Fuels & Lubricants Magazine

2017
Fuels
&Lubricants
JOURNAL FOR TRIBOLOGY, LUBRICATION, APPLICATION OF LIQUID AND GASEOUS FUELS
AND COMBUSTION ENGINEERING
October 2017 IISSN 2584-4512
Issue No. 1

SUCCESS
TOGETHER
SUCCESS
TOGETHER

Editor’s Letter
Dear readers,
Although we love our tradition, we are more than aware of challenging, dynamic
and fast pacing future in the business. Keeping that in mind, Croatian society for fuels
and lubricants with 50 years of tradition made a decision to change the concept of its
publication Fuels and Lubricants. The main goal of this change was to make the Fuels
and Lubricants more dynamic, informative and closer to you, the readers.
Professional and scientific papers will remain the core of the magazine. We will continue
to support professionals and scientist in publishing the results of their research
and to share the experience and knowledge with us. Especially we would like to open
our pages to young professionals and scientists and encourage them to enter the world
of research and professional publication.
Aside of professional and scientific papers, the new concept will be dynamically divided
in number of short, useful, actual and informative parts. With them we would like
to cover recent developments, events, interesting conferences, legislation changes and
all related topics for which we are sure that will provide fast and useful information.
We named them corners. Each corner is dedicated to certain topic and its main goal is
to give information related to one professional field. Corners will not be fixed. We will
tailor them according the content which will in our opinion be the most informative
for the respective period.
We also take this opportunity to welcome you to the 50th Lubricants and base oil
symposium which will be held in Zagreb from 18-20 October 2017 in one of the most
iconic places in Zagreb, Hotel Esplanade. The jubilee Symposium will provide the
latest information in additive, base stock and lubricants development, future outlook
for lubricants industry, markets and trends, highlights on the latest development in
automotive lubricants and related fluids, recent movements of industrial lubricants
including MWFs and greases, the newest HSE regulations impact on lubricants industry,
condition monitoring, laboratory and tribological testing and practical experience
in R&D and application of lubricants. The list of the speakers represents the high level
of international experts and together with the extensive networking and social events
the benefit of the Symposium will for sure increase.
At the end we can conclude that we have something old and something new but both
prepared with respect to our tradition and the obligation to look in the future. We
hope that you will enjoy them together with us.
Sanda Telen
Editor in Chief
Fuels&Lubricants No. 1 OCTOBER 2017 1

Contents
4
Metalworking fluid
emulsion stability and
base oil properties
- some critical
correlations
Prof. Thomas Norrby,
Dr. Pär Wedin,
Linda Malm
8
Legislation Corner
Legislation Overview
Related to Oil and Gas,
Fuels and Lubricants
Business
- 2017
12
Interview
Delayed Coking:
Advanced Valve Solutions
for Secure Operation
18
Upgrading options of
heavy residues, rubber
modified bitumen case
study
András Holló,
András Geiger,
Péter Gergó
24
Green Corner
Sustainability of
Bioenergy Supply Chains
Workshop
28
Conference Report
World Petroleum Congress,
Istanbul 2017
34
Technology Corner
Big Data in Oil & Gas
36
Fuels Corner
Fuels and Fuels Processing
38
Lubes Corner
Lubricants and Lubrication
Engineering
42
Lab Corner
Symposium of Petroleum
Laboratories in the Region
44
Technical News
ACEA & API Approved
Lubricants
Fuels and Lubricants
October 2017
Issue No. 1
Fuels and Lubricants: Journal for Tribology,
Lubrication, Application of Liquid
and Gaseous Fuels and Combustion
Engineering
Founder and Publisher:
GOMA - Croatian Society for Fuels
and Lubricants
Berislavićeva 6
HR-10000 Zagreb
Email: goma@goma.hr
Tel: +385 1 4873 549
Fax: +385 1 4872 503
Editorial Team:
Sanda Telen, Editor in chief
Ivana Lukec
Bruno Novina
Graphic Design:
Kristina Babić
Printer:
Kerschoffset
Abstracting & Indexing Services:
EBSCO Host © , ProQuest: Technology
Research Database, Engineering
Research Database, Materials Research
Database, Abstracts in New Technology
& Engineering, Mechanical & Transportation
Engineering Abstracts...
All enquiries and requests for advertising
should be addressed to:
Bruno Novina
Email: bruno@goma.hr
Phone: +385 98 404 786
Annual subscription: 25 € (185 kn)
ISSN 2584-4512
UDK 621 + 66 (05)
2 Fuels&Lubricants No. 1 OCTOBER 2017

egida
Specialty oils for maximum emulsion
stability and high solvency
The superiority of metalworking fluids made with Nynas base oils is just one
example of how a daily chore can turn into a regular delight with the right
naphthenic solution. The same goes for greases and lubricants, where Nynas
base oils offer high solvency and excellent low temperature properties.
www.nynas.com/base-oils

Metalworking fluid emulsion
stability and base oil properties
- some critical correlations
Prof. Thomas Norrby
Nynas AB, Naphthenics
TechDMS, Nynäshamn,
Sweden
thomas.norrby@nynas.com
Dr. Pär Wedin
Nynas AB, Naphthenics
Research, Nynäshamn,
Sweden
Ms. Linda Malm
Nynas AB, Naphthenics
TechDMS, Nynäshamn,
Sweden
Introduction
Metalworking fluids (MWF)
are used to aid the process of metal
machining, mainly by providing lubrication
of the workpiece and tool,
by providing cooling and corrosion
protection. Many different MWF
formulations are needed for the
vastly differing needs under varying
operating conditions!
Metalworking fluids can be generally
categorized as being either
emulsions (“coolants”), which mainly
cool and protect against corrosion,
or neat oils, which can handle better
high deformation, severe boundary
lubrication and offer improved tool
wear protection.
The make-up of a typical metalworking
fluid emulsion is a dilution
(hence not a “neat” oil!) of 5 to 10
volume-% mineral oil concentrate in
water. This water could be tap water,
with whatever water hardness the
local source offers, of demineralised
(Demin) or Reverse Osmosis (RO)
water which is very soft. The mineral
oils content is high, typically
60-70% of the concentrate, and the
remainder being oil soluble additives:
Emulsifiers, Lubricity additives,
Corrosion inhibitors, Biocides,
Antifoams and Mist suppressants.
Applications for emulsions include
use as cutting fluids, corrosion
protecting fluids and hot rolling
fluids. Emulsions are suitable for
high-speed cutting operations where
much heat is generated.
Naphthenic base oils provide
several advantages to MWF formulations.
High solvency allows for the
dissolution of high amounts of additives,
and contributes to increased
emulsion stability. In addition, a
lower density difference between
naphthenic oil and water compared
to paraffinic oils also provides increased
emulsion stability, as gravity
has less of a density difference to pull
on. This also increases emulsion resistance
to centrifugal forces during
pumping.
Emulsion stability is key to metalworking
fluid (MWF) usefulness- if
the emulsion breaks, it has ceased
to function. Investigations of the
relationship between formulation
and emulsion stability thus is a first
step towards better understanding
of the complex chemistry of a fully
formulated MWF. Test variables in
the study were base oil type selection,
water hardness and emulsifier
chemistry and Hydrophile-Lipo-
4 Fuels&Lubricants No. 1 OCTOBER 2017

