Performance you can rely on. Lubricant base stocks InfineumInsight.com/Learn 1 © 2018© 2018 Infineum Infineum International International Limited. Limited. All Rights All Rights Reserved. Reserved. 2018012.2018160. 2018012. Performance you can rely on. Outline • What are base stocks? – Why are base stock important? – Composition of base stocks • Refining processes – Overview – Major base stock types • Solvent Extraction (SE) • Hydrocracking (HC) • Synthetics • Others • API base oil groups • Names and definitions • Measurements and typical targets • Recent trends 2 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Lubricant base stocks • A lubricant component – Roughly 80-99+% of petroleum products • Usually doesn’t have all required properties – needs additive enhancement • Mineral oil base stocks – Refined from crude oil Found in minerals, not made of minerals • Petroleum = “Petra-oleum” = “Rock Oil” – Common processes • Solvent extraction – Separate “good” from “bad” molecules • Hydrocracking – Convent “bad” molecules into “good” molecules Most of the starting • Synthesis materials come – “Built” from chemical reactions from crude oil • Animal and vegetable oils also used 3 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Why are base stocks important? 1. They are the major component in lubricants 100% 80% 60% Component 40% ~ 65 – base 80% stock ~ 75 – 85% base stock 20% ~ 80 – 90% base stock ~ 98 – base stock 100% Additives 0% Industrial PCEO HDDO Marine Product Type 4 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Why are base stocks important? 2. They have a major effect on performance (oxidation) Base Stock C • Gasoline Engine Oxidation Test • Same PCEO Additive System in different base stocks Base Stock B Oxidation Base Stock A 0 0 Time 5 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Why are base stocks important? 3. They have a major effect on performance (soot-handling) • Diesel Engine Soot Test (retarded timing for NOX control) Base Stock F • Same HDDO Additive System in different base stocks Base Stock E Base Stock D Soot-Induced Thickening 0 0 Soot, percent 6 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Lubricant properties affected by base stocks • Viscometrics – SAE viscosity grade (e.g., SAE 5W-30) – Pour point and low temperature fluidity – Fuel economy – Wear protection • Oxidation – Viscosity increase – Acid formation, that leads to corrosion – Deposit control • Dispersancy and solvency – Soot control (HDD) – Viscosity increase and filter plugging – Sludge – Deposit control • Foaming and air entrainment • Volatility (evaporation) – Oil Consumption and Flash Point 7 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. What are base stocks? • Base stocks are primarily hydrocarbons – Hydrocarbon = molecule containing hydrogen and carbon – Sometimes generalized to molecules with other elements • Equivalent chemical symbols: H HHH H H C5H12 ==C C C C C H (pentane) H H H H H (three-dimensional) C C ==C C C 8 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Chemical bonds and terminology • Carbon likes to have four bonds – In three dimensions C • Carbon can form chains (straight or branched) HHHH – Hydrogen fills in the remaining four spaces H CCCC H • All positions filled relatively unreactive HHHH • Saturated (paraffin) HHHH • If there’s a missing place, a double bond forms H CCCC H – Prefer to fill the spaces more reactive; e.g., oxidation H H • Unsaturated = missing spaces HH H C H H C C H C C H • Ring structures (saturated) H C H H – Six-membered rings are common, but others are possible HHH • Naphthene (cyclo-alkanes) H C H C C C C • Six-membered rings with three double bonds H C H – Lots of empty space reactive H • Aromatic 9 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Base stock molecules – hydrocarbons Type Structure Properties • Saturates • Paraffins (no rings) Very high VI (~175) Excellent oxidation • Straight chain Very high pour point Best lube • Branched chain High VI (~100-150) molecules Good oxidation Medium pour point • Naphthenes Medium VI (~60-110) (saturated rings) Poor oxidation Low pour point Low VI (<60) • Aromatics Very poor oxidation (unsaturated rings) Low pour point 10 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Base stock molecules – polars Type Structure Properties •Sulfur – Dibenzothiophene Antioxidant S Corrosive – Dialkylsulfide S • Nitrogen Mild pro-oxidant – Alkylhydrocarbazole N O • Oxygen Usually not in OH base stock – -naphthenoic acid (formed during oxidation) 11 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Base stock refining 12 © 2018© 2018 Infineum Infineum International International Limited. Limited. All Rights All Rights Reserved. Reserved. 