A. Tungler BUTE Package 3 Products: modern fuels, high-tech lubricants, raw materials for the...

A. Tungler BUTEA. Tungler BUTE

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Products: mProducts: modern fuels, high-tech odern fuels, high-tech lubricants, raw materials for the lubricants, raw materials for the

petrochemical and chemical petrochemical and chemical industry, alternative fuels industry, alternative fuels


Modern fuels: gasolineModern fuels: gasoline

Otto enginesOtto engines Four-stroke:Four-stroke: Intake of fuel-air mixtureIntake of fuel-air mixture Compression of the Compression of the

mixture and timed mixture and timed ignitionignition

Combustion and Combustion and expansion (working expansion (working stroke)stroke)

Exhaust of combustion Exhaust of combustion gasesgases


Modern fuels: gas oilModern fuels: gas oil

Diesel engineDiesel engine The fuel-air mixture is The fuel-air mixture is

heterogeneous, the heterogeneous, the ignition is thermalignition is thermal

Fuel is injected into Fuel is injected into the heated air shortly the heated air shortly before the end of the before the end of the compression stroke, compression stroke, where it self-ignites.where it self-ignites.


Quality of gasolineOctane number

Determination in comparative measurement, n-heptane has 0 octane number, 2,2,4-trimethyl pentane(iso-octane) has 100 octane number.

Measurement in a one-cylinder, four-stroke test engine, it has a mechanically adjustable compression ratio. The compression ratio is increased until „knocking” occurs. The fuel’s octane number is coming from the composition of the n-heptane-iso-octane mixture, which gives the same knock level.


Quality of Quality of gasolinegasoline

Volatility: balanced distillation performance

Benzene content

Aromatic content

Sulfur content


Gasoline componentsGasoline components

Straight-run gasolineStraight-run gasoline Thermally cracked gasolineThermally cracked gasoline Catalytically cracked gasolineCatalytically cracked gasoline Catalytic reformateCatalytic reformate IsomerizateIsomerizate AlkylateAlkylate Polymer gasolinePolymer gasoline Oxygenates (MTBE, ETBE)Oxygenates (MTBE, ETBE)



Quality of Diesel fuels (gas oil)Quality of Diesel fuels (gas oil)Ignition qualityCetane numberDetermination in comparative measurement, methyl-naphtalene has 0 cetane number, cetane (n-hexadecane) has 100 cetane number.Measurement in a one-cylinder, four-stroke test engine, ignition delay can be altered, varying the compression ratio or throttling the qantity of intake air.


Quality of Diesel fuels (gas oil)Quality of Diesel fuels (gas oil)

DensityDensity Sulfur contentSulfur content

ViscosityViscosity Deposit formationDeposit formation

Cold flow properties (summer and winter gas oils)Cold flow properties (summer and winter gas oils)


Diesel fuel components

Straight-run middle distillate

Thermally cracked gas oil

Catalytically cracked gas oil

Hydrocracked gas oil

Synthetic diesel fuel: SMDS (Shell Middle Distillate Synthesis) from natural gas through steam reforming, Fischer-Tropsch synthesis, isomerization, distillation


Fuel additivesFuel additives

Gasoline additivesGasoline additives Antiknock agents: lead Antiknock agents: lead

compoundscompounds Antioxidants: amines and Antioxidants: amines and

phenolsphenols Metal deactivatorsMetal deactivators Corrosion inhibitorsCorrosion inhibitors Anti-icing agentsAnti-icing agents Detergents: avoiding Detergents: avoiding

deposits on injectors, ensure deposits on injectors, ensure intake valve cleanlinessintake valve cleanliness

Additives for combatting Additives for combatting combustion chamber combustion chamber depositsdeposits

Spark aider additivesSpark aider additives

Additives for diesel fuelAdditives for diesel fuel Ignition improvers (formation of free Ignition improvers (formation of free

radicals upon decomposition)radicals upon decomposition) Detergent additivesDetergent additives Soot suppressors-combustion Soot suppressors-combustion

enhancersenhancers Cold-flow additives (avoid wax Cold-flow additives (avoid wax

crystallization)crystallization) Flow improvers (EVA copolymers)Flow improvers (EVA copolymers) Cloud point depressantsCloud point depressants Wax antisettling additivesWax antisettling additives Additives for improving lubricityAdditives for improving lubricity Additives for increasing storage Additives for increasing storage

stabilitystability DehazersDehazers BiocidesBiocides Antistatic additivesAntistatic additives Antifoam additivesAntifoam additives ReodorantsReodorants


