Together
to success
since 1997
INTECH GmbH
We are interested in cooperation with the manufacturers of industrial oil purification equipment, who are looking for an official and reliable distributor to deal with supply & delivery of their equipment to the industrial plants in Russia.
The company’s top management and sales team are well acquainted with the Russian market, its mentality and laws; they also understand industrial specifics of the financial and economic activities of the Russian customers. All our sales managers have a large customer database, extensive experience of successful sales and well-established connections with the potential buyers of your industrial oil purification equipment. This allows our managers to promptly set out the most promising directions for promotion and to ensure a rapid entry of the products into the promising Russian market. Our employees, who are fluent in English and German, are focused on working at the international market with the supplies of foreign equipment.
Our team of experienced engineers, who can handle the most serious technical problems, constantly keeps in touch with the Russian customers, holds meetings and delivers presentations regarding the latest achievements of our manufacturing partners. They point out the engineering challenges and actively communicate with all the departments at Russian plants. That is why the specifics of doing a business in the Russian Federation are well-known to us, and we also know the equipment of the local industrial plants and their up-to-date modernization needs.
Once we become your authorized representative in Russia, our marketing staff will carry out a market research in order to check the demand for industrial oil purification equipment, will submit a market overview for industrial oil purification equipment that you offer and evaluate the needs for this type of equipment at local plants. Our specialists will also estimate the potential and capacity of this market at local industrial plants. Our IT-team will start developing a website for your products in Russian. Our experts will assess the conformity between your industrial oil purification equipment and customer needs as well as analyze the common reaction to the new goods in general. We will look into the categories of potential customers, and pick out the largest and the most promising plants.
Upon becoming your authorized agent on the territory of Russia, ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will obtain certificates, if required, for a batch of the goods, for various types of industrial oil purification equipment in compliance with Russian standards. We can also arrange the inspection in order to obtain TR TS 010 and TR TS 012 Certificates. These certificates provides permission to operate your equipment at all industrial plants of the EAEU countries (Russia, Kazakhstan, Belarus, Armenia, Kyrgyzstan), including the hazardous industrial facilities. Our company is eager to assist in issuing Technical Passports for industrial oil purification equipment as per Russian and other EAEU countries’ requirements.
Our engineering company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), collaborates with several Russian design institutes in various industrial segments, which allows us to conduct preliminary design as well as subsequent design works according to the standards, construction rules and regulations that are applicable in Russia and other CIS countries. It also enables us to include your industrial oil purification equipment into the future projects.
The Company has its own logistics department that can provide packing service, handling as well as the most efficient and cost effective mode of transportation of the goods (incl. over dimensional and overweight goods). The goods can be delivered on DAP or DDP-customer’s warehouse basis in full compliance with all the relevant regulations and requirements that are applicable on the Russian market.
Our company has its own certified specialists who will carry out installation supervision and commissioning of the delivered equipment, as well as further guarantee and post-guarantee maintenance of industrial oil purification equipment. They will also provide necessary training and guidance for the customer’s personnel.
Industrial oils make 30% of the total number of oils used for lubrication of various operating mechanisms in industrial equipment (machine tools, reduction gears, draw-works, etc.). There are 3 groups of industrial oils:
Industrial oils (of general application) are employed to lubricate equipment units and components. Distillate oils are used for hydraulic systems, machine tools, presses and automatic lines. A mixture thereof with residual oil can also be used. It derives from sulfur crude and low sulfur oil as a result of solvent refining or low sulfur oil after acid-base purification. Industrial oils are polluted with mechanical impurities while in operation of the equipment, in case of incorrect storage and improper transportation. Oil gets particularly polluted due to unsatisfactory washing of the lube oil system after installation or repair, as well as filling or draining of the lube oil system in the absence of the oil stations.
