the typical lubricant tests and their significance.

Leseprobe

CONTENTS

COVER

TITLE PAGE

COPYRIGHT PAGE

PREFACE

PART I: LUBRICANT BASICS

CHAPTER 1: INTRODUCTION

REFERENCES

CHAPTER 2: CLASSIFICATION OF LUBRICANTS

AUTOMOTIVE ENGINE OILS

INDUSTRIAL OILS

METAL WORKING FLUIDS

AVIATION OILS

GREASES

ISO 3448 VISCOSITY CLASSIFICATION FOR INDUSTRIAL OILS

ENGINE OIL CLASSIFICATION

VISCOSITY

ABSOLUTE AND KINEMATIC VISCOSITIES

NEWTONIAN AND NON-NEWTONIAN FLUIDS

VISCOSITY MEASUREMENT

VISCOSITY INDEX

API AND ILSAC CLASSIFICATION OF ENGINE OILS

SAE CLASSIFICATION OF AUTOMOTIVE GEAR OILS

TWO-STROKE ENGINE OILS

RAIL ROAD OILS

NLGI CLASSIFICATION OF GREASES

METAL WORKING OIL CLASSIFICATION

CHAPTER 3: MINERAL AND CHEMICALLY MODIFIED LUBRICATING BASE OILS

HYDROPROCESSES FOR LUBE PRODUCTION

CATALYTIC HYDROPROCESSING/DEWAXING PROCESS

WAX HYDROISOMERIZATION PROCESS

UNCONVENTIONAL OR CHEMICALLY MODIFIED LUBRICANT BASE OILS

GTL BASE OILS

NATURAL GAS AND GTL

CHARACTERIZATION OF LUBRICATING BASE OILS

BASE OIL TOXICITY

REFERENCES

CHAPTER 4: SYNTHESIZED BASE OILS

POLYALPHAOLEFINS

POLYINTERNALOLEFINS

ALKYLATED AROMATICS

POLYISOBUTYLENES

REFERENCES

CHAPTER 5: LUBRICANT ADDITIVES AND THEIR EVALUATION

BASE OIL QUALITY AND ADDITIVE TREATMENT

HINDERED PHENOLS

ALKYLATED AROMATIC AMINES

PHENOTHIAZINES

METAL DIALKYLDITHIOCARBAMATE

BENZOTRIAZOLE AS METAL DEACTIVATOR

EVALUATION OF ANTIOXIDANTS

INDUSTRIAL TURBINE, HYDRAULIC, AND CIRCULATING OILS

COMPRESSOR OILS

GEAR OILS

CORROSION INHIBITORS

RUST INHIBITOR

FRICTION MODIFIERS/LUBRICITY/FILM STRENGTH/OILINESS ADDITIVES

ANTIWEAR AND EP ADDITIVES

SULFUR COMPOUNDS

SULFURIZED HYDROCARBONS

SULFUR–PHOSPHOROUS ORGANO-COMPOUNDS

ZINC DIALKYL DITHIOPHOSPHATES

PHOSPHOROUS COMPOUNDS

ALKYL PHOSPHITES

PASSIVE EP ADDITIVES

RIG TESTS FOR THE EVALUATION OF ANTIWEAR AND EP ADDITIVE-CONTAINING OILS

FOUR-BALL WEAR TEST (ASTM D-4172 FOR OILS AND ASTM D-2266 FOR GREASES)

FOUR-BALL EP TEST (ASTM D-2783)

TIMKEN EP TEST (ASTM D-2782)

FZG LOAD-CARRYING CAPACITY TEST (IP334/DIN 51354)

FZG MICRO PITTING TEST

DENISON T6C HYDRAULIC VANE PUMP TEST (DENISON SPECIFICATION TP-30283)

POUR POINT DEPRESSANTS

VISCOSITY MODIFIERS (VISCOSITY INDEX IMPROVERS)

SHEAR STABILITY TEST—KURT ORBAN (CEC-L-14-A-48)

