Condition monitoring of regenerated lubricating oil of critical plant

equipments
Pradip Sahana 1*, G Sneha Raju 2, C Kumar 1, P Pathak 1 and N Mondal 1
1
R&D Centre for Iron and Steel, Ranchi
2
Bokaro Steel Plant, Bokaro
*
Corresponding Author email: pradipsahana@sail.in

ABSTRACT

In order to reduce the consumption of lubricating oil, plant operation cost and protect the environment from
pollutant most of the steel plant started regeneration of used lubricating oils. One of the SAIL steel plants uses
regenerated lubricating oil in the auxiliary units or less critical areas of plant without its evaluating its physico-
chemical properties. These regenerated lubricating oils may also be used in the critical area of the plant if the
lubricants are found in good condition. In view of this, a method has been adopted to analyze the exact physico-
chemical conditions of regenerated lube oil before deciding the suitability of its use in any critical or auxiliary
system. This method includes measurement of viscosity, elemental analysis, moisture content, wear debris &
measurement of total acid (TAN) content of regenerated lubricating oils. Based on analysis results and
comparisons with the results of similar grade fresh oil, the plant was recommended to reuse regenerated oils in
the suitable area. Regular use of this method may lead to optimum use of costly lubricating oil to reduce the
lubricant consumption of plan and environmental pollution.

Keywords: Lubricating oil, Oil regeneration, Elemental analysis, Total acid number

INTRODUCTION
Lubricating oils, used in different industries is usually a special formulation made to meet the
needs of that particular industry. Oil regeneration / reclamation is a process of restoring the
oils performance characteristics to its original new like condition. In other words, reclamation
allows used oil to be used over and over against without the need for disposal. For example, it
may be oils contaminated with foreign particles and with high moisture content that are
successfully removed during the reclamation process.  Additionally, with regard to the oil
formulation, refortification of the oil may be required to reintroduce an additive package to
the oils.  

The research regarding the actual proved reserves of crude oil show the fact that these can
only be exploited on a limited period of time [1]. The conservation of lubricant has been
declared national policy in several countries [1,2]. Consequently, the management of these
resources search for means to recover the used oil, direction to which recovery of used
lubricating oils. The concern regarding used oils processing has been known for some time
now, but it became a priority in the context of the growing need of protecting the natural
environment [2]. The used lubricating oil represents a very pollutant product for the earth as
much as for the water. Therefore, its recycle has a positive impact both on environmental
protection and oil cost. The methods of used oils processing for reuse are: regeneration (re-
refining), thermal cracking, gasification, mild/severe reprocessing, combustion. Among the
regenerating technologies such as acid/clay, distillation/clay, distilation/ chemical treatment or
solvent extraction etc [3,4,5,6]. The most used procedure and the most economical is acid/clay
[7,8,9]. The acid/clay oil treatment consists in the following steps: acid treatment for
removing gums, greases etc., bleaching or discoloration, neutralization, sedimentation,
decantation and filtration [10,11].

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Bokaro Steel Plant (BSL) is presently using around 10 lakh litres of different types of
lubricating oil annually in different areas of plant. Oil regeneration Unit (ORU) of BSL is
using used lubricating oil for its regeneration. The process involves dehydration and
elimination of contaminants from the used lubricating oils. Earlier, used lubricating oils were
regenerated and reused in the auxiliary units without its physico-chemical evaluation.
Expenditure on lubricating oil contributes a huge amount of operating cost of plant. So, a
method has been adopted to know the exact conditions of regenerated lubricating oils before
deciding the suitability of its use in any critical equipment or any auxiliary system so as to use
the lubricating oils optimally.

In view of the above, this work was initiated to analyses the physico-chemical conditions of
regenerated oils and to provide the recommendation to the plant for suitability of further use
in the critical equipment or auxiliary units of the steel plant

EXPERIMENTAL
Sample collection and Laboratory investigations: In order to investigate the physico-
chemical conditions of regenerated lube oils, fresh oil samples were also collected for
laboratory studies and generate base data (physic-chemical properties) for comparison
purpose. Regenerated oil samples were collected periodically from Oil Regeneration Unit
(ORU) of BSL and analysed in laboratory. Following tribological parameters was evaluated at
Tribology Laboratory.
(a) Elemental analysis
(b) Measurement of viscosity at 40°C.
(c) Determination of moisture content
(d) Wear particle analysis (Ferrous)
(e) Determination of Total Acid Number (TAN)

Elemental analysis of oil samples

Wear metals, contaminations and additives concentration of lube samples were determined
using RotrOil Spectrometers as shown in Fig. 1. It measures the important elements (ppm or
1mg./L) such as iron, chromium, copper, silicon, Tin, calcium, magnesium, molybdenum,
sodium, Phosphorus, Zinc and sulphur etc present in oil sample. It can analyze up to 21
elements and sensitivity of wear metals up to 10 μm.