2018012.2018160. 2018012. Performance you can rely on. Refinery overview Crude oil Refinery processes Petroleum products 13 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Crude oil • Crude oil is a mixture of thousands of different molecules – Some are GOOD for lubricants – some are BAD for lubricants As defined • Various classifications on earlier – “Light” vs. “Heavy” Viscosity pages – “Sweet” vs. Sour” Sulfur content – Paraffinic vs. Naphthenic vs. Aromatic Sweet Sour West Texas Intermediate (WTI) Light-Sour Blend (Canada) Light Brent (North Sea) Arabian Extra Light Cano Limon (Colombia) Maya Heavy (Mexico) Heavy Minas (Indonesia) Merey (Venezuela) Sources: Shell; Stratas Advisors; Sanford C. Bernstein 14 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Refining in a nutshell • Start – Crude oil – Mixtures of GOOD and BAD molecules • Goal – REDUCE the Proportion of BAD molecules – INCREASE the Proportion of GOOD molecules • How Do They Do That? – Refining – Separation Solvent Extraction • Remove the BAD molecules – Throw them away? – Use them for something else! – Conversion Hydrocracking • Change BAD molecules into GOOD molecules – Synthesis Synthetics • Build GOOD molecules from small ones 15 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Base stock refinery process overview • De-salting – To avoid corrosion in refinery units • Distillation – Separates lighter from heavier fractions – Selects viscosity “cut” and controls volatility (evaporation) – Also used at end as a “clean-up” step • Major Base Stock Refining Process – Solvent Extraction – Hydrocracking • De-asphalting – Removes asphaltenes (heavy aromatics) • Dewaxing – Removes wax and improves low temperature properties – Either solvent dewaxing or catalytic dewaxing or catalytic iso-dewaxing • Processes are combined to create refinery ‘schemes’ – Optimized based on crude source and refinery assets 16 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Major base stock refinery processes Light ends - volatility • Distillation – Separates lighter from heavier fractions – Selects viscosity ‘cut’ → – Controls volatility (evaporation) → Gases Heavy ends - deposits # Carbons Yield Gasoline 5 – 10 30% Jet Fuel 11 – 13 Diesel Fuel Refinery 30% Crude Kerosene Optimized 14 – 25 Oil for Process Oils 10% Base Stocks Lubricating Oils 26 – 40 10% Wax 5% Heavy Fuel 10% Heavy Bottoms Asphalt 5% 17 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. U.S. refinery yields Asphalt 3% Wax 0.1% Chemical Feedstocks 2% Gases Base Stocks 1.1% 8% Jet Fuel 12% Gasoline 36% Distillate 31% 83% liquid fuels Energy Information Agency, U.S. Department of Energy 18 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Major base stock refinery processes • Solvent Extraction (Group I) – Separation technology – Polar solvent removes aromatics leaving good saturated molecules – Removes sulfur, which is predominantly in aromatic molecules • Hydrocracking (Group II & III) – Conversion technology – Breaks chemical bonds and adds hydrogen – Increases saturates by adding hydrogen – Removes sulfur, converting to volatile H2S – Group II vs III is a function of feedstock and hydrocracker severity • Synthesis (Group III, IV, & V) – GTL – Gas to Liquid – combine methane (natural gas) into large hydrocarbons – PAO – PolyAlphaOlefin – combine small double-bond molecules – Esters – Build up specific molecules using various starting molecules 19 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Solvent extraction refinery process Gases Gasoline Kerosene Diesel fuel Gases Atmospheric Naphtha Distillation Vacuum gas oil (VGO) Crude S100N Distillation Hydrofinishing Vacuum Extraction S150N Dewaxing Solvent Solvent residuum Atmospheric S600N Lube Raffinates Dewaxed Base oil oil stocks distillates Bright Extract stock Vacuum residuum Deasphalted resid Wax Deasphalting Asphalt 20 © 2018 Infineum International Limited. All Rights Reserved. 2018012. Performance you can rely on. Hydrocracking refinery process Atmospheric Distillation Naphtha Naphtha Naphtha Distillation Light Vacuum Crude