TACKINESS ADDITIVES

ANTIFOAM COMPOUNDS

DETERGENTS AND DISPERSANTS

SYNTHETIC OR PETROLEUM SULFONATES

PHENATES

ALKENYL SUCCINIMIDE DISPERSANTS

EVALUATION OF DETERGENTS AND DISPERSANTS

EMULSIFIERS AND DEMULSIFIERS

COMPATIBILITY OF ADDITIVES AND LUBRICANT BLEND STABILITY

SYNERGISM OF METAL DEACTIVATORS WITH ANTIOXIDANTS

ANTIOXIDANT–METAL DEACTIVATOR–EP AGENTS

DETERGENTS, DISPERSANTS, AND ANTIWEAR ADDITIVES

ACIDIC AND BASIC ADDITIVES

SOLID LUBRICANT ADDITIVES

REFERENCES

CHAPTER 6: LUBRICATION, FRICTION, AND WEAR

FRICTION

INTERFACE BETWEEN THE TWO CONTACTING SURFACES

FRICTION: TYPES

WEAR

WEAR MECHANISM AND MEASUREMENTS

EXTREME PRESSURE TESTS

LUBRICATION REGIMES

HYDRODYNAMIC OR FLUID FILM LUBRICATION

HYDROSTATIC LUBRICATION

BOUNDARY LUBRICATION

ELASTOHYDRODYNAMIC LUBRICATION

REFERENCES

PART II: INDUSTRIAL LUBRICANTS

CHAPTER 7: STEAM AND GAS TURBINE OILS

CLASSIFICATION OF TURBINE OILS

SPECIFICATIONS

PROPERTIES AND FUNCTIONS OF TURBINE OILS

VISCOSITY

RUST AND CORROSION PROTECTION

WATER SEPARATION CHARACTERISTICS OR DEMULSIBILITY

AIR RELEASE

FOAM CONTROL

ANTIWEAR PROPERTY

OXIDATION STABILITY

GAS TURBINE OILS

REFERENCES

CHAPTER 8: HYDRAULIC FLUIDS

CLASSIFICATION OF HYDRAULIC FLUIDS

SPECIFICATION OF HYDRAULIC FLUIDS

HYDRAULIC OIL PERFORMANCE TESTS

HYDRAULIC OIL CLEANLINESS

HYDRAULIC FLUID PROPERTIES

HYDRAULIC FLUID TECHNOLOGY

FIRE-RESISTANT HYDRAULIC FLUIDS

HFAE: OIL-IN-WATER EMULSIONS

HFAS: AQUEOUS CHEMICAL SOLUTIONS

HFB: INVERT EMULSION (WATER-IN-OIL)