Sample Cup

Fig. 1: Photograph of RotrOil Spectrometer and its spark chamber

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Measurement of Viscosity
Saybolt viscometer (Fig. 2) was used to determine viscosity of lube oil. In this test, time in
seconds is noted for 60 ml of the lube at specified temperature (at 40°C) to flow through an
orifice of a specific size. Saybolt universal viscosity is specified by the ASTM D2161 and the
test result is presented in Saybolt universal seconds (SUS). SUS is compared with standard
viscosity chart for measurement of viscosity of lube in centistokes (cSt).

Determination of moisture content

Moisture content of oil samples was determined using Oil view analyser as shown in Fig. 2.
It measures the moisture (in wt%) present based on dielectric property of the lubricant. Then
the sample bottle with sensor plugged into the sensor grid of equipment for measurement of
moisture content in the sample with the help of the suitable software. The equipment
compare with clean oil to determine regenerated lube oil moisture content.

Fig. 2: Photograph of Oil View analyser with oil sample

Determination of Wear particles

The equipment used for determination of contamination of lubricants is Direct Reading
Ferrograph/ Duplex Ferrograph analyser (Fig.3). The Direct Reading Ferrograph operates by
flowing lubricant through a precipitator tube over a high powered magnet. The large wear
particles in the lubricant are quickly attracted to the magnet, while the smaller particles gather
at the exit end of the magnet. Light is then transmitted through the sample where photo
sensors on the other end measure the amount of light passing through the sample. The results
received are ferrous large (DL) greater than five microns in size and ferrous small (DS) which
are those particles less than five microns in size.

Determination of Total Acid Number (TAN)

The instrument used for determination of Total Acid Number (TAN) is Potentiometric TAN
titrator (Fig.4). The acid number (AN) expresses the quantity of base required to neutralize all
acidic constituents of the sample. It is a quality feature for freshness of oils. In this test 10g of
oil sample is dissolve in 50g solvent. Then prepared sample was titrated with base solution
with known concentration and it gives the TAN value of the oil sample in mg KOH/ g of oil
sample. A high concentration of acidic compounds in a lubricant can lead to corrosion of machine
parts and clogged oil filters due to the formation of varnish and sludge.
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 Fig. 3: Photograph of Duplex Ferrograph analyser

Fig. 4: Photograph of Total acid number (TAN) titrator

RESULTS AND DISCUSSION

Elemental analysis of Regenerated Oil Samples (OS), measured through RotrOil

Spectrometer, is given in Table-1. The elemental analysis of fresh oil samples is also
mentioned in Table-1 for comparison purpose. The elemental analyses showed that parts per
million (ppm) of all the important elements of oil samples. Analysis results of regenerated oil
samples shows (Fig. 5) increase in concentration of wear elementals (Al, Cr, Cu, Fe & Sn)
and contaminant (Si) and decrease in concentration of additives elements (Na, Ca, Zn & P)in
Fig.6. Increase in concentration of wear metals in regenerated samples are due to the
inefficient filtration from the filtration system. Concentration of wear metals and other
contaminants of the regenerated oil may be decreased by lowering the flow rate of oil at the
time of filtration and use of suitable membrane filter and periodic cleaning of the filter cloth.

Viscosity analysis results of regenerated oils sample at 40°C shows in Table 2 mostly
increasing trends (Fig. 7). However, sometimes decreasing trends was also observed. Increase
in viscosity of regenerated oils samples is due the presence of wear metals and other
contamination. A decrease in viscosity may occur when non-lubricants like solvent and diesel
Table 1: Elemental analysis of Fresh lubricant and regenerated oil samples
Oil sample Elements (ppm)
Al Cr Cu Fe Si Sn Na Ca Zn P

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 Fresh OS 0 0.2 0.3 0 0.1 1.8 381.3 175 333.7 532.5
Reg. OS 1 1.4 2 12.7 24.2 0.1 3.3 163.9 92 223.6 375.6
ISO
Reg. OS 2 2.1 1.4 13.9 14.8 1.7 2.5 284.4 82.5 249.9 402.5
VG 46
Reg. OS 3 2 0.7 43.1 41.9 4.4 5.3 365 66.9 75 302
Reg. OS 4 0.8 0.5 10.6 33 2.3 3.6 219 38.0 180.5 365.2

Fig 5: Graphical representation of wear elements present in oil samples

Fig. 6: Graphical representations of different additives present in ISO VG 46 oil samples

fuel accidently get into the lubricant. If viscosity of the lubricant differs by more than 10%
from nominal grade, a change of oil is typically recommended by the lubricant supplier. Oil
viscosity is expected to rise over time and use, while a decrease in viscosity is considered to
be more serious than an increase. Therefore, a working alarm range is +20% to-10%, i.e. not
more than 20% over nominal, and not less than 10% under nominal grade.