phile Balance (HLB) value selection.
We sought to understand how the
properties of the base oils, especially
solvency (as indicated by the Aniline
Point), and the water hardness (°dH)
would influence emulsion stability
over test period up to one week. A
second investigation was made utilizing
a semi-synthetic formulation
giving translucent micro-emulsions
with the same base oil slate.
Figure 2. Droplet
Size Distribution at
HLB 12, soft water
(0 °dH).
Experimental work
Metalworking fluid
emulsions
A metalworking fluid (MWF) Soluble
Oil (Conventional Oil) emulsion
stability study was set up, comparing
the properties of a Naphthenic
base oil, versus three paraffinic type
base oils of similar viscosity, ca. 20
cSt (100 SUS) at 40 °C, see Figure 1.
NYNAS T 22 is a good example
of the quintessential “100/100”
metalworking fluid oil, having a
viscosity of 100 SUS at 100 °F. As
Group I oils we picked a traditional
SN 100 oil, and the NYBASE ® 100,
which belongs to a new range (NR)
of Group I replacement products.
These have been designed to have
Kinematic Viscosity (KV), Viscosity
Index (VI) and Aniline Point (AP)
closely matching those of existing
Solvent Neutral Group I base oils.
The properties of these new products
are described in a previous
publication [1] and more information
is available on www.nynas.com.
In this study, further work on model
metalworking fluid emulsions was
undertaken to search for more likenesses
versus Group I. The last test
oil was a conventional Group II base
oil of similar viscosity.
The solvency, as indicated by the
Aniline Point (AP), varies across the
base oils studies:
1. Naphthenic NYNAS T 22
(~100 SUS), AP = 76 °C
2. SN 100, AP = 100 °C
3. NYBASE® 100, AP = 101 °C
4. HP4, a Group II base oil, 20 cSt @
40 (4 cSt @ 100 °C), AP = 108 °C
Standard emulsifiers (surfactants),
Span 80 (Sorbitan monooleate),
with a Hydrophile-Lipophile Balance
(HLB) number of HLB 4.3
and Tween 80 (Polyethylene glycol
sorbitan monooleate), HLB 15,
were utilized to make nine different
blends with HLB:s ranging from 9 to
13, in half-steps. Butyldiglycol was
employed as solubiliser (co-emulsifier,
coupling agent).
All emulsion concentrates were
of the same oil content, with surfactants
to make up the required
HLB value. The concentrate was
added to the water at ca. 5 v/v-%,
and sonicated at low power for three
minutes.
Droplet size distribution
experiments
The Soluble oil (milky) emulsion
droplet size distribution (DSD) was
determined at three different times;
at mixing, after one day, and again
Figure 1. From left:
NYNAS T 22, SN
100, NYBASE® 100
and HP4.
Fuels&Lubricants No. 1 OCTOBER 2017 5

after seven days. The droplet size
was measured at high dilution by a
Malvern Mastersizer 3000 E.
The droplet size distribution varies
over two orders of magnitude,
from very small (1 µm or less) to
close to 100 µm, see Figure 2. The
smaller the droplet size, the more
stable the emulsion.
In Figure 3, the droplet size distribution
statistical mean value is
plotted versus HLB. These graphs
typically will show an “U”-shaped
minimum where the emulsion
droplet size, is the smallest, and
hence at which HLB the most stable
emulsions are formed. Similar plots
were obtained for the Group I, NY-
BASE® new range Group I replacement,
and Group II formulations.
An increase in mean droplet size
over time is observed: Day 0 (Blue
bar), Day 1 (Red bar) and Day (7
Green bar) in general show increasing
value with time (larger droplet
size). Since a gradual increase of
droplet size would be the earliest
warning sign and the first steps
towards coalescence and emulsion
break-up, this is very interesting
information.
For the more paraffinic oils the optimum
HLB was close to 10, but the
value of the minimum droplet size
was in no case below 10 µm, more
than 20 times larger than for the
naphthenic NYNAS T 22 oil. One
example is shown in Figure 4.
Emulsion phase thickness
and stability determination
The emulsion phase thickness was
determined by light scattering determination
at different time intervals
utilizing a Turbiscan LAB, measurements
at actual concentration “asis”.
The Turbiscan Stability Index
(TSI) was utilized to characterise
emulsion stability.
The TSI development during the
first ten minutes after sonication is
shown for nine samples with HLB
from 9.5 to 13. The most stable
properties for the NYNAS T 22
based emulsion were found around
HLB 12, similar to what the droplet
side distribution (DSD) experiment
indicated. A good correlation was
found between the DSD established,
and the TSI calculated from the
emulsion phase thickness measurements
utilising the Turbiscan instrument,
for those oil and emulsifier
combinations that gave good (small)
Figure 3. DSD
development over 7
days versus TSI (10
minutes) for a NY-
NAS T 22 based
milky emulsion, soft
water (0 °dH).
Figure 4. Emulsion
based on NYBASE®
100 in soft water (0
°dH) displaying a
minimum droplet
size at HLB 10.5.
droplet sizes. In Figure 3, the “Ushape”
of the DSD is mirrored by the
TSI values (the thin purple line).
Semi-synthetic translucent
micro emulsions
As a second phase of the study, we
made semi-synthetic translucent micro
emulsions of the same four base
oils. The emulsion concentrate contained
36% water, 30 % base oil, and
a range of additives (34% in all): Tall
Oil Fatty Acid (TOFA) as the main
emulsifier, a non-ionic Fatty alcohol
alkoxylate as co-emulsifier, aminic
bases, steel and yellow metal corrosions
inhibitors, coupling agents
and a biocide. The concentrate was
added to the water at ca. 5 v/v-%,
and sonicated at low power for three
minutes.
The resulting semi-synthetic micro
emulsion droplet size distribution
(DSD), Figure 5, showed some
interesting differences versus the
milky Soluble oil emulsion, Figure
2. All four oils, in hard or soft water,
display droplet sizes below 10 µm.
For the T 22 in soft water (both on
Day 0 and Day 7), most of the droplet
sizes are below 1 µm (the absorption
peak below 1 µm). In contrast, in
hard water, T 22 displays two peaks,
at 0.3 µm and one about 1.3 µm.
The SN 100 in hard water displays a
broad peak around 0.5 µm (both Day
0 and Day 7). In soft water, the peak
is shifted up towards 0.8 µm and is
narrower in shape. The Group II oil
(HP 4) display narrow peaks centred
6 Fuels&Lubricants No. 1 OCTOBER 2017

around 1 µm in both hard and soft
water. The NYBASE® 100 at Day
7 displays broader peaks centred
around 1.2 µm, in hard water, a
broad peak (0.5 µm to 5 µm) above
1.1 µm, possibly obscuring a bi-phasic
behaviour, which is not baseline
separated. In contrast, in soft water
the peak at 1.2 µm is (somewhat)
more narrow.
An attempt to summarize the
above results would be that T 22
in soft water yields the most stable
emulsion with the smallest mean
DSD. For hard water, the result
spread is larger, and both SN 100
and T 22 display notable peak maximum
shifts, but in opposite directions
of change with water hardness.
Results and discussion
Figure 5. The Semi-
Synthetic formulation,
droplet size
after 7 days under
hard (20 °dH) and
soft (0 °dH) water
conditions,
In this study, we set out to investigate
different parameters affecting
the primary emulsion stability of
model metalworking fluids. We
could determine the optimal HLB
value for the different base oils, and
could also observe large differences
in emulsion stability. The primary
contribution to stability, as demonstrated
by a low (1 µm or less)
mean droplet size, was found to be
solvency; the lower the aniline point,
the more stable the emulsion formed
in the Soluble oil coarse (milky)
emulsion system based on non-ionic
emulsifiers. The Naphthenic base oil
emulsions display the highest stability,
followed by the Group I and
Group I replacement base oils, then
Group II. The solvency, as indicated
by the aniline point (AP), mirrors
this order, and thus apparently plays
an important role for emulsion stability
in the systems investigated.
The second part of the study
was made on semi-synthetic formulations,
based on anionic and
non-ionic surfactants. For these
samples, the droplet size in general
was much smaller, indicating an
even higher emulsion stability. The
semi-synthetic formulation did
display a greater sensitivity towards
water hardness, as expected from the
anionic surfactant chemistry. The
extent and character of this effect
was different for the different base
oils. The clear bi-phasic nature of the
T 22 based translucent micro emulsion
in hard water, warrants closer
study. Also, the peak area around
10 µm would be expected to grow at
longer observation times, and would
be interesting to follow. Possibly
this is a similar bi-phasic behaviour,
but shifter up towards much larger
droplet size? However, the general
stability trend follows what we found
for the milky emulsions: Naphthenic
> Group I > Group II.
Conclusions
Two complementary methods for
the determination of droplet size
were utilised to study emulsion
stability: droplet size distribution
(DSD), and light scattering and
transmission. The two methods yield
comparable results, especially for
small droplet sizes (“good” emulsion
quality).
We could determine a preferred
HLB value for each base oil type,
where the optimum conditions for
emulsion stability were found. This
HLB value was found to be about
two (2) units higher for the naphthenic
base oil compared to the
paraffinic Group I and II base oils,
and would serve as a rule of thumb
recommendation. The droplet size
and stability nevertheless was found
to be better for the naphthenic base
oil systems, showing an inherent difference
under these varying conditions.
The key base oil property difference
identified was solvency, as
expressed by the aniline point. The
water hardness played little role in
the non-ionic surfactant (emulsifier)
systems, but made a difference in
several ways in the semi-synthetic
emulsion systems, containing also
anionic surfactant.
Increasing the fundamental understanding
of important oil and emulsion
properties hopefully is a useful
tool for formulators and developers
in different parts of the world, where
water hardness differs and the choice
of base oils available may be bewildering!
References
[1] Norrby, T., Salomonsson, P., and
Malm, L. “Group I Replacement
Fluids - a Hydraulic Fluid Formulation
and Compatibility Study”,
Tribologie + Schmierungstechnik,
Vol. 64, No. 1 (2017), pp. 31-41.
© 2017 Nynas.
All rights reserved.
NYNAS and NYBASE ®
are trademarks of Nynas.
Fuels&Lubricants No. 1 OCTOBER 2017 7