HFC: WATER–GLYCOL SOLUTIONS

HFD: NONAQUEOUS FIRE-RESISTANT FLUIDS

AIRCRAFT AND MILITARY HYDRAULIC FLUIDS

BIODEGRADABLE AND ENVIRONMENT-FRIENDLY HYDRAULIC FLUIDS

REFERENCES

CHAPTER 9: COMPRESSOR, VACUUM PUMP, AND REFRIGERATION OILS

DYNAMIC OR T RESSORS

POSITIVE-DISPLACEMENT COMPRESSORS

RECIPROCATING COMPRESSORS

ROTARY COMPRESSORS

CLASSIFICATION AND SPECIFICATIONS OF COMPRESSOR OILS

FUNCTIONS OF COMPRESSOR OILS

LUBRICATION OF RECIPROCATING COMPRESSORS

COMPRESSOR OIL PROPERTIES

LUBRICATION OF ROTARY COMPRESSORS

LUBRICATION OF DYNAMIC OR TURBO COMPRESSORS

SYNTHETIC COMPRESSOR OILS

VACUUM PUMP OILS

REFRIGERATION COMPRESSOR OILS

REFRIGERANTS

REQUIREMENT OF REFRIGERATION OILS

MINERAL OILS

SYNTHETIC OILS

SPECIFICATIONS OF REFRIGERATION OILS

REFERENCES

PART III: GEAR OILS AND TRANSMISSION FLUIDS

CHAPTER 10: INDUSTRIAL AND AUTOMOTIVE GEAR OILS

TYPES OF GEARS

TYPES OF GEAR OILS

INDUSTRIAL GEAR OIL SPECIFICATIONS

GEAR FAILURES

PROPERTIES

TOXICITY AND SAFETY

GEAR OIL FORMULATION

REFERENCES

CHAPTER 11: AUTOMATIC TRANSMISSION FLUIDS

AUTOMATIC TRANSMISSION FLUIDS

FUNCTIONS OF AUTOMATIC TRANSMISSION FLUIDS

SPECIFICATIONS OF AUTOMATIC TRANSMISSION FLUIDS

TRANSMISSION FLUID FORMULATIONS

REFERENCES

PART IV: AUTOMOTIVE LUBRICANTS AND MWFs

CHAPTER 12: PASSENGER CAR MOTOR OILS

BASIC CONCEPT

DEPOSIT IN ENGINE

ENGINE OIL CLASSIFICATION

ENGINE OIL PERFORMANCE

ENGINE OIL SPECIFICATION

OEM SPECIFICATIONS

JAPANESE ENGINE TESTS

EUROPEAN TESTS

ENGINE OIL FORMULATIONS

ENERGY-EFFICIENT FRICTION-MODIFIED OILS

CORROSION AND WEAR

VISCOSITY MODIFIER IN MULTIGRADE OILS

SYNTHETIC GASOLINE ENGINE OILS

REFERENCES

CHAPTER 13: ENGINE OILS FOR COMMERCIAL VEHICLES

PERFORMANCE CHARACTERISTICS: DIESEL ENGINE OILS

CONTAMINANT CONTROL

LUBRICANT PERFORMANCE: FRICTION AND WEAR REDUCTION

DIESEL ENGINE OIL SPECIFICATION

OEM SPECIFICATIONS

EUROPEAN ENGINE TESTS

NORTH AMERICAN ENGINE TESTS

DIESEL ENGINE OIL FORMULATION

DIESEL ENGINE OIL DEVELOPMENT TRENDS

SOURCE OF SULFATED ASH

SOURCE OF SULFUR

SOURCE OF PHOSPHORUS

LONG-DRAIN ENGINE OILS

ENGINE TECHNOLOGY AND LUBRICANTS

SYNTHETIC ENGINE OILS

REFERENCES

CHAPTER 14: TWO-STROKE AND SMALL ENGINE LUBRICANTS

SPECIFICATIONS AND CLASSIFICATIONS

LUBRICANT FORMULATION

FOUR-STROKE FC-W OILS FOR OUTBOARD ENGINES

BIODEGRADABLE OUTBOARD TWO-STROKE ENGINE OIL

FOUR-STROKE MOTORCYCLE OILS

REFERENCES

CHAPTER 15: RAILROAD, MARINE AND NATURAL GAS ENGINE OILS

RAILROAD OILS

LMOA CLASSIFICATION OF RAILROAD OILS

PERFORMANCE EVALUATION OF RAILROAD OILS

CHALLENGES IN RAILROAD OIL FORMULATIONS

MARINE LUBRICANTS

CRANKCASE LUBRICATION

MEDIUM-SPEED TRUCK PISTON ENGINE OILS

TBN DEPLETION IN MEDIUM-SPEED TPEO

HIGH-SPEED DIESEL ENGINES FOR AUXILIARY EQUIPMENT

MARINE OIL APPROVALS

ENVIRONMENTAL CONCERNS

MARKETING OF MARINE LUBRICANTS

NATURAL GAS ENGINE OILS

CLASSIFICATION OF GAS ENGINES

REFERENCES

CHAPTER 16: METALWORKING FLUIDS

MECHANISM OF CHIP FORMATION IN MACHINING DUCTILE MATERIALS

CLASSIFICATION OF METALWORKING FLUIDS

EMULSIONS AND LUBRICANTS

SURFACE-ACTIVE COMPOUNDS IN METALWORKING FLUIDS

METALWORKING FLUID MONITORING

ROLLING OILS FOR STEEL

TYPES OF COLD ROLLING MILLS

ROLLING OILS

PERFORMANCE EVALUATION OF STEEL ROLLING OILS