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Table 2: Physico-chemical properties of Fresh lubricant and regenerated oil samples
Physico-chemical properties
Oil sample Kin. Viscosity at Moisture content TAN (mg KOH/ g of
Contaminant (DL + DS)
400C (cSt) (ppm) oil)
Fresh OS 40.7 0 13.1 0.5763
Reg. OS 1 45.1 115 5.3 0.3758
ISO
Reg. OS 2 53.7 84 177.9 0.5925
VG 46
Reg. OS 3 45.5 12 42.5 0.5025
Reg. OS 4 44.2 20 156.5 0.6548

Moisture content analysis results in Table 2 of regenerated oils sample revealed the presence
of small concentration (ppm) of moisture which varies from 12-115 ppm (Fig. 7). Water
ingression generally occurs around seals and breathers of the system. Presence of moisture/
water is usually not desirable in oil, water can be detected visually if gross contamination is
present (cloudy appearance). Excessive water in a system destroys a lubricant's ability to
separate opposing moving parts, allowing severe wear to occur with resulting high frictional
heat. As a thumb rule, water concentration should not exceed 300 ppm.

Fig. 7: Graphical representations of change in Kin. Viscosity, moisture and contaminant

present in ISO VG 46 oil samples

Contamination analysis results in Table 2 of Duplex Ferrograph analysis result shows the
presence wear metals (magnetic) in the regenerated oil samples. Presence of wear metals in
regenerated oil due to the improper filtration at the time of processing at regeneration unit.
Contamination level of this oii should be varies between 100-200ppm.

Total Acid Number (TAN) of oil samples were measured and it reveals that the acid number
of the regenerated lubricant within the acceptable limit (Fig. 8) and less deterioration of the
oil. An abrupt rise in TAN would be indicative of abnormal operating conditions (e.g.
overheating). Usually a rise of 0.5 over the starting value is cause for concern.  TAN value
can be higher than expected for some oils due to the additive packages present. Generally, an
acid number of anything over 1 is considered high.

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 Fig. 8: Graphical representations of change in TAN value of ISO VG 46 oil samples

CONCLUSIONS

The following conclusions are drawn based on laboratory analysis of regenerated oils:
1. Although the process used in ORU is called regeneration but the process involves
is actually a re-refining process of used oil. In which, removal of moisture and
contaminants present in used oil are taking place. In oil regeneration process after
re-refining of used oil, addition of additive is required to make it similar to the
fresh oil.
2. Elemental analysis results of regenerated oil revels the presences of sufficient
concentration of wear metals and contaminants. This may be due to the excessive
oil pressure at the time of filtration in the filter press. It can be avoided with
adjustment of proper inlet oil pressure before entering to filter press, use of proper
membrane filters and contamination free cloth filters.
3. Viscosity analysis results of oil samples at 40°C indicate the increasing trends in
regenerated oil samples. Increasing in viscosity of regenerated oils samples may be
due the presence of wear metals and other contamination.
4. Oil View analysis result reveals the presence of moisture in the regenerated oils. It
varies between 12 to 115 ppm and is within the acceptable limit (≤200ppm).
5. Duplex Ferrograph analysis results revels the presence of sufficient wear metals
(DL<5µm &DS>5 µm) in the oil samples. This is due to the improper filtration
system.
6. TAN results of regenerated oil samples indicate the not much deterioration of
lubricants.
7. Depletion of additive package, variation of viscosity results, and presence of
excessive concentration of wear metals makes the regenerated oil unfit for use in

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 critical components in plant. In view of the above, it was recommended to use the
regenerated oils in the less critical areas or auxiliary units of plan.

ACKNOWLEDGEMENTS

The taskforce members are grateful to RDCIS and BSL management for support and
encouragement in pursuance of this project. Taskforce members are also thankful to Sri
Jaynta Kumar of ORU, BSL for collection of regenerated oil samples and laboratory staff of
Tribology Lab of RDCIS for conducting different analysis of fresh as well as regenerated lube
samples.

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