Detailed Project Report (DPR) on lubricant blending unit and grease unit

LUBRICANT BLENDING UNIT AND GREASE UNIT
[CODE NO.3761]  


Lube  oils  generally  include all  classes  of  lubricating materials  that are applied as fuels.  Nearly all of the world's lube oils are made from the move viscous portion of the crude oil which  remain after removal of gas oil and lighter  fractions  by distillation. Much of the variations in physical characteristics and  performance  qualities of lubricating oils prepared from different crude sources can be accounted for by the millions  of variations that can exist in a single large hydrocarbon molecule.  In order to minimize variations and produce products that provide consistent  performance in specific applications, four steps  are followed in the manufacture of finished lubricating oils from the various  available crudes.  Selection and aggregating of crudes according to the principal types of  hydrocarbon present; distillation of the crude to separate it into fractions containing hydrocarbons in the same sp  range;  processing to remove undesirable  constituents from the various fractions or to convert  same  of these materials constituents from  the  various fractions or to convert same of these materials to more desirable materials,  and blending to attain the  physical  characteristics that  are  required in the finished  products  and  incorporating chemical agents to improve performance.

Basically, Lube oil is classified into two parts:-


1)   Naphthenic oil (low cold-test)

2)   Paraffinic oil


Naphthenic oil is more preferable then paraffinic oil because of its fluidity at low temperature, particularly in cold weather.

Paraffin’s have relatively low viscosity, density and high freezing point as compared to other types, they are used more commonly.


Greases:

TYPE OF GREASE

Lithium, Calcium, Soda, Aluminium,Complex and Mixed soap base Greases, Soap free Grease, PTFE, Silicone and Molybdenum modified Greases, Specialty and Synthetic Greases.

Grease can be divided into 6 general categories or types; i.e., mixtures of mineral oils and solid materials, heavy, asphaltic-type oils blended with lighter oils, extreme-pressure greases, roll-neck greases, soap-thickened mineral oils and multipurpose grease.

Mineral of oils mixed solids

These types of greases are very heavy lubricants for specialized applications. Such greases lubricate rough-fitting machine parts operating under heavy pressures or loads at relatively slow speeds. Examples of equipment that will typically use this type of grease include concrete mixers, bearings and rollers on conveyors and heavy construction equipment.


Heavy-Asphaltic-type oils blended with lighter oils

These types of lubricants are classified as greases but are actually thick, heavy oils used to lubricate open-type gearing and wire rope. A primary advantage of these oils is that they form a heavy protective film when heated or painted on surfaces and then allowed to cool. Lighter oil is typically blended with the heavy oils in order to improve the pour point of the oil.


Extreme-pressure greases

The unique characteristic of this type of grease is that it contains additives to improve firm strength under various applications. In essence, film strength provides the resistance of the lubricant to being torn apart, thus preventing metal-to-metal contact of the equipment being lubricated. A film is formed by a chemical reaction of the metal to the additives in the grease. The chemical reaction is usually brought about (or accelerated) by pressure exerted on the grease, creating heat.

A few of the additives used in EP greases include compounds containing parts of chlorine, phosphorus, active and/or passive sulfur, chlorinated waxes and phosphates. Zinc and lead may also be added, as well as asbestos in some lubricants as a filler to cushion the shock loading on gear drives. The specific additive being used will always depend on the application for use. Factors to be considered for types of additives include specific equipment operating conditions such as load, speed, surface condition and inherent design characteristics.

Roll Neck Greases

Roll neck greases are specialized lubricants used almost exclusively for lubricating plain bearings in rolling equipment. For example, it’s fairly common to use a block of NLGI No. 6 grease, which has the consistency of a bar of soap, carved to mate with the shape needed to accommodate the bearing of heavily loaded equipment.


Soap Thicked Mineral Oils

This is by far the most widely used category of grease in industry today. This type of grease varies by the additive that forms the soap in the lubricants chemical makeup.

Sodium-base greases are also general-purpose greases. Because they have a higher dropping point (approximately 300o to 350ºF), they are often used to lubricate machine parts operating near heat. Sodium greases made with lighter oils are used for ball and roller bearing lubrications, as are combinations (mixed base) of calcium and sodium grease. Sodium-soap greases have a spongy or fibrous texture and are yellow or green in color. Because of their working stability and intermediate melting point, they are used for lubricating wheel bearings (other than disc brakes) and for general-purpose industrial applications. Typical examples include rough, heavy bearings operating at low speeds, as well as skids, track curves and heavy-duty conveyors.