REFERENCES

PART V: BLENDING, RE-REFINING, MONITORING AND TEST METHODS

CHAPTER 17: LUBRICANTS

CHOICE OF BLENDING

OTHER FACILITIES

CONTAMINATION CONTROL IN BLENDING PLANT

CONTAMINATION FROM CONTAINERS (PACKAGES)

HANDLING AND STORAGE OF LUBRICATING OILS

OUTDOOR STORAGE METHOD

GUIDELINES FOR INDOOR STORAGE

HANDLING OF LUBRICATING OILS AND GREASES

SHELF LIFE OF OILS AND GREASES

CHAPTER 18: REREFINING AND RECYCLING OF USED LUBRICATING OIL

USED OIL AND ITS COMPOSITION

ENVIRONMENTAL IMPACT

REFERENCES

CHAPTER 19: IN-SERVICE MONITORING OF LUBRICANTS AND FAILURE ANALYSIS

LUBRICANT CONDITION MONITORING

DEBRIS MONITORING

LUBRICANT CONDITION MONITORING

LOCAL AREA NETWORKING AND DATA MANAGEMENT IN OIL ANALYSIS LABORATORY

SAMPLE HANDLING FOR CONDITION MONITORING

TESTS TO BE CONDUCTED ON DIFFERENT OILS

INTERPRETATION OF LABORATORY RESULTS

REFERENCES

CHAPTER 20: LUBRICANT TESTS AND THEIR SIGNIFICANCE

RIG TESTS

ABBREVIATIONS OF ORGANIZATIONS

INDEX

END USER LICENSE AGREEMENT

List of Tables

Chapter 02

Table 2.1 ISO viscosity classification of industrial oil

Table 2.2 Automotive lubricant viscosity grades

Table 2.3 Development of gasoline engine oil specifications

Table 2.4 Development of diesel engine oil specifications

Table 2.5 Four-stroke classification JASO T-903, 2011

Table 2.6 SAE viscosity of automotive gear oils—SAE J306 June 2005

Table 2.7 Two-stroke classification: ISO/JASO

Table 2.8 Two-stroke classification: TISI 1040

Table 2.9 NLGI classification of greases by cone penetration

Table 2.10 ISO 6743/7 metal working lubricant classification L—Family M and applications

Table 2.11 DIN 51385 classification of metal working fluids

Chapter 03

Table 3.1 Typical properties of raw vacuum distillates

Table 3.2 Typical operating conditions of hydroprocesses for lube base oils

Table 3.3 API-1509: Base oil categories

Table 3.4 Some typical characteristics of API Group I, II, III, PAOs and GTL base oils

Chapter 04

Table 4.1 Typical properties of some commercial PAOs

Table 4.2 Synthetic jet engine oils

Chapter 05

Table 5.1 Typical properties of different category of base oils

Table 5.2 Effect of amine antioxidant and an MDA in a gear oil

Chapter 07

Table 7.1 Classification of lubricants for turbines: ISO 6743-5, family T

Table 7.2 Comparison of important turbine oil properties

Table 7.3 Key Mitsubishi turbine oils specification, MS 4-MA-CL 001, CL 002, 003

Table 7.4 Key properties of GEK-107395A turbine oil specification

Chapter 08

Table 8.1 Classification of hydraulic fluids: ISO 6743/4, category H, hydrostatic–hydraulic systems

Table 8.2 ISO 6743/4, classification of fire-resistant hydraulic fluids

Table 8.3 Water-free, rapidly biodegradable hydraulic fluids

Table 8.4 Specifications for different category of hydraulic fluids

Table 8.5 Key properties of R&O and antiwear hydraulic oil specifications

Table 8.6 Key properties of DIN 51524 part 3 standard for HVLP oils

Table 8.7 Key properties in SAE MS 1004 hydraulic oil specification

Table 8.8 Various hydraulic fluid pump tests and their test conditionsa

Table 8.9 NAS and ISO cleanliness categories

Table 8.10 NAS 1638 cleanliness class and particle size in µm, no. of particles/100 ml