Legislation Corner
Legislation Overview Related
to Oil and Gas, Fuels and
Lubricants Business - 2017
Adriana Petrović
The overview of most
important legislation
acts gives information
of dynamic changes in
Croatian and EU
legislation
Croatian legislation overview for 2017
Due to repeated elections and government changes
in Croatia, adoption of new laws and bylaws was not
executed with the expected and planned dynamics for
the year. The adoption of few already prepared acts was
postponed or returned for revision. It is expected that
during the autumn parliament and government sessions,
the process of adoption will be intensified to avoid
further delay in the process of legal regulation of the
business environment.
Here is the list of the most important laws regarding
the business area:
Decision on the adoption of the Waste Management
Plan for Republic of Croatia for the period
2017 - 2022 (OG 3/2017) - January 2017
The Plan creates the preconditions for the implementation
of the Circular Economy Concept promoting waste
re-use, recycling and composting with the primary
focus on the municipal waste. It does not have significant
impact on the current fuel and lubricant business
operations but may be considered as a framework for
developing new business cases aligned with the Circular
Economy Concepts.
Act on the Amendments to the Gas Market Act
OG 16/2017- February 2017
The Act represents to certain degree a change towards
open market trading, abolishing the obligation of gas
producers to sell the gas on prescribed price to the
wholesale gas market supplier. However HEP (appointed
by Croatian Government for a transitional period) as
wholesale gas market supplier will be obliged to sell gas
under regulated conditions to suppliers which are holders
of public service obligation of gas supply of household
customers.
8 Fuels&Lubricants No. 1 OCTOBER 2017

Decision on the adoption of the National Policy
Framework for the establishment of infrastructure
and market development of alternative
fuels in traffic OG 34/2017 - April 2017
The National Policy Framework (NPF) for the establishment
of infrastructure and market development of alternative
fuels in traffic has been adopted pursuant to the
Act on the Deployment of Alternative Fuels Infrastructure.
The NPF the proposes measures on the national
level and on the level of local and regional self-government,
as well as measures which may be used to promote
the establishment of infrastructure for alternative fuels
within the public transportation services. Elaboration of
NPF measures is foreseen on a three-year basis through
the National energy efficiency action plans.
The purpose of the Low-carbon
Development Strategy in Croatia
is to achieve a competitive low
-carbon economy in Croatia by
2050
Regulation on Liability for Environmental
Damage (OG 31/2017) - April 2017
The Regulation regulates the activities considered to
be hazardous for the environment and/or humans, the
criteria for assessing threats and identifying environmental
damage, the most appropriate measures for the
elimination of environmental damage, their purpose
and method of selection, the way to remedy the damage
to the environment and the method of specifying costs
related to the identification and elimination of threats
and environmental damage.
The Regulation repeals the Regulation from 2008. In
comparison to the previous Regulation, the changes are
not substantial and do not have any additional impact on
fuel and lubricant business operations.
Amendments to the Regulation on Prevention
of Major Accidents involving Dangerous
Substances (OG 31/2017) - April 2017
Amendments were adopted to harmonise the existing
Act with the Directive 2012/18/EU -Seveso III and the
amendments in the Air Protection Act (OG 61/2017).
Act on Amendments to the Air Protection Act
(OG 61/2017) - June 2017
Air Protection Act (OG 130/11, 47/14) was amended
(OG 61/2017) to include several EU Directive changes
fulfilling the obligations following the Clean Air Policy
Package primarily laying down the rules concerning
reference methods, data validation and location of
sampling points for the assessment of ambient air quality
defined trough the Ordinance on air Quality monitoring
(OG 79/2017) - August 2017.
Fuels&Lubricants No. 1 OCTOBER 2017 9

Legislation Corner
Regulation on the Quality of Liquid Petroleum
Fuels and the Method of Monitoring and
Reporting and Methodology of Calculating
Greenhouse Gas Emissions in the Life Cycle
of Supplied Fuels and Energy (OG 57/2017)
- June 2017
The Regulation transposes the Directive 2015/1513 relating
to the quality of petrol and diesel fuels and amending
Directive 2009/28/EC on the promotion of the use
of energy from renewable sources into the legislation of
the Republic of Croatia. In relation to the obligation
prescribed by the Directive to reduce GHG by 6% by
2020 (compared to 2010) in the life cycle of fuels and
energy per unit of energy prescribed by the Regulation,
designed suppliers will be obliged to calculate and report
following the definitions and the calculation method
starting in 2018 with verified data for 2017.
Regulation on the limitation of emissions
values of air pollutants from stationary
sources (OG 87 /2017) - September 2017
This Regulation lays down mainly the emission limit
values ​of air pollutants from stationary sources, the
monitoring and evaluation of emissions, the manner of
reducing emissions of pollutants into the air, the manner
and timing of delivery of emission reports to the Croatian
Environment and Nature Agency and to the competent
bodies of the European Union as well as the level
of tolerance for the existing sources for a certain period.
The primary reason for the revision of the Regulation is
harmonization with the Directive (EU) 2015/2193 of
the European Parliament and of the Council on the limitation
of emissions of certain pollutants into the air from
medium combustion plants.
“Europe on the Move” is
a series of proposals aimed
to encourage clean and
sustainable mobility
Low-carbon Strategy
Through half June/half July 2017 public hearing and
public presentation of the draft of Low-carbon Development
Strategy in Croatia was held. Strategy draft
establishes measures which can be taken to reduce
greenhouse gas emissions in different sectors (energy,
industry, transport, agriculture, waste management...).
The purpose of the low-carbon Development Strategy in
Croatia is to achieve a competitive low-carbon economy
in Croatia by 2050. The strategy sets the way for transition
towards sustainable competitive economy in which
economic growth is achieved through activities, industries
and fuels with low greenhouse gas emissions.
10 Fuels&Lubricants No. 1 OCTOBER 2017

egida
Photos: www.pixabay.com
EU legislation overview
- most important topics
On EU level there are several EU Commission proposals
discussed and amended through Parliament Committees:
• Energy Union Governance proposal: COM (2016) 759
final,
• Energy Efficiency Directive: Proposal COM (2016)
761 final,
• Renewables Energy Directive - RED II proposal:
COM (2016) 767 final.
The documents are expected to be approved during
Q3/Q4 2017 on Parliament Plenary voting (TBC) and
will represent the legislation frame for fuels & lubricants
products, producers and distributors for the 2020-2030
period.
WFD revision proposal COM (2015)0595
- C8-0382/2015 - 2015/0275(COD)
European Parliament adopted on 14 March 2017 the
proposal for the revision of Waste Framework Directive
(Ordinary legislative procedure: first reading), where
regeneration and re-refining of waste oils are required
(Article 21). In May the European Parliament voted on a
mandate to open negotiations with the Council.
EU Commission launched the Mobility
Package - Europe on the Move
At the heart of the Mobility Package published by the
European Commission on 31.5.2017 “Europe on the
Move” is a series of proposals aimed to encourage clean
and sustainable mobility, harnessing automation and
developing socially fair and competitive transport
networks. The proposals include new monitoring and reporting
system for new Heavy duty vehicles (CO 2
emissions)
and recommendation to move towards the use of
the World Harmonised Light Vehicles Test Procedure
(WLTP) for car labelling. Further legislative proposals
are expected notably with regards to post-2020/2021
CO 2
targets for cars and vans, and the introduction of
CO 2
emission standards for heavy duty vehicles (early
2018).