The most common forms of industrial oil pollution are: mechanical impurities resulting from the friction of lubricated operating surfaces, condensed moisture, various metallic particles, as well as plastic particles and seal rubber. Oils accumulate oxidation products (oil-based) in dissolved or colloidal form with the equipment operation. Those lead to a change in physicochemical parameter of industrial oil. Therefore, to extend the production life of the oils themselves, lubricated components and equipment mechanisms it is necessary to remove pollution products from oils, i.e. to depurate them by using filter units and lines of all types and design.
In case of b change of the oil general properties, such as viscosity, flash point, density, acid number and color oils should be regenerated. That means the removal of "aging" products via advanced purification. Advanced purification is in its turn one of the most common ways of industrial oil purification. It involves thermic dehydration, contaminant removal by means of sorbents, subsequent oil settling, its filtration or spinning. Industrial oil must meet all the requirements for industrial oils of general application next to advanced purification.
The commercial cost of industrial oils is quite high so far. In addition, salvaging of spent industrial oil often cost more than buying new ones. The norms of legislative documents on environmental protection are getting more and more stringent every year. In view of this, the usage of spent or short-term oils turns out to be disadvantageous. This fact explains the desire of enterprises to support their oils in operating condition as long as possible.
Industrial oil purification and regeneration processes are generally meant to provide the following advantages:
A huge number of lube oil systems, now in use in industry, mostly use industrial oils of general application. In order to protect these systems from damage they are equipped with fixed filters while completing. Their usage is essential as 80% of all faults in the oil equipment operation occur due to impurities. They may already appear together with the oil entering the system or in the process of refueling. Impurities can also accumulate in the course of system operation. In the latter case the oil is polluted with insoluble substances, such as sand, dust, or rubber. These impurities reduce operating reliability and service life of oil systems.
Industrial oil restoration is quite a time-consuming process. It is based on the selection of special tools and equipment in the form of various stations and installations that effectively performing their functions by optimally selecting purification methods. It does not matter what equipment is provided to be used for the industrial oil purification. It can be a stand, a mobile or stationary unit, a centrifugal separator or a separate filter, as all these purification systems are typically composed of a number of essential components. Typical installation equipment generally comprises of filters (typically primary purification) which remove solids. In case of need they are fitted with an electric heater, as well as nutrient pumps for pumping the spent oil and delivery of the clean oil into the system. Any installation of industrial oil purification of, if necessary, can be equipped with a special alarm system. It is triggered in the case of any failures or accidents. As a rule, such equipment must additionally be provided with a water seal monitoring system.
If the polluted oil purification process and recovery process are conducted by specialized enterprise or at the oil collecting and cleaning site, the operating procedure involves several steps:
Industrial oil purification stations can be upgraded with the drying and oil degasification units, vacuum ejector, a vacuum pump, respectively, control, control panel, instrumentation and controls according to the purification method. Conception determines the station assignment. They can be manufactured by stationary and mobile (on the basis of a trailer or a container).
Purification or regeneration methods for industrial oils can be classified as follows:
1. Physical methods
They are aimed to remove solids, water micro-droplets and, if possible, resinous and coke-like formations. Oils are treated in the force field when using centrifugal and gravitational forces. Magnetic, electrical and vibration impacts, as well as filtration, water washing, and evaporation and vacuum distillation are less commonly used. Evaporation removes low-boiling impurities. Heat exchange processes of various kinds, as well as mass-exchange processes are also physical methods. They address the removal of water, hydrocarbon oxidation products and low-boiling impurities from spent oil.
1.1. Settling
This is the simplest way of oil purification. It lies in natural settling-down of mechanical particles in a liquid medium. It occurs by the action of gravitational forces, as well as in the segregation of the liquid phases having different densities. Depending on the level of oil pollution and the purification time, settling is applied as either a separate process or a preliminary stage before filtration or centrifugation. The disadvantage of this method is considered the long duration of the particle settling-down process. It is necessary for the complete oil purification, as well as the removal of only the large particles having size of 50-100 microns.