Table 8.11 Classification of fire-resistant hydraulic fluids and biodegradable fluids

Table 8.12 Standard tests for fire-resistant properties

Table 8.13 Military hydraulic fluid specifications

Table 8.14 Water-free biodegradable hydraulic fluid categories and their applications

Table 8.15 Comparison of key properties of VDMA fluid specification

Chapter 09

Table 9.1 Air compressor lubricant standard DIN 51506

Table 9.2 Air compressor lubricant standard DIN 51506: VB, VBL, VC, and VCL grades

Table 9.3 Air compressor lubricant standard DIN 51506: VDL grades

Table 9.4 Air compressor lubricant standard ISO/DP 6521 Draft 1983 mineral oil-based lubricants for reciprocating compressors

Table 9.5 Air Compressor Lubricant Standard ISO/DP 6521 Draft 1983-mineral oil-based lubricants for rotary screw compressors

Table 9.6 Key performance characteristics of SAE MS 1003-2 synthetic compressor oil specification

Chapter 10

Table 10.1 Key performance properties of EP industrial gear oil specifications

Table 10.2 Additional requirements of Flender above DIN 51517 part 3

Table 10.3 SAE J306 automotive gear viscosity classification

Table 10.4 Performance requirements for SAE J2360, November 1998 (previously MIL-PRF-2105E lubricants)

Table 10.5 API GL-4, GL-5, and MT-1 performance test criteria, comparison

Chapter 11

Table 11.1 Comparison of Ford MERCON V and GM DEXRON VI (GM16444) test requirements

Table 11.2 Allison transmission C4 heavy-duty transmission fluid specification

Table 11.3 Allison transmission C4 heavy-duty transmission fluid specification

Table 11.4 Caterpillar TO-4 transmission and drive train fluid requirements

Table 11.5 Caterpillar TO-4 transmission and drive train fluid requirements

Chapter 12

Table 12.1 Lubrication regimes in IC engine

Table 12.2 Performance engine tests in API category gasoline lubricants

Table 12.3 ILSAC specifications: key bench and engine tests

Table 12.4 Comparison of API SN and ILSAC GF5: engine and bench tests

Table 12.5 ACEA service fill oils for gasoline and diesel engines: designations

Table 12.6 ACEA service fill oils for gasoline and diesel engines: designations

Table 12.7 Fuel economy of 10W-30 oils in sequence VI and VIA tests with different VMs and base oils

Chapter 13

Table 13.1 Tolerance of soot by oils meeting API category

Table 13.2 Performance engine tests in API-category diesel engine lubricants

Table 13.3 ACEA service fill for heavy-duty diesel engine oil: designations

Table 13.4 ACEA service fill for heavy-duty diesel engines: key requirements

Table 13.5 Global diesel engine oil specification DHD-1: key test requirements

Table 13.6 U.S. military diesel engine oil specifications: key bench and engine tests

Chapter 14

Table 14.1 Two-stroke classification: API-TC

Table 14.2 Two-stroke classification: ISO/JASO

Table 14.3 Two-stroke classification: TISI 1040

Table 14.4 SAE miscibility for two-stroke engine oils

Table 14.5 Two-stroke classification: NMMA TC-W3

Table 14.6 Classification standards for JASO T 903, 2011, four-stroke motorcycle oils

Table 14.7 Physical/chemical properties for JASO T 903, 2006 and 2011, four-stroke motorcycle oils