Aviation Turbine Fuels Aviation Turbine Fuels

Kerosene type fractionsKerosene type fractions

Bulk propertiesBulk properties Density. Density. Specific Energy Specific Energy Volatility Volatility Combustion Combustion Elastomer Compatibility Elastomer Compatibility

Low-Temperature OperabilityLow-Temperature Operability

Trace PropertiesTrace Properties Oxidative Stability Oxidative Stability Corrosivity Corrosivity Water Separation Water Separation Static Electricity Static Electricity

Nonspecification Properties : Absolute Vapor Pressure, Water Miscibility, Lubricity

Additives : Oxidation Inhibitors, Metal Deactivators, Corrosion Inhibitors and Lubricity Improvers, Static Dissipater Additives (SDAs),

Anti-icing additive, Biocides, Thermal Stability Additives

Desirable crudes are low in sulfur (sweet crudes), low in n-hydrocarbons (nonwaxy crudes), low in aromatic content, and high in product boiling between 160 and 290 °C.


Typical viscosities vs. temperatureTypical viscosities vs. temperature for for jet fueljet fuel


True vapor pressures for jet True vapor pressures for jet fuelfuel


The source of jet fuel will be the crude oil distillate in the next decades.


Fuel standardization and testingFuel standardization and testing DIN and ASTM testing methodsDIN and ASTM testing methods

Storage and transportation

Storage: floating and fixed-roof tanks

Transportation: pipelines, tank ships, rail tankers, road tank trucks


Route of liquid hydrocarbons from

the well to the consumer


Alternative fuels


Petrochemical and chemical raw materialsPetrochemical and chemical raw materials

Ethylene production (as a percentage of total ethylene produced)Ethylene production (as a percentage of total ethylene produced)


Feedstock requirements for a Feedstock requirements for a

500 000 t/a ethylene plant500 000 t/a ethylene plant


The cracking furnaceThe cracking furnace

Linde-Pyrocrack coils

Typical arrangement of furnace elements


Cracking yields for various

feedstocks


Approximate energy consumption to Approximate energy consumption to produce 1 kg of ethylene from various produce 1 kg of ethylene from various

feedstocksfeedstocks

The olefin production is very energy intensive, the feasibility depends on energy prices and energy integration of the olefin plant.


Refinery products for the Refinery products for the chemical industrychemical industry

Aromatic compounds: benzene, toluene, xylenes (BTX)

Olefines

Acids

Alcohols

Solvents



LubricantsLubricants

The most important function of lubricants is The most important function of lubricants is the reduction of friction and wear. the reduction of friction and wear.

Mineral oil components continue to form the Mineral oil components continue to form the quantitatively most important foundation of quantitatively most important foundation of lubricants. Petrochemical components and lubricants. Petrochemical components and increasingly derivatives of natural, increasingly derivatives of natural, harvestable raw materials from the oleo-harvestable raw materials from the oleo-chemical industry are finding increasing chemical industry are finding increasing acceptance because of their environmental acceptance because of their environmental compatibility and some technical advantages compatibility and some technical advantages


Tribology (derived from the Greek tribein, or tribos meaning rubbing) is the science of friction, wear, and lubrication.

The tribological system (commonly referred to as the tribosystem) consists of four elements: the two contacting partners, the interface between the two and the medium in the interface and the environment.

In lubricated bearings the lubricant is located in this gap. In plain bearings, the material pair are the shaft and the bearing shells; in combustion engines they are the piston rings and the cylinder wall or the camshaft lobes and the tappets and in metalworking, the tool and the workpiece.

The variables are the type of movement, the forces involved, temperature, speed, and duration of the stress. Tribometric parameters — such as friction, wear, and temperature data — can be gathered from the stress area. Tribological stress is the result of numerous criteria of surface and contact geometry, surface loading, or lubricant thickness.


Sliding and rolling

Friction is the mechanical force which resists movement (dynamic or kinetic friction) or hinders movement (static friction) between sliding or rolling surfaces. These types of friction are also called external friction.