1.2. Filtration
It belongs to the most effective methods of the removal of mechanical impurities from the oil. Filtration aims at extracting mechanical impurities and particles of resinous compounds. It is carried out by passing the polluted oil through the porous filter walls (mesh or porous). Meshes (metallic and plastic), various tissues, felt, paper, composite materials and ceramics may be filtration material. Disposable or reusable filters are used for filtration. Purification may be implemented in steps. This generates primary purification stage with the largest impurities being removed from oil, and fine purification stage with the final post-treatment. The disadvantage of this method is considered to be a need for the constant procurement of filtering elements, their regeneration and subsequent utilization (in the case of disposable filters utilization is required after the disposable filter end-of-life).
1.3. Centrifugal oil purification
This oil purification method is based on the use of centrifuges. It is considered the most highly efficient and efficient, aimed at mechanical impurity removal. This process allows combining the impurity removal with water removal. Centrifugal purification lies in separating the various fractions that make up the heterogeneous mixture. This occurs under the influence of centrifugal forces. The complexity of the purification process of the centrifuge itself from mechanical impurities can be considered the disadvantage. Water removal rate by using centrifugal purification is relatively high, but the purification degree is low. That often requires further purification by other methods. In addition, centrifuge is one of the devices difficult in operation. They require manual adjustments and therefore a constant presence of the operator.
2. Physical-chemical methods
The methods of this group may include the following processes: adsorption, coagulation, ion exchange and selective dissolution of the oil impurity particles. The method for chemical purification of industrial oils is based on the acid purification process. There is a method for purification of industrial oils with concentrated sulfuric acid (based on 10 w/w % on raw). The process is accompanied by intensive stirring, followed by water washing. As sulfuric acid is a b oxidizing agent, it does not only resinify impurities. It can resinify hydrocarbon oil base as well. This method has the following disadvantages: formed stable emulsion does not foster the rapid phase separation; formed large number of acidic and environmentally hazardous sludge is difficult in utilization.
General disadvantages of used purification methods for spent industrial oils lie in choosing very aggressive reagents and complex, multicomponent compositions. The purification process becomes multi-step and often requires the creation of high-temperature conditions.
2.1. Adsorption oil purification
Industrial oil purification by this method contributes to acidity reduction and water removal. The basic principle is to absorb various oil polluting components, including water, with the help of adsorbents. They are solid materials with a high porosity. The nature and size of the adsorbent pores considerably determine its applicability for oil removal from certain pollutants. The method is considered simple. However, it has poor efficiency. It also requires recycling of environmentally aggressive adsorbents.
2.2. Thermal vacuum drying
This method is used to remove water from oils. The method is based on the separation of oil and water fractions. It occurs due to the difference in boiling points. Spent oil is sent through a low-pressure container with water beginning to evaporate already at room temperature. Process intensification can be achieved by oil spraying into the vacuum environment created by vacuum pumps. Thermal vacuum drying allows to remove the following from oil:
During the fine dispersion oil quickly gives up its water. Gas and water vapor and the air leave the unit and oil (drained and degassed) precipitates at the bottom of the vacuum container. The purification high degree, simple construction, high reliability of the equipment and purification modes without complicated settings complement the positive characteristics of this method having the possibility of automated schemes integration within purification process. However, the water removal rate by this method is considered relatively low. An important aspect in thermal vacuum drying is a condition to prevent air from entering the unit from the external environment. That may lead to a number of negative consequences:
3. Chemical methods
This group of methods is based on the chemical treatment of oil polluted with acids or alkalis. Alkaline treatment may also be used as an additional purification stage, aimed as well at neutralizing acid residues after acid treatment. The basic reagent in acidizing is sulfuric acid. The basic idea of the method lies in chemical action with oil polluting components. It results in their turning into easily detachable forms (water dissolution, precipitation, etc.). In this regard, chemical treatment is often complemented by other purification methods designed to remove chemically modified pollutants from oils. This may be adsorption, filtration, separation and other methods.
According to areas of its purpose, aviation oils are classified into oils for gas turbine (turbo-jet and turbo-prop) and piston aircraft engines, as well as for various helicopter nodes. Low viscosity oils are poured into the second type engines, more viscous oils are used for the first type engines.