Table 14.8 Four-stroke classification JASO T 903, 2011

Chapter 15

Table 15.1 RR diesel engine oil performance categories

Table 15.2 OEM engine tests

Table 15.3 RR engine builder lubricant requirements

Table 15.4 Some key EPA emission regulations for locomotives

Table 15.5 Marine engine oil requirements

Table 15.6 MARPOL Annex VI: NOx emission limits, g/kWh

Table 15.7 MARPOL Annex VI: fuel sulfur limits, % m/m

Table 15.8 Heat of combustion for some liquid and gaseous fuels (higher value)

Table 15.9 Classification of gas engine oils

Table 15.10 Major gas engine builders

Table 15.11 Some key element of OEM NGEO specifications

Table 15.12 Requirements of ash and performance level: other OEMs

Chapter 16

Table 16.1 ISO 6743/7 metalworking lubricant classification L—family M

Table 16.2 Main application of ISO MWF categories

Table 16.3 Some typical additives used in MWFs

Table 16.4 Oil particle size in different types of fluids

Table 16.5 Typical composition of soluble and synthetic emulsifying MWFs

Table 16.6 Microemulsion-based MWF

Table 16.7 Characteristics of different MWFs and their composition

Chapter 18

Table 18.1 Comparison of steps involved in rerefining processes

Table 18.2 Waste oil properties for recycling and rerefining processes in India

Chapter 19

Table 19.1 Typical tests to be conducted on used oil sample

Table 19.2 Visual appearance and oil condition—indicator

Table 19.3 Possible sources of element in used lubricating oil

Table 19.4 Typical rejection limits for lubricants

Chapter 20

Table 20.1 Common tests, terms, and their significance

Table 20.2 Standard test methods for lubricating oils: equivalent chart

List of Illustrations

Chapter 03

Figure 3.1 Conventional refinery production of lubricating base oil.

Figure 3.2 Integration of hydroprocessing with conventional extraction and dewaxing processes to produce API group I, II, and III base oils.

Figure 3.3 IGCC and FT synthesis to produce power, fuels, and base oils.

Chapter 06

Figure 6.1 Frictional force and load relationship.

Figure 6.2 Typical roughness profile of surface.

Figure 6.3 Contact zones between the two metal surfaces—asperities.

Figure 6.4 Contact geometry.

Figure 6.5 Typical lubrication regimes by Streibeck curve in plain bearing.

Figure 6.6 Hydrodynamic lubrication/fluid film lubrication.

Figure 6.7 Journal bearing at rest and under rotation.

Figure 6.8 Boundary lubrication—metal-to-metal contacts.

Chapter 08

Figure 8.1 Example of power transmission in hydraulic jack.

Chapter 09

Figure 9.1 Typical refrigeration system.

Chapter 12

Figure 12.1 Typical energy distribution in an IC engine.

Figure 12.2 Composition of SAE 30, 10W-30, and 5W-30 engine oils.

Figure 12.3 Viscosity–temperature trend of SAE 30, 10W-30, and 5W-30 engine oils.

Chapter 16

Figure 16.1 Chip formation during cutting operation.

Figure 16.2 Emulsifier or surface-active compound structure.

Figure 16.3 Oil droplet (dispersed phase) stabilized by surfactant in oil-in-water emulsion.

Chapter 17

Figure 17.1 Typical blending plant arrangements.

Guide

Cover

Table of Contents

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DEVELOPMENTS IN LUBRICANT TECHNOLOGY

S. P. Srivastava

Copyright © 2014 by John Wiley & Sons, Inc. All rights reserved

Published by John Wiley & Sons, Inc., Hoboken, New JerseyPublished simultaneously in Canada

No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, scanning, or otherwise, except as permitted under Section 107 or 108 of the 1976 United States Copyright Act, without either the prior written permission of the Publisher, or authorization through payment of the appropriate per-copy fee to the Copyright Clearance Center, Inc., 222 Rosewood Drive, Danvers, MA 01923, [phone], fax [phone], or on the web at www.copyright.com. Requests to the Publisher for permission should be addressed to the Permissions Department, John Wiley & Sons, Inc., 111 River Street, Hoboken, NJ 07030, [phone], fax [phone], or online at http://www.wiley.com/go/permission.