Internal friction results from the friction between lubricant molecules; this is described as viscosity


‘Wälzreibung’, mixing of rolling and sliding motions.

a) Rolling in metal forming; v1, initial speed of the sheet metal; v2, final speed of the sheet metal; v3, speed of the roller; vr, speed difference in the roll gap (sliding part); N, neutral point (non-slip point, pure rolling)

b) Engagement of gear teeth, 1, 2, 4. high sliding/rolling ratio; 3. pitch circle (pure rolling, no slip)


Hydrostatic lubrication as a form of fluid Hydrostatic lubrication as a form of fluid

frictionfriction


Stribeck graph according to H. CZICHOS and K.-H. HABIG [53]

1) Boundary friction (h ® 0 ); 2) Mixed film friction (h»R); 3) Elastohydrodynamic lubrication (h > R); 4) Hydrodynamic lubrication (h >> R)

http://www.mrw.interscience.wiley.com/ueic/articles/a15_423/bibliography.html#ref55


Improvement of hydrodynamic lubrication clearance between two rollers by Hertzian deformation (elastohydrodynamic contact, EHD contact), pressure distribution in the Hertzian contact


The measure of internal friction in a fluid is viscosity. Viscosity and its dimensions are best explained with a model of parallel layers of fluid which could be viewed molecularly. If this packet of fluid layers is sheared ( t), the individual fluid layers are displaced in the direction of the shearing force. The upper layers move more rapidly than the lower layers because molecular forces act to resist movement between the layers. These forces create resistance to shearing and this resistance is given the term dynamic viscosity. The difference in velocity between two given fluid layers, related to their linear displacement, is referred to as shear rate S. This velocity gradient is proportional to the shear stress ( t). The proportionality constant h is called dynamic viscosity and has the unit Pa · s.

The viscosity index VI is for the description of viscosity – temperature behavior.


Graphical illustration of viscosity index (VI)


Various lubricant structures (a, b, c) with high sensitivity against shear stress


Various Various V – TV – T characteristics for characteristics for

several oilsseveral oils


Yield of the various cuts in conventional lube oil refining of a typical lube crude


Base oils are the most important components of lubricants

The target of base oil distillation is the viscosity desired at 40 °C and 100 °C. The same distillation cut (same boiling point distribution) with different chemical structures leads to different viscosities. A highly naphthenic cut produces a higher viscosity than a paraffinic cut. In other words, equiviscous cuts of different chemical structures have different boiling-point distributions.

Processes in refining for producing base oils: Distillation, Deasphalting, Traditional Refining Processes, Solvent Dewaxing, Finishing, Hydrogenation and Hydrocracking, Manufacturing Naphthenic Base Oils by Hydrogenation, Production of White Oils, Lube Hydrocracking, Catalytic Dewaxing, Wax Isomerization, All-Hydrogen Route.



Classes of synthetic lubricantsClasses of synthetic lubricants


Additives can be classified into types that 1. influence the physical, e.g., V – T characteristics, demulsibility, low

temperature properties, etc., and chemical properties, e.g., oxidation stability, of the base fluids

2. affect primarily the metal surfaces modifying their physicochemical properties, e.g., reduction of friction, increase of EP behavior, wear protection, corrosion inhibition, etc.

Antioxidants Friction Modifiers

Viscosity Modifiers Corrosion Inhibitors

Pour Point Depressants

Detergents and Dispersants

Antifoam Agents

Demulsifiers

Dyes

Antiwear and Extreme Pressure Additives


Viscosity modifiers, chain structures, Viscosity modifiers, chain structures,

and monomer make-upand monomer make-up


Scheme of lubrication points in an Scheme of lubrication points in an

engineengine Engine oils have to fulfil a wide range of functions in engines. The purely tribological task consists of guaranteeing the functional reliability of all friction points in all operating conditions. In addition, engine oils have to perform a number of other functions. This begins with the sealing the cylinder and ends with the transport of sludge, soot, and abraded particles to the oil filter.


Comparison of monogrades and multigrades motor Comparison of monogrades and multigrades motor

oilsoils


Performance additivesPerformance additives


Lubricating oil supply, use and disposal in Western Lubricating oil supply, use and disposal in Western

EuropeEurope

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