Interview
Delayed Coking:
Advanced Valve
Solutions for
Secure Operation
Interview with Mr. Raimar Hellwig, Metso’s
expert for delayed coking
Raimar Hellwig
The function of a delayed coker is
to convert low value “bottom of the
barrel” feed into higher value
products and it is one of the most
demanding processes in oil refining.
It sets especially high requirements
for valve reliability where
valves must handle a range of gases,
liquids and solids at varying pressures
and temperatures. GOMA
has been talking about advanced
valve solutions for delayed coker
unit with Metso’s coking expert
Mr. Raimar Hellwig. Metso is an
industrial company serving mining,
construction, and oil and gas industries
with the intelligent solutions
and services from the processing
equipment and systems to industrial
valves and controls.
Mr. Hellwig, can you highlight some points of the delayed
coking process?
Yes, delayed coking is part of a refinery process. We refer here to
the thermal cracking method in which low-value hydrocarbon
feedstock is converted to lighter, more valuable products, and
coke. The process involves handling a range of gases, liquids and
solids at high pressures and temperatures up to +550 °C.
But not every refinery has a delayed coking unit, right?
Correct! Delayed coking is not feasible for every refinery. However,
for heavy and sour oil refineries in particular, a coker represents
practically an upgrade that increases feed flexibility. Therefore,
the delayed coking unit is potentially one of the most profitable
operations at a refinery. It also affects plant-wide downstream operations.
So, it depends greatly on efficient flow control solutions
like valves, which must handle a range of gases, liquids and solids at
varying pressures and temperatures. Reliability is not optional.
Mr. Hellwig, Metso has been quite successful with delayed
coker valves recently. Can you tell us more about this?
Metso has been in this market since the 80’s providing valves for
delayed coker units. They are generally on-off or control valves for
different functions, such as emergency shutdown or fuel gas control.
But the crowning glory or highpoint is the coke drum isolation
valve.
Why is this the highpoint?
Our coke drum isolation valves really show that our customers
trust in our performance, our technology and our brand. During
the recent past years, Metso has supplied more than 200 of these
12 Fuels&Lubricants No. 1 OCTOBER 2017

Delayed Coking Diagram,
source Metso
The delayed coking
unit is potentially one
of the most profitable
operations at a refinery.
It affects plant-wide
downstream operations
and depends greatly on
efficient flow control
solutions like valves.
special valves for the coke drum. The four-way switching, isolation
and overhead control valves play a critical role in the performance
and safety of the coking process. Poorly designed valves quickly
allow heavy residuum to creep into the ball/seat or stem areas,
causing a valve seizure, operational downtime and unsafe working
conditions.
What makes this process around the coke drums so critical?
The feed undergoes partial vaporization and mild cracking as it
passes through a coking furnace into the coke drum. This is where
the vapor undergoes further cracking, and the liquid undergoes
successive cracking and polymerization until it is completely converted
into vapor and coke.
The extreme heat and potential volatility of the thermal cracking
process make coking a potentially dangerous application. The escape
of process medium must be prevented to avoid possible lethal
situations. These safety considerations, in addition to increasing
uptime requirements, demand exceptional valve technology and
performance.
With these thoughts in mind, it makes me proud to see the recent
proven viability of our solutions in a range of successful projects.
These include a revamp project in India and a Greenfield project in
Central Europe.
Can you tell us why customers choose Metso for these critical
valves?
With such a challenging application, it is natural that a customer
must weigh different criteria carefully before making a decision.
Those include everything from safe operation, maintenance costs,
Fuels&Lubricants No. 1 OCTOBER 2017 13

INTERVIEW
A valve that is not
working properly has a
direct impact on the
total cost of ownership.
A worst-case scenario,
if the refinery has to
shut down the coker
unit for maintenance
and repair, can easily
turn into a daily cost of
over EUR 300,000 in
lost production.
maximum yield and runtime. Metso engineers have meticulously
developed valves to tackle extreme conditions. For example, the
seat back cavities have been designed to prevent residuum from
entering in the first place and are easily purged to prevent accumulation
in the valve.
What is the scenario if the valves are not working as planned?
A valve that is not working properly has a direct impact on the
total cost of ownership, especially when it comes to coke drum
valves. This starts, for example, with excessively long cycling times
when coke accumulation jams the proper movement of the valve,
resulting in purge steam loss and reduced production efficiency.
What is a worst-case scenario if the valves are not working
as planned?
A worst-case scenario would be if the refinery has to shut down the
coker unit for maintenance and repair. Depending on the size of
the unit, this can easily turn into a daily cost of over EUR 300,000
in lost production. To avoid that, many refineries have fairly modest
targets. They will stop their unit every four years to overhaul
the critical coke drum valves. And then, even the valves that may
still be working fine are changed.
Do you have other examples where expectations were
exceeded?
An example of exceeding expectations is with our condition monitoring
service. Valve performance should be analyzed regularly
during operations. This can be done with the help of Metso service
experts. Thanks to this approach, we can then mutually decide
with the customer before a shutdown which valves should be serviced
and which will stay installed until next time.
In 1999 at a refinery in the US, a customer commissioned 19 of its
critical valves around the coke drum. For the first repair work in
October 2007, only four of these valves were determined to need
a service and spare parts exchange. With proper planning, this
service was completed within the five-day shutdown. Notably, the
remaining 14 valves stayed unchanged in the pipe. So, in this case,
we first exceeded the common valve operational time, and now the
valves are still continuing to operate after an additional 7, 8, 9 or
more years.
Valves by Metso, source Metso
14 Fuels&Lubricants No. 1 OCTOBER 2017

About Raimar
Mr. Raimar Hellwig is Area Business
Manager at Metso Flow Control for
Central Europe and India. Raimar
has been working as a manager in
sales, sales support and product
management. He holds a degree in
mechanical engineering and started
in international sales for engineered
valves over 12 years ago. Today, he
works as Area Business Manager to
win business and execute the growth
strategies. He can be reached at
raimar.hellwig@metso.com
What is the difference if a coker valve operates 4 years or
an additional 8 years?
The number of years a valve continues to operate has a direct effect
on the total cost of ownership. Service costs are roughly 1/3 of a
new valve. If the refinery is servicing and replacing valves every 4
years or 8 years, just think of the impact this will have on operational
costs when multiplied by about the 10 to 20 of the special
coker valves or hundreds of the unit valves.
Is Metso represented in Croatia and in the region?
Yes, of course, I am happy to say that for 13 years now we successfully
cooperate with our partner, Eco consult d.o.o. (ecoconsult.hr)
from Croatia. We have very good and close cooperation and have
successfully delivered projects in Croatia, Balkan region, Belarus,
Russia and Middle East, not only in oil & gas industry, but in all
process industries, energy projects, steel production, etc. Eco consult
is engineering company whose mission is to provide energy
efficient solutions by optimizing control loops in process industries,
increasing use of renewable energy sources and reducing
emissions. Our proven valve technologies and their added value
expertise are key to success and our customers have recognized
benefits of using package solutions we together provide.

egida
One Portfolio – Many Possibilities
Product Offering for Fuel and Lubricant Solutions
INNOVATIVE
Engine Coolants
GLYSANTIN ® engine coolants provide 3-fold protection
against corrosion, overheating and frost. BASF first
patented GLYSANTIN ® in 1929, and the brand has
been very popular with motorists ever since. This
engine coolant has the most OEM approvals from the
large motor manufacturers.
FUEL
Comprehensive Fluid Solutions
LUBRICANTS
Brake Fluids
PROVEN
HYDRAULAN ® premium brake fluids, for more than
60 years, stand for the reliability of the brake system
and therefore for the safety of vehicles. As an established
partner of the automotive industry, we continuously
develop products that meet and exceed both current and
future requirements.
EXPERTISE
Fuel Performance Packages
BASF’s fuel performance packages are designed to make the
difference for any kind of fuel and have established us as the
leading supplier of fuel performance packages worldwide. The multifunctional
KEROPUR ® performance packages keep engines clean and
protect the entire fuel system. BASF’s portfolio comprises gasoline and
diesel performance packages for maximum engine cleanliness, better
fuel economy, lower emissions and a better driving experience. When it
comes to transportation above the ground, our KEROJET ® aviation fuel
additives can help reduce the costs of maintenance, improve efficiency
and sustain the high performance of aviation gas turbines.
Refinery Additives
Creating chemistry and solutions for our customers, BASF is a strong
and reliable partner for the mineral oil industry. Whether in terms of flow
improvement, property enhancement or stabilization, our innovative
solutions deliver the reliable performance needed by our partners in the
refinery industry, as demonstrated for example by our custom-made
KEROFLUX ® flow improvers and wax antisettling additives which ensure
the operability of diesel fuels even at cold temperatures.
Polyisobutene
Polyisobutene (PIB) has been a core business of BASF for more than
85 years. As one of the world’s leading producers of PIB, we offer the
broadest range of polyisobutenes with different molecular weights. The
unique properties mean that our products are ideally suited to enhance
manufacturing processes and product effectiveness in a wide range
of industries and applications – including the manufacture of fuel and
lubricant additives, adhesives, sealants and chewing gum base. The
products are marketed worldwide under the brands of GLISSOPAL ®
(low-molecular weight PIB) and OPPANOL ® (medium- and high-molecular
weight PIB).