A constant aviation oil lubrication of engine reduction gears, bearings, stuffing boxes and slotted joints must be maintained in order to avoid overheating friction units in the aircraft. In this regard, the aviation oils for jet engines need regular and careful inspection. Aviation oils are used in the aircraft engine operation relatively recently. It is known that the oils operate 10 hours in summer, in winter their operation period is 20 hours. That means that a certain amount of oil filled into a tank of an aircraft or a helicopter has to be replaced within 10-20 hours of an aircraft engine operation, not just in the tank, but also in wet sump. Lubrication should be performed carefully in order to avoid mechanical impurities getting inside.
After several hours of operation oil loses its inherent form and looks like a spoiled material. In such case the smell of oil changes greatly due to the degradation products. Oil located on the cylinder walls significantly changes its appearance and physical and chemical characteristics in a few hours of operation. Studies have shown that aviation oil does not reach such criticality level when working on aircraft engines with a partial loss of qualities that there is an urgent need to replace it with a new one. Oil wearing property is primarily caused by a high temperature. It leads to oxidation of the most volatile contained hydrocarbons. The oxidation leads in turn to an increase in the acid and resin content. Changing the resin molecular structure contributes to the asphaltene formation. The latter cause the carbenes and carboides appearance. Spent aviation oil is characterized by the presence of sediment, poor saponification number and overacidity.
Oil may also be a subject to various chemical changes during a certain operating time. For example, however, these factors usually do not favor deep chemical reactions and mostly affect the unstable oil fraction within 10-12 hours of aviation oil operating in the engine. A large part of the spent oil is suitable for further use. It is usually sufficient to release the oil from the part polluted with the product of the transformation to return the oil to the system. That part lowers the lubricating oil characteristics. Spent oils can be used again for the same purpose, as fresh ones, after regenerating operations. Recovering spent aviation oils means its purification from mechanical impurities and asphalt-resinous substances. Asphalt-resinous compounds can be removed as reagents from the oil by means of chemical purification. Therein bleaching earth, sulfuric acid, sodium hydroxide, triphosphoric acid sodium and sodium carbonate are used. All the reagents (except for earth) contribute to the settling of resin colloidal particles, hydrocarbons, solids. Bleaching earth absorbs them due to its porous structure.
Pollution fraction of spent aviation oil consists of ash, hydrocarbons, water, zinc, phosphorus, calcium, and solids. At the same time chemical composition of the spent aviation oils differ is the same for various types and kinds. Such set of pollutants makes it necessary to carry out the disposal of the spent product. This must be carried out by specialized companies and at relevant enterprises. This process is a significant challenge that requires a certain cost of money, time and efforts.
Aviation oil purification is the removal of the following components from it:
When refueling aircraft hydraulic systems ceramic-metal or stainless steel filters are used mainly for removal of oil impurities. Ceramic-metal or stainless steel filters have porous structure. Linear filters with a nickel mesh having a twill weave provide filtration fineness of 12 µm. Ceramic-metal filters of porous (stainless) steel provide filtration fineness up to 5 µm. When filling engine lubrication systems with oil disc filters (discs of brass mesh) are used. Their filter fineness is comparatively lower. Their filter material usually does not hold particles smaller than 60 µm. However, modern models of refueling aircraft equipment have two-stage filtration. It provides a higher purity of refueled oils.
Good lubrication at the contact of aircraft engine moving parts (and consequently, its long term reliability) can be ensured in case of good oil purification (filtration) from the metal chip, dust, various fibers and water droplets. In this case oil filters must be placed in the engine, or in external circulation loop of the lubrication system. Number of the oil filters can vary, but it generally is at least two. A filter is installed on the incoming oil pipeline, the other is installed on the outgoing oil pipeline. If the engine is equipped with only one filter, an additional filter is installed in the external circulation system. Additional filters may be installed in the oil system, but they are generally placed on the engine oil supply line.
Oil deasphalting is conducted with liquid propane by mixing it with the refined oil (10: 1) under pressure up to 4 MPa. The oil being refined enters the middle column of a special cavity. Propane is sent to the bottom part. Tar is removed from the lower part of the column. The oil refined from asphalt is removed through the top of the column and separated from the solvent.