Limit of Liability/Disclaimer of Warranty: While the publisher and author have used their best efforts in preparing this book, they make no representations or warranties with respect to the accuracy or completeness of the contents of this book and specifically disclaim any implied warranties of merchantability or fitness for a particular purpose. No warranty may be created or extended by sales representatives or written sales materials. The advice and strategies contained herein may not be suitable for your situation. You should consult with a professional where appropriate. Neither the publisher nor author shall be liable for any loss of profit or any other commercial damages, including but not limited to special, incidental, consequential, or other damages.

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Library of Congress Cataloging-in-Publication Data:

Srivastava, S. P. (Som Prakash), 1940–Developments in lubricant technology / S.P. Srivastava.  pages cm Includes index.

 ISBN 978-1-118-16816-5 (cloth)1. Lubrication and lubricants. I. Title. TJ1077.S74 2014 621.8′9–dc23

2013051266

PREFACE

Lubricating oils are extremely important products without which no machinery or engines can run. Modern high-quality industrial products cannot be manufactured without the application of specific lubricants. Each class of equipment needs a distinctive product. Lubricants constitute a group of more than 600 products with different viscosity and quality levels, and hence oil companies manufacturing them continuously strive to develop and upgrade these products through extensive research and development. Lubricant development is a multidisciplinary effort that involves various fields such as chemistry, physics, metallurgy, chemical/mechanical/automobile engineering, surface science, and polymer science and requires good teamwork for successful production. There are several advanced books that deal with lubricants, lubricant additives, and tribology, but there is a shortage of a simple, concise book that would be useful for scientists and engineers who want to have in-depth knowledge on the subject. Unfortunately, this subject does not form part of a university/college curriculum, mainly because of the fact that this knowledge is regarded as a trade secret, and open literature is not available. During my 40 years of interaction with lubricant users, scientists, engineers, technical service staff, and production and marketing professionals, I have found that there is a considerable gap in knowledge between the users and developers. However, there are some organized industrial sectors, such as the OEMs, where engineers are highly knowledgeable about their equipment and lubricant requirements. If the science of lubrication and its application is understood properly by all users, tremendous benefits can be derived by realizing fuel economy, energy efficiency, reduced wear and tear of equipment, and consequently longer life.

It is with this objective that this concise book has been written, and I am confident that it would be well received by students and all those connected with the development, manufacturing, marketing, and application of lubricating oils. The book covers all the major classes of lubricants such as turbine, hydraulic, compressor, gear, transmission, gasoline engine, diesel engine, two-stroke engine, marine engine, natural gas, and rail road engine oils. However, it has not been possible to cover all the grades of minor lubricants such as specific industry-related products for the textile, cement, paper, sugar mill, and food industry. Nevertheless, it would not be difficult to understand the minor grades of lubricants after going through the major classes covered in this book.

Dr. S. P. Srivastava

Faridabad, India

June 2014

PART ILUBRICANT BASICS

CHAPTER 1INTRODUCTION:LUBRICANT SCENARIO

Lubricants are required in every machinery and engine for reducing friction, wear, and energy consumption. Depending upon the operating and design parameters of the equipment, a properly formulated lubricant can play a major role in extending equipment life and saving energy. For manufacturing modern lubricating oils, lube base oils and chemical additives are required. While base oils are produced in the refineries, chemical additives are manufactured separately in chemical plants, as it involves chemical reactions between several materials and specialized testing facilities. Currently, about 41 MMT (million metric ton) of lubricants are produced globally, and the market is growing slowly at the rate of about 2% per annum. The demand pattern has been described in several publications [1–5]. The growth is mainly in Asia. India and China are the fastest growing countries in this sector (3–5%). Asia Pacific is the largest consumer of lubricants (35%) followed by North America (28%), central and southern America (13%), western Europe (12%), and others (12%). Asian market is dominated by China (4 MMT), Japan (2.8 MMT), India (2.4 MMT), and Korea (1 MMT/year). Asia Pacific countries contribute to about 14 MMT of lubricant business per year.