Barium-soap greases are general-purpose types, valued for their ability to work over a wide temperature range. Their dropping point is approximately 350ºF or higher, although they are not intended to be used in continuous operation at temperatures above 275ºF. Barium-soap greases are chosen for a variety of jobs, especially for nearly all types of bearing lubrications. They have high-soap content. However, this makes this type of lubricant less suitable for use at low temperatures and in very high-speed applications. They have a buttery of fibrous texture and are reddish-yellow or green in color.

Lithium-soap grease handles extremes of temperature quite well, which makes them highly suitable for both high and low temperature application. They have a dropping point of approximately 350ºF, and can be used in continuous temperatures of 300ºF. One reason for their successful low-temperature performance is that they are made with oil having a low pour point. In fact, lithium-soap greases have been used successfully at temperatures of -60ºF. Use of lithium-soap grease at higher temperatures requires a different formula; however the same grease can't be used at both extremes of high and low temperatures because the change would be in the viscosity of the oil used in the grease. Basically, lithium-soap greases have very good stability; good water resistance, and are also readily pumpable. They have a buttery texture and a brownish-red color.

Calcium-soap, also called lime-soap greases, are probably the best known and most often used of all greases. Depending on the method of manufacture they are usually relatively inexpensive. Uses include axle grease, water pump grease and general machinery applications. Because its water content begins to dry out, and the soap and oil separate, calcium-soap grease isn’t suited to applications where the temperature will get above 160ºF. The major advantage of calcium-soap grease is that they don’t dissolve in water. However, it is not suited to use in lubricating high speed bearings. Ordinary general-purpose calcium-soap greases have a dropping point of approximately 175o to 200ºF. Calcium-complex grease has unusually high heat resistance making it of considerable value in extreme-pressure applications. The dropping point of this type of grease is 500ºF or even higher. This means that this type of lubricant will maintain its stability while running continuously at high temperatures. However, this type of grease has not replaced lithium-soap greases because they are not as mechanically stable. Calcium-soap greases are yellow or reddish in color, and have a smooth buttery texture.

Aluminum-soap greases are special-purpose lubricants. Their particular advantage is that they are very sticky making them perfect for applications requiring surface lubrication.


Multi- Purpose Grease

Multi-purpose grease is lubricating grease for general applications, where no specific requirements are asked. Multi-purpose greases combine the properties of two or more specialized greases. It is possible to replace as many as specialized types of grease with single multi-purpose grease and get better results all at the same time. This permits the use of a single type of grease for a variety of applications. It is possible to replace as many as six specialized greases with single multi-purpose grease and get better results all at the same time. Most of the multi-purpose greases have a soap base of barium, lithium, or calcium complex. For example, the lithium soap greases discussed earlier. They are not only water-resistant and corrosion inhibiting, but they have very good mechanical and oxidation stability as well.

By reducing the number of lubricants, which a company keeps in stock, the lubricator's job becomes much easier. Another advantage is that it helps reduce the chances of error in application.

Good multi-purpose lubricating grease has to perform well in a number of applications. It should have a high melting point, and operate well at continuous temperatures of 250ºF or more. Such grease should also have good resistance to water, and exceptional stability.  

COST ESTIMATION


Land & Building (16,000 sq.mt.)      Rs. 10.55 Cr         
Plant & Machinery                      Rs. 5 Cr     
Working Capital for 2 Months     Rs. 33.84 Cr
Total Capital Investment              Rs. 49.69 Cr
Rate of Return            48%                   
Break Even Point             31%                