Paraffin and ceresin are separated from oil (dewaxing process) by deep cooling. Before the start solvents are input into the oil with the subsequent heating of the mixture to a temperature higher in 15-20 °C than complete dissolution temperature of the ceresin and paraffin. The mixture is then cooled and subjected to filtration or centrifugation processes. Separation of solidified ceresin and paraffin particles takes place during those processes. However, the preference is given to the input of additives in oil instead of further purification of spent oil. They provide the necessary performance.
The technological processes of manufacturing aviation oils also provide their purification changing the properties of oils. The following purification methods take place in the oil production:
- Acid-contact oil purification
It includes purification using a reagent that reacts with harmful impurities. This reagent is sulfuric acid. When added to oil it destroys such compounds as unsaturated hydrocarbons and asphalt-resinous substances precipitating together with unreacted acid and forming the acid sludge. Sulfuric acid does not "touch" cyclane hydrocarbons as they are valuable for oil. After separating the acid sludge they are washed with an alkaline solution with water which neutralizes the residue of acid sludge and sulfuric acid. The process is completed by washing the oil with water, followed by drying with hot air or superheated vapor. Acid purification is known as the acid-contact at contact filtration through bleaching earth. The disadvantage of this purification method is high consumption of sulfuric acid and the formation of acid sludge. It is a waste product, very harmful and environmentally toxic under this method and requires disposal.
- Selective solvent oil purification
It is a modern and effective method for oil purification. Repeated use of selective solvents in the purification process is typical for this method. Solvent mixes with oil and selectively dissolves the harmful impurities, but not the oil, at a given temperature and in the required quantitative ratio to the refined oil. After the selective treatment two layers are formed: a layer of refined oil and solvent layer with dissolved harmful impurities (extract). Refined oil is again refined with bleaching clay. The extract is recovered by separating from harmful products that allows using the solvent again.
- Combined oil purification
It is a combined selective and acid-contact purification with the oil being exposed to cresol, phenol and nitrobenzene. Selective purification aviation oils are the best stability indicators in comparison with sulfuric acid purification oils. However, sulfuric acid purification oils are slightly better in their binding capacity than selective purification oils. That does not meet the modern motor industry requirements. To enhance the aviation oil stability the effect on the aluminum chloride processing was investigated. It had good effect on the characteristics of aviation oil in conjunction with the nitrobenzene oil processing.
- Membrane purification oil
New purification methods are often performed with the help of membrane technologies. Modern membranes are able to filter at the molecular level, skipping, for example, the hydrocarbon molecules and delaying molecules of oxidative polymerization product (unwanted impurities). Spent oil purification can be made using membranes by reducing the content of metal, sulfur and ash, as well as make the recovery of free of suspended solids and the mud possible. Inorganic membranes (oxides of aluminum, titanium, zirconium, silicon or ceramic) with a pore size of 0.1-0.2 µm subjected to periodic chloroform washing (methanol, methylene chloride, tetrachlorethylene or mixtures thereof) may also be used as the filter material.
Filters
Upon becoming the official distributer of fabric filters, our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), carries out the following: finds the buyers of your products on the market, conducts technical and commercial negotiations with the customers regarding the supplies of your equipment, concludes contracts. Should a bidding take place, we will collect and prepare all the documents required for the participation, conclude all the necessary contracts for the supply of your equipment, as well as register the goods (fabric filters) and conduct customs clearance procedures. We will also register a certificate of transaction (Passport of Deal) required for all foreign trade contracts in the foreign currency control department of the authorized Russian bank so that currency transaction could be effected. If required, our company will implement an equipment spacing project in order to integrate your equipment into the existing or newly built production plant.
We are convinced that our company ‘Intech GmbH’ LLC (ООО «Интех ГмбХ»), will become your reliable, qualified and efficient partner & distributor in Russia.
We are always open for cooperation, so let’s move forward together!