egida
Compounded Lubricants
BASF’s Compounded Lubricants ensure first-class results in terms of
gear wear, seal life, fluid oxidation and oil life. Our synthetic lubricants
also help to improve energy efficiency, which reduces fuel consumption
and decreases CO 2
emissions. With their renewable content, they fall
into today’s class of more carbon-neutral, sustainable technologies.
Our compounded lubricants for transportation applications (EMGARD ® )
are recognized as the industry standard, providing superior performance.
In actual field use, our products have protected trucks for over
1.6 million miles without a lubricant change – in other words: 30 times
around the world without changing the axle and transmission oil. While
our transmission lubricants allow for longer maintenance intervals and
reduced oil usage as well as downtime and considerably lower operating
costs, our axle lubricants provide measurable fuel savings and enable
maximum component life as well as smaller quantities of used oil for
disposal. BASF also markets a wide range of ready- formulated lubricants
for industrial applications (EMGARD ® / PLURASAFE ® ) in many market
segments, such as: gear lubricants for wind turbines, high-performance
bio- hydraulic fluids for mobile construction equipment or energy-efficient,
longer life compressor coolants for general industrial applications. We
partner with leading industrial lubricant marketers, OEMs and machine
builders to provide the latest in high- performance, quantifiably sustainable
lubrication solutions, providing extended component life, greater
environmental compatibility and lower overall cost. When it comes
to refrigeration oils (PLURASAFE ® ), BASF produces a broad range of
lubricants for air conditioning and industrial cooling applications around
the world. In close cooperation with refrigeration oil marketers and
system OEMs, we provide high performance and optimum compatibility
with all refrigerant technologies. The benefits of our patented refrigeration
lubricant technology include lower cost, hydrolytic stability, lower wear
and superior miscibility with refrigerants.
Lubricant Oil Additives
BASF offers a broad range of additives, including antioxidants, anti-wear
additives, metal deactivators, corrosion inhibitors, pour point depressants
and viscosity modifiers, needed to formulate solutions for nearly every
imaginable application. The aforementioned additives when correctly
formulated into lubricants enable the lubricants to ‘stay in grade’. This
term is widely used in relation to lubricant performance requirements.
It addresses the need that the lubricant remains fit for purpose both
freshly prepared and throughout its specified lifetime. Our IRGANOX ® ,
IRGALUBE ® , IRGACOR ® , IRGAMET ® and IRGAFLO ® additives enable
the formulation of high-performance and cost-effective lubricants
by providing protection to the base oil as well as metal surfaces. For
industrial applications as, for example, turbine oils and hydraulic fluids,
BASF also offers ashless additive packages under its IRGALUBE ®
trademark. BASF’s unmatched production network provides our
customers with supply reliability and security.
Base Stocks for Lubricants and Components
for Metalworking Fluids
As a leading global supplier of high-performance synthetic lubricant base
stocks as well as metalworking fluid components, we are committed
to supplying the lubricant market with our expertise and best-in-class
solutions. Our broad product range of PAG and Ester lubricant base stocks
plays an important role in a wide variety of applications requiring high
performance and unique properties. Demand for improved fuel economy,
extended equipment life and solutions delivering on sustainable development
are resulting in a need for improved lubricant performance. BASF’s
lubricant base stocks have a very broad performance range and are the
ideal choice to meet current and future performance requirements. The
portfolio for metalworking formulations includes a wide range of surfactants
and emulsifiers as well as solubilizers, corrosion inhibitors and foam control
agents to ensure trouble-free operations meeting environmental, health
and safety standards. As a strong and established partner for lubricant
formulators, we continuously develop products that meet our customers’
requirements. The products are available worldwide and marketed under
the brand names SYNATIVE ® , BREOX ® , PLURACOL ® and PLURASAFE ® .
Fuel and Lubricant Solutions
EVO 1720

Upgrading options of heavy
residues, rubber modified
bitumen case study
András Holló
ahollo@mol.hu
MOL Plc, Hungary
András Geiger
ageiger@mol.hu
MOL Plc, Hungary
Péter Gergó
gergop@almos.uni-pannon.hu
University of Pannonia,
Hungary
Abstract
Heavy residues are still used as fuel oil,
bunker oil or bitumen in the transportation
and construction industries.
However, the quality requirements of
these products are also increasing continuously.
The reasons are mainly the
tightening environmental regulations.
On the other hand, the increasing
quantity demand of liquid fuels for
internal combustion engines requires
“bottom of the barrel” conversion
technologies in crude oil refineries.
Thanks to these separation, thermal or
catalytic processed heavy residues are
converted to lighter, more profitable
products.
For many decades, bitumen has been
successfully used in asphalt concrete
to construct roads. Despite the improvements
of bitumen production,
road design and construction, there
are limits to meet new challenges like
growing traffic, extreme climates and
construction shortcomings. Polymer
modified bitumen (PmB) can help to
overcome these challenges, however,
the application of these polymers is too
expensive.
The production of rubber bitumen
by blending of bitumen with used tyres
based crumb rubber is not just a waste
handling method, but an excellent
solution to upgrade the quality of
bitumen, improving economically the
performance of asphalt pavements.
Beside the advantages, many existing
rubber bitumen technologies and their
products have some drawbacks: e.g. altering
product quality, phase separation
and high viscosity.
To overcome the disadvantages
University of Pannonia and MOL Plc.
jointly developed a new, patented production
method (WO/2007/068990),
which is capable to produce the so
called chemically stabilized rubber
bitumen in a crude oil refinery. In
the technology by applying a special
anti-settling additive the phase separation
of the disperse system and the
unfavourable high viscosity can be
significantly decreased. In this paper
the different upgrading technologies of
heavy residues, the main characteristics
of chemically stabilised rubber bitumen
and its commercial experiences
are summarised.
Keywords: heavy residue upgrading;
rubber modified bitumen;
asphalt; performance
Introduction
The yield of vacuum residues produced
via crude oil distillation can
significantly depended of the crude
oil. However, the market demand for
these heavy residues as fuel oil, bunker
fuel or bitumen decreases and
18 Fuels&Lubricants No. 1 OCTOBER 2017