INTRODUCTION    
BASICALLY, LUBE OIL IS CLASSIFIED INTO TWO PARTS    
GREASES    
TYPE OF GREASE    
MINERAL OF OILS MIXED SOLIDS    
HEAVY-ASPHALTIC-TYPE OILS BLENDED WITH LIGHTER OILS    
EXTREME-PRESSURE GREASES    
ROLL NECK GREASES    
SOAP THICKED MINERAL OILS    
MULTI- PURPOSE GREASE    
VARIANTS OF GREASES    
VARIANTS OF LUBRICANT OILS    
USES AND APPLICATIONS    
USER INDUSTRIES OF LUBRICANTS    
LUBE OIL    
FLOW CHARACTERISTICS ARE GIVEN AS FOLLOWS    
GREASES    
1) VISCOSITY OF THE OIL    
2) LOSS OF EVAPORATION    
3) OXIDATION STABILITY    
4) HEAT STABILITY    
COMPONENTS FOR GREASE MANUFACTURE    
PALM OIL    
THICKENER    
SPENT BLEACHING EARTH    
FUME SILICA    
ADDITIVES    
USUAL GREASE ADDITIVE LEVELS (%)    
THE MOST COMMON ADDITIVES ARE:    
COMPONENTS AND CHARACTERISTICS OF GREASE    
GREASE COMPONENTS    
GREASE CONSISTENCY    
DEFINITION OF NLGI GRADES    
GREASE STRUCTURAL STABILITY    
GREASE AT END OF ASTM D1831 ROLLER TEST    
APPLICATION AND FUNCTIONAL PROPERTIES OF GREASE    
FUNCTIONAL PROPERTIES OF GREASE    
B.I.S. SPECIFICATION    
GLOBAL MARKET POSITION OF LUBRICANTS    
MARKET OVERVIEW OF LUBRICANTS IN INDIA    
OIL SUPPLY AND DEMAND IN INDIA    
GAS SUPPLY AND DEMAND IN INDIA    
EXPORTS OF PETROLEUM PRODUCTS FROM INDIA    
UPSTREAM SEGMENT: CRUDE OIL AND GAS PRODUCTION     
UPSTREAM SEGMENT: EXPLORATION AND DEVELOPMENT ACTIVITIES    
PIPELINES: CRUDE PIPELINE NETWORK    
PIPELINES: EXISTING PIPELINES IN INDIA    
PIPELINES: REFINED PRODUCTS AND LPG PIPELINE NETWORK    
DOWNSTREAM SEGMENT: REFINERY CRUDE THROUGHPUT     
DOWNSTREAM SEGMENT: PETROLEUM PRODUCTS    
DOWNSTREAM SEGMENT: DISTRIBUTION AND MARKETING    
STATE-WISE CRUDE RESERVE, CAPACITY AND THROUGHPUT    
MARKET OVERVIEW OF GREASE IN INDIA    
MANUFACTURERS/SUPPLIERS    
LUBRICATING OIL FORMULATION    
TYPICAL PROPERTIES OF THESE MOLECULES ARE:    
GRADE    
TYPICAL GREASE COMPOSITION    
FORMULATION OF LUBRICATING GREASE USING BEES WAX THICKNESS    
FORMULATIONS OF GREASES LEAD BASE LUBRICANT GREASES    
PROCEDURES    
MANUFACTURING PROCESS    
(A) FOR LUBE OIL BLENDING    
FORMULATION    
PROCESS FLOW DIAGRAM    
MANUFACTURING PROCESS    
FORMULATIONS OF LUBRICATING GREASES    
FORMULATION OF LUBRICATING GREASE USING BEES WAX THICKNESS    
SOME TYPICAL FORMULATIONS OF DIFFERENT TYPES OF GREASES
   ARE GIVEN BELOW    
1) SODIUM SOAP GREASE    
2) BALL - BEARING GREASE    
3) HIGH SPEED BALL BEARING GREASES    
4) CALCIUM SOAP GREASES    
5) STUFFING BOX GREASES    
6) TRANSPARENT LUBRICATING GREASES    
FORMULATIONS OF CALCIUM BASE GREASE    
FORMULATION NO. 1    
GREASE FORMULATION GUIDE FOR GREASE MANUFACTURE    
PRACTICE FOR BLENDING AND HANDLING LUBRICANT PRODUCTS    
SUPPLIERS OF RAW MATERIALS    
LUBRICANTS & SPECIALITY PRODUCTS    
SUPPLIER OF BASE OILS    
RESORCINOL    
NAPHTHOLS    
ANTIOXIDANT    
LUBE OIL BLENDING    
SUPPLIERS OF RAW MATERIALS    
SUPPLIERS OF PLANT AND MACHINERY    
APPLICATION PROCEDURE    
CONSTRUCTION AND SPACING OF TANKS    
STORAGE TANK DESIGN SPECIFICATION AND FITTINGS    
IN ALL CASES, TANKS SHALL    
ENVIRONMENTAL PROTECTION    
FIRE FIGHTING AND PROTECTION MEASURES    
QUALITY CONTROL    
LICENSING PROCEDURE
    

APPENDIX – A:

01.    PLANT ECONOMICS    
02.    LAND & BUILDING     
03.    PLANT AND MACHINERY    
04.    OTHER FIXED ASSESTS    
05.    FIXED CAPITAL    
06.    RAW MATERIAL    
07.    SALARY AND WAGES    
08.    UTILITIES AND OVERHEADS    
09.    TOTAL WORKING CAPITAL    
10.    TOTAL CAPITAL INVESTMENT    
11.    COST OF PRODUCTION    
12.    TURN OVER/ANNUM    
13.    BREAK EVEN POINT     
14.    RESOURCES FOR FINANCE    
15.    INSTALMENT PAYABLE IN 5 YEARS    
16.    DEPRECIATION CHART FOR 5 YEARS    
17.    PROFIT ANALYSIS FOR 5 YEARS    
18.    PROJECTED BALANCE SHEET FOR (5 YEARS)