their quality have to be improved
too. The strict SO 2
emission limits
in EU forced power plant operators
to switch from high sulphur fuel oil
to cleaner natural gas or build SO 2
scrubbers. International Maritime
Organisation has also introduced a
plan to decrease the sulphur content
of bunker fuels both inside and
outside of Emission Control Areas
(ECA). The max. sulphur limit of
ECAs bunker fuel has been reduced
from 1.0 % to 0.1 % from January
2015. The max. sulphur limit of
non-ECAs bunker fuel is planned to
reduce from the actual 3.5 % to 0.5
% from January 2020. On the other
hand the global demand of crude oil
products will be increased in longterm,
especially in the non-OECD,
developing countries (Table 1).
Among these products the demand
of both motor gasoline and JET/
diesel fuel will be higher (Table 2).
Thus in order to meet the quantity
and quality demand of the market of
different crude oil products, refineries
have to convert these residues to
lighter and more valuable fuels and
other products (1-3).
There are many proprietary technologies
for upgrading of heavy residues
and producing lighter fractions
(Fig. 1): like separation (e.g. vacuum
distillation, solvent deasphalting),
thermal technologies (e.g. visbreaking,
fluid/flexi coking, delayed
coking), catalytic technologies (e.g.,
ebullated bed residue hydrocracking,
slurry phase residue hydrocracking
and residue fluid catalytic
cracking) and gasification with or
without synthesis gas conversion.
Thanks to these technologies, heavy
residues can be converted to more
profitable products like motor
gasoline and middle distillates (JET
and diesel fuels). Unfortunately,
the investment cost of these deep
conversion units is very high and
the payback period greatly depends
on the capacity utilisation and the
market economics (4-11).
2015 2020 2025 2030 2035 2040
OECD America 24.4 24.8 24 22.8 21.5 20.1
OECD Europe 13.7 13.5 13 12.4 11.8 11.1
OECD Asia Oceania 8.1 7.7 7.3 6.9 6.5 6.1
OECD Total 46.2 45.9 44.3 42.1 39.7 37.3
Latin America 5.6 6 6.4 6.7 7 7.3
Middle East & Africa 3.8 4.2 4.6 5.1 5.5 6
India 4.1 5.1 6.4 7.7 9 10.4
China 10.8 12.2 13.6 14.9 16.1 17.1
Other Asia 6.3 7.1 7.9 8.7 9.3 9.8
OPEC 10.9 12.2 13.3 14.3 15 15.4
Developing
countries total
41.5 46.8 52.2 57.4 62 66.1
Russia 3.4 3.5 3.6 3.6 3.6 3.5
Other Asia 1.9 2.1 2.3 2.4 2.5 2.5
Eurasia Total 5.3 5.6 5.8 6 6.1 6
World 93 98.3 102.3 105.5 107.8 109.4
Table 1: Long-term oil demand according to OPEC (bbl/d)
2015 2020 2025 2030 2035 2040
Ethane/LPG 10.4 11.1 11.7 12.1 12.4 12.7
Naphtha 6.2 6.5 6.9 7.4 7.9 8.5
Gasoline 24.2 26.1 26.9 27.4 27.8 28
Light products total 40.8 43.7 45.5 46.9 48.2 49.1
Jet/kerosene 6.8 7.3 7.8 8.4 9 9.4
Gasoil/diesel 27.5 29.5 31.1 32 32.7 33.2
Middle distillates total 34.3 36.7 38.9 40.4 41.7 42.6
Residual fuel 7.7 7.2 6.9 6.9 6.7 6.4
Other products 10.3 10.7 11 11.3 11.3 11.2
Heavy products total 17.9 17.9 18 18.1 18 17.7
World total 93 98.3 102.3 105.5 107.8 109.4
Table 2: Long-term oil demand by product category according to OPEC (bbl/d)
Fuels&Lubricants No. 1 OCTOBER 2017 19

Because of the development of
road transportation and the constant
quality problems of roads, in some
less developed countries, new and
economical solutions are needed in
road constructions. For a century,
bitumen has been successfully used
in asphalt, concrete to construct
roads. Despite the improvements of
bitumen production, road construction
and design, there are limits to
meet new challenges. Growing traffic,
increasing loads of heavy trucks,
extreme climates and construction
shortcomings are taking a toll.
Additionally, there is an increasing
demand for safer, quieter highways
and roads. Polymer modification
(e.g. styrene-butadiene-styrene or
SBS) of bitumen can help to overcome
these challenges. However, the
application of the special bitumen
additives is expensive (12, 13).
The production of rubber bitumen
by blending of bitumen with
used tyres based crumb rubber is not
just a waste handling method, but
an excellent and economic solution
to upgrade the quality of the heavy
residue, improving the performance
of asphalt pavements compared to
roads made of conventional bitumen.
The technology was applied
first in the US in the sixties. The
following advantages are usually
highlighted in case of rubber bitumen
application (12-14):
• longer life time,
• lower life cycle cost,
• better low temperature performance,
• wider utilization temperature
range,
• less deformation,
• better fatigue characteristics,
• better adhesion to aggregates results,
thus improved durability,
• noise reduction effect.
However, many existing technologies
and rubber bitumen products
have some drawbacks (12-15):
• altering product quality,
• quick phase separation (transportation
and storage problems),
• high viscosity (pumping problems),
• spraying problems,
• necessity of special equipment
(investment required),
• special asphalt mixture is required,
• compatibility problems,
• emission of harmful gases.
Therefore University of Pannonia
and MOL Plc. developed a
new, patented production method
(WO/2007/068990, HU226481),
which is capable to produce chemically
stabilized rubber bitumen in a
crude oil refinery according to the
best available technique. The target
was to keep the advantageous properties
and minimise the disadvantages
of rubber bitumen product.
Results and discussion
As it was presented in our earlier
publications (14, 15) several rubber
modified bitumen (RmB) production
test runs were organised by the
research team of University of Pannonia
and MOL before 2012 in Zala
Refinery (Hungary) after temporary
modification of an existing polymer
modification bitumen (PmB) plant.
Test runs with regard to the following
asphalt laboratory assessments,
asphalt mixture productions and test
road constructions were very promising.
The quality and durability of
constructed asphalt roads together
Figure 1: Upgrading
options of heavy
residues producing
lighter fractions
with the gained experiences stimulated
the construction of a new rubber
bitumen unit. As a result MOL
revamped an existing PmB plant. In
the unit both PmB and chemically
stabilised RmB with the improved
wet process can be produced. The
nominal capacity of the prototype
RmB unit is 5 kt/year.
The patented process, consists
of two technological steps. In the
first one, chemical degradation of
crumb rubber occurs at high temperature.
The second step involves
a high shear mixing with the application
of colloid mill. It occurs at
moderate temperature and supports
re-vulcanization of dissolved parts
of crumb rubber in bitumen. During
the production a multifunctional
additive (produced by MOL) is applied
as well, which promotes rubber
dissolution and decreases separation
ability of undissolved rubber particles.
At the same time, the applied
additive decreases the viscosity of
the product providing better processability
in asphalt mixing and
pavement construction.
The insoluble particles in the final
RmB product are below 50% calculated
on the initially added crumb
rubber. It means that more than half
of used rubber completely dissolves
and behaves as active modifying
agent similarly to SBS used for
polymer modified bitumen production.
The swelled but not completely
dissolved particles contribute to
20 Fuels&Lubricants No. 1 OCTOBER 2017

excellent low temperature characteristics
of RmB.
Stable crumb rubber quality and
its particle size distribution are one
of the most important criterion for
rubber bitumen production process.
During crumb rubber production
waste tyres are shredded, fabric and
steel used as reinforcement material
are removed. Used tyres should be
cleaned and impurities have to be
removed before shredding (e.g. clay,
sand and gravel).
The most valuable component of
crumb rubber is the polyisoprene
content. Crumb rubber derived
from tyres of passenger cars contains
10-20% polyisoprene, this value
is around 35-45% in truck tyres.
Further constituents of crumb rubbers
are synthetic rubber (15-45%),
carbon black (25-30%), inorganic
additives (5-15%) and plasticisers (5-
15%) measured according to ASTM
D297-15 standard (16).
Asphalt mechanical tests were
also carried out in the development
phase using different bitumen
products produced in Zala Refinery.
The properties of binders applied
for asphalt tests are summarised in
Table 3. The softening point of RmB
is between the values of other two
commercial products. The highest
penetration ensures good workability
in asphalt mixing and compaction.
RmB has the best breaking point.
Dynamic viscosity of RmB is near to
those value of PmB 25/55-65.
Significantly better results were
measured in asphalt mixtures (Table
4). It has almost the same characteristics
as PmB and far better than
50/70 road bitumen.
It has to be mentioned that fatigue
character of different asphalt types
produced with RmB has been furher
improved last years. Recently this
performance character is on the
same level than that of asphalt mixtures
produced with PmB. Other favourable
properties like traffic noise
reduction (-3.2 dB), better adhesion
Property Test method RmB
50/70 road
bitumen
Softening point, °C EN 1427 59 51 74
Penetration at 25 °C,
0.1mm
EN 1426 65 56 45
Fraass breaking point, °C EN 12593 -24 -12 -14
Dynamic viscosity at 180
°C, mPas
Table 3
EN 13702-2 480 90 410
Requirement RmB
50/70 road
bitumen
PmB
25/55-65
Binder content, % 5.1 5.1 5.1
Permanent deformation/Wheel tracking (EN 12687-22)
Relative deformation, % Max, 5.0 1 3.6 1
Resistance to fatigue (EN 12687-24)
Ehhmax, (N=106), microstrain To be reported 160 143 201
PmB
25/55-65
Asphalt cracking*
Cracking temperature, °C Max, -18.0 -31 -18 -24.8
Table 4: AC-11 type of asphalts produced with different bitumen binders
properties (Fig. 2, tested in 60°C
after 36 hours based on the method
developed by the National Road and
Traffic Research Institute, Sweden)
and stopping distance lowering (-5%
at 50 km/h and -10% at 100 km/h)
were also proved comparing RmB
and 50/70 road bitumen based
asphalts (14).
Based on a recent lifecycle analysis
(17) the complex comparison of asphalt
wearing courses made by RmB
45/80-55 and by normal (unmodified)
road construction bitumen
50/70 were compared. The calculation
resulted + 50% lifetime expectation
and - 29-32% lifetime cost for
the whole lifecycle of the wearing
course.
Among several test road construction
the main road of the Danube
Refinery was also reconstructed in
2012. No fatigue cracks, thermal
cracks and rutting can be observed
after 5 years of heav traffic on the
road (Fig. 3).
In 2015 the Hungarian Standards
Institution published the MSZ
930:2015 standard entitled Bitumen
and bituminous binders. Rubber
modified bitumen. Requirements
(18). This specifies the main quality
requirements of the RmB product
(Table 5).
MOL rubber modified bitumen
won the following awards during the
last years:
• Innovative Product Award of
Institution of Chemical Engineers,
UK (IChemE), 2016,
• Environmental Innovation Award
2014 of Hungarian Ministry of
Agriculture,
• To prove its eco-friendly nature
MOL rubber modified bitumen
gained ECO-label in November,
2014 from Hungarian ECO-labelling
Organisation,
• House of the Hungarian Quality
Award 2013 for MOL rubber
modified bitumen process from
Hungarian Society for Quality,
2013.
Fuels&Lubricants No. 1 OCTOBER 2017 21

Figure 2: Adhesion
characteristics of
50/70 road bitumen
(left) and RmB
45/80-55 (right)
Conclusions
Figure 3: Test road
before (left) and after
(right) the RmB road
construction
Property Test method RmB
Penetration at 25 °C, 0.1mm EN 1426 45-80
Softening point, °C EN 1427 ≥ 55
Fraass breaking point, °C EN 12593 ≤ -16
Storage stability EN 13399
Softening point difference, °C EN 1427 ≤ 8
Flash point, °C EN ISO 2592 ≥ 235
Dynamic viscosity at 180 °C, mPas EN 13702-2 ≤ 500
Table 5: Main requirements of MSZ 930:2015 standard
Heavy or vacuum residues of crude
oil processing are mainly converted
to more valuable and lighter products.
Though the demand of cheap
but high quality road construction
binder, like road construction bitumen
is increasing too. One solution
could be the production of chemically
stabilised rubber bitumen. Applying
MOL proprietary technology,
similar or in some cases even better
quality of asphalt can be constructed
than that of the top quality asphalt
containing expensive polymer
modified bitumen. RmB production
could improve the environmental
awareness and could demonstrate
the corporate social responsibility
of the manufacturer. The reason is
the utilisation of a waste tyre based
crumb rubber. Many road construction
companies have applied MOL’s
rubber modified bitumen product in
Hungary and Slovakia and acquired
asphalt mixing and road construction
experiences during its application.
RmB can significantly contribute
to the construction of roads
having better lifetime, better quality
and lower maintenance cost, as well
as to the sustainable transportation
and increased waste re-utilisation.
The excellent product quality and
its economic, environmental and
social effects were acknowledged by
domestic and international organisations.
22 Fuels&Lubricants No. 1 OCTOBER 2017

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2017, Dubrovnik, 1-20, 2017.
HOLLÓ A., GEIGER A., VARGA G.,
Proceedings of the European Refining
Technology Conference, 18 th Annual
Meeting, Budapest, 1-27, 2013.
KALOUSH K. E., Construction and
Building Materials, 67, 258-264,
2014.
GEIGER A., et al., MOL Group Scientific
Magazine, 2, 54-59, 2012.
GEIGER A. et al., MOL Group Scientific
Magazine, 2, 74-83, 2014.
American Society for Testing and
Materials (ASTM) standard: ASTM
D297- 15, Standard Test Methods
for Rubber Products - Chemical
Analysis, 2015.
Institute for Transport Sciences
Non-Profit Ltd (Hungary) :’Lifecycle
parameters’ of asphalt wearing
courses containing rubber modified
bitumen binder, Budapest, 2013.
Hungarian Standard Institute: MSZ
930:2015, Bitumen and bituminous
binders. Rubber modified
bitumen. Requirements, 2015.
Fuels&Lubricants No. 1 OCTOBER 2017 23

Green Corner
Sustainability of Bioenergy
Supply Chains Workshop
A very successful inter-task workshop was held in Gothenburg
in May 2017 on sustainability of bioenergy supply chain
Vesna Kučan Polak
Sustainability of liquid and
solid biofuels production is
under continued scrutiny,
including topics such as iLUC,
food vs. fuel, forest carbon
accounting and sustainable
forest management principles
Sustainability of liquid
and solid biofuels
production is under
continued examination
and monitoring
International Energy agency - IEA founded
in1974, was designed to help countries coordinate a
collective response to major disruptions in the supply of
oil, such as the oil crisis of 1973-74. During years IEA
has evolved and today examines the wide range of energy
issues including renewable energy, electricity markets,
energy efficiency and much more. The IEA agency is
autonomous, based in Paris and has 29 member countries.
The main decision-making body is the Governing
Board composed of energy ministers from each member
Country. IEA is providing authoritative analysis through
a wide range of publications, including the World Energy
Outlook and the IEA Market Reports; data and statistics,
such as Key World Energy Statistics and the Monthly
Oil Data Service; and a series of training and capacity
building workshops, presentations and resources.
IEA Bioenergy is an organisation set up in 1978 by
the International Energy Agency (IEA) with the aim to
improve international cooperation and information between
and among different entities, such as government
institutions, universities, utilities and private companies
in bioenergy research, development and deployment.
IEA Bioenergy’s mission is to facilitate the commercialisation
and market deployment of environmentally
sound, socially acceptable and cost competitive bioenergy
systems and technologies and to advice policy and
industrial decision makers accordingly.
The activities of IEA Bioenergy are organised in Tasks
which have well defined objectives, budgets and time
frames. Ongoing tasks are: raw material related Tasks
(43, 36), conversion process related Tasks (32, 33, 34,
37, 39, 42), assessment based Tasks (40, 38), ITP- Intertask
projects and SP- special projects.
24 Fuels&Lubricants No. 1 OCTOBER 2017

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Green Corner
Comprehensive and scientific
guidelines, regulations and
standards must ensure that
increased biomass outputs
respect sustainability
considerations
A very successful inter-task workshop was held in
Gothenburg in May 2017 on the topic of sustainability of
bioenergy supply chain with approximately 100 attendees.
The preliminary project results of inter-task project on
“Measuring, governing and gaining support for sustainable
bioenergy supply chains” (2016-2018, synthesised
works of Task 37, 38, 39, 40, 42, 43) are covering three
main objectives:
An overview and examples of calculation methods &
tools to assess the sustainability of various biomass and
bioenergy supply chains.
Comparison and assessment of the legitimacy, including
effectiveness and efficiency of a variety of approaches
on how to govern and verify sustainability of biomass
and bioenergy supply chains in different conditions.
Understanding the positions and underlying motivations
of stakeholder groups relative to their perceptions
of bioenergy and inform dialogues/discussions to avoid
misconceptions and gain trust in bioenergy.
The workshop held on the first day included two
tracks, with one focused entirely on measuring sustainability
and the second on governance and stakeholder
involvement. An overview and examples of calculation
methods & tools to assess the sustainability of various
biomass and bioenergy supply chains focusing largely on
the agriculture, forestry and biogas sectors were provided.
Also compared a variety of approaches on how to
manage and verify sustainability of biomass and bioenergy
supply chains in different conditions. Second day of
Conference highlighted stakeholder involvement with
a focus on biofuels based on several case studies that are
underway from different countries (Denmark, USA and
Canada).
Participants highlighted that sustainability of liquid
and solid biofuels production is under continued examination
and monitoring. Very often it is complicated,
depending on different views and perceptions of stakeholders
both within and outside the value chains and
sometimes the same system provide a different results.
Barriers to mobilizing bioenergy supply chains are not
only due to the technologies and economics but also in
institutional development. Lessons learned generally
show that almost all significant bioenergy developments
have political background which is necessary. Policies
need to be coordinated across different and wide areas
(e.g., forestry, agriculture, energy, environment, and climate
change). Comprehensive and scientific guidelines,
regulations and standards must ensure that increased
biomass outputs respect sustainability considerations,
which also need to be better understood.

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Conference Report
World
Petroleum
Congress,
Istanbul 2017
After Moscow in 2014, the triennial World Petroleum
Congress widely known as the “Olympics of the Oil
and Gas Industry” was welcomed in Istanbul
28 Fuels&Lubricants No. 1 OCTOBER 2017

Conference Report
Adriana Petrović
The oil and gas industry has very complex
and challenging task and responsibility to
help drive the transition to a low carbon
economy.
Basilica Cistern Istanbul, Claudia Wehrli, www.publicdomainpictures.net
The 22 nd World Petroleum
Congress was held in Istanbul,
Turkey, from 9-13 July 2017. The
triennial World Petroleum Congress
is widely known as the “Olympics of
the Oil and Gas Industry” and covers
all aspects of the industry from
technological advances in upstream
and downstream operations to the
role of natural gas and renewables,
management of the industry and its
social, economic and environmental
impact. It’s a prestigious and leading
event for the global oil and gas
industry every time, but additional
significance of the 22 WPC was due
to the specific political, economic
and industrial changes which are
currently occurring in the world.
The theme of the 22 nd WPC was:
Bridges to Our Energy Future. It
was the platform for open dialogue
to build bridges between consumers
and producers, governments
and industry, academia and financiers,
leaders and society, in order
to address open issues and present
debates, developments and solutions
for sustainable production, ensuring
the use of the world’s energy resources
but respecting the environmental
requirements and fulfilling
the world’s expectations.
All the majors O&G companies
were represented at the highest
level. Exxon Mobil Corporation,
BP, Royal Dutch Shell, Total, Saudi
Aramco to name the most famous
were represented with large delegation
and Presidents and CEOs,
whose plenary debates and interviews
were the most attended.
Important institutions and organization
attended and participated in
Fuels&Lubricants No. 1 OCTOBER 2017 29

Conference Report
the Congress organization such as
International Energy Agency IEA,
OPEC, IFP Energies Nouvelles,
International Energy Forum IEF
and others. The congress took place
and evolved through broad and
complex programme structure over
four days. More than 600 speakers
covered the latest developments and
future strategies for the oil and gas
sector. High level Plenaries from
leading industry decision makers,
interactive Round tables and Special
sessions with CEOs and international
experts, in-depth Forums and
innovative Posters on wide variety of
industry sectors addressed the status
quo and the main challenges the sector
is facing.
Although the official statistics and
Congress outcomes have not yet
been published here are the most
important messages and congress
topics in the view of the author of
this article:
Population
The United Nations indicated that
the world population could possibly
exceed 16 billion by the end
of the century, or more conservative
growth assumptions suggest
a global population to be around
9 billion by 2050 and 11 billion by
2100. Demand for energy will grow
as well. Forecast shows the demand
will go up around 30% over the next
two decades. To meet the increasing
demand and rising living standards,
oil and gas will still play a vital role
in energy supply with a different
more sustainable energy mix, with
new energy sources and innovative
technologies.
The growing population and the
rising energy demand will happen in
non-OECD countries, at the same
time it is expected that OECD countries
energy demand will decrease,
part of the demand will be compensate
with by increased energy
efficiency. As a consequence the
industry is migrating to the Eastern
Hemisphere were emerging economies
(such as India and China) and
strong consumer are (Japan).
Paris agreement
The Paris 2015 climate agreement
signed and ratified by 160 countries
and parties so far, aims to limit the
global average temperature increase
well below 2°C by century end
compared to the preindustrial era. It
means the inevitable need to reduce
GHG (mostly carbon) emission and
to build the low carbon economy by
the end of the century.
The oil and gas industry have
a responsibility to help drive the
transition to a low carbon economy.
The task is very complex and challenging:
to provide more energy than
ever and reduce carbon emission
more than ever before in the world
that will be more competitive than
The oil and gas industry
has to be the leader
in finding the solution
to provide more energy
than ever and reduce
carbon emission
more than ever before.
ever before. The oil and gas industry
have to be the leader in finding the
solution and being the part of the
solution.
Natural gas and LNG
The more logic first step in the transition
to low carbon economy is the
increase of use of natural gas, with
lower carbon dioxide emissions and
virtually no nitrogen oxide, sulphur
dioxide and particulate matter emissions.
It has been estimated that if
all existing coal-fired power stations
were switched to gas fired plants, the
total energy related greenhouse gas
(GHG) emissions would be reduced
by 10 percent. It will be a tough and
lengthy process.
Natural gas as Liquefied Natural
Gas (LNG) will be used increasingly
as a transport fuel for heavy duty
road vehicles and ships, especially
in major markets of North America,
Europe and China.
Renewables and alternative
fuels
Today more than 56 % of oil produced
is used in the transport sector.
The transport sector is the second
largest contributor (after the power
sector) of GHG emissions with 23 %
of current world CO 2
emissions. The
need of substantial emission reduction
in transport is obvious trough
energy efficiency and alternative
fuels. The use of biofuels of the first
generation and advanced biofuels
(second generation technologies
from lingo-cellulosic biomass) is
growing not only in road transport
but in aviation sector as well.
Electric vehicles are regarded as
one way to reduce environmental
impact of transport. It is expected
that the light-duty EV market (including
battery electric and plug-in
hybrid electric vehicles) will considerably
grow. Despite the recent
enthusiasm, 1 million EV in 2015
little more electric cars now days,
displace only 0.01 % of global oil
demand, and with possible 100 million
EV by 2035 in total can reduce
the oil demand by 1-1.5%. Hydrogen
and fuel cells with zero tail-pipe
emissions could play an important
role in air pollution reduction.
All known alternative solutions to
fossil fuels could result in only 15%
reduction of today’s oil consumption
in 2040. It would represent
significant part of oil consumption
but it would not represent a radical
change in the transport energy mix.
New solutions are needed to make
the change.
30 Fuels&Lubricants No. 1 OCTOBER 2017

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No. 1 OCTOBER 2017 31

Conference Report
It should be emphasized the need
for increased use of renewable energy
to maintain long term growth,
such as construction of large wind
and solar power plants. The major
O&G companies are on that path
already.
Costs and Investments
The must for conventional and nonconventional
oil and gas production,
as well as crude processing, storage,
transport and distribution is
to increase the safety of operations,
increase energy efficiency and decrease
cost of operations. The oil and
gas industry have to learn to work
and prosper at low product prices,
accommodating operational costs at
lower levels.
Investments as a consequence
of oil price drop had dramatically
declined over last two years and only
modest signs of recovery are seen
in 2017. It is essential that governments
and companies gain sufficient
confidence in market conditions to
start a new cycle of investments in
order to find new solutions, build
new technologies and solve the challenges
facing the oil and gas business
in the coming decades.
Investment in talents and
knowledge
During the 2014-2016 crisis oil and
gas companies were downsizing
their workplaces in order to contain
costs. Accelerated retirement among
older personnel was advised and
supported, a huge number of workers
were layoff. Oil and gas business
have lost a lot of skilled and knowledgeable
personnel. On the other
hand digital technologies and automation
have changed the business
and entirely new skillset are needed.
Education systems have not adapted
to the speed, change and demand of
industry in general, but particularly
of oil and gas industry. If something
essential is not done immediately in
oil and gas industry, very soon there
will be not enough talented specialist
not only to find new solutions, invent
new technologies but even run properly
and safely oil and gas operations.
It is extremely necessary to prepare
consistent long-term education
plans for young talents, develop targeted
recruiting methods and take
care of constant knowledge upgrading.
Therefore it is crucial priority
to invest in education and research,
to secure steady development and
growth of oil and gas industry.
All known alterna -
tive solutions to fossil
fuels could result in
only 15% reduction
of today’s oil consumption
by 2040.
New solutions are
needed to make the
change.
Partnership
To cover the increasing energy
demand, to make energy accessible
to the world community through
networks and infrastructure and at
the same time comply with stringent
environmental requirements is a difficult
and complex task. Partnership
between major companies, partnership
between companies and institutions
is critical to facilitate the process
of solving the task. Partnership
between countries and companies
is important for mutual trusting in
long term agreements. Partnership
between countries, governments
and companies with a shared sense
of purpose can create a positive and
stable geopolitical environment in
which solutions and agreements can
be successfully worked out.
Inventions and solutions
All discussed possibilities of development
in the oil and gas industry,
investments in known solutions
and technologies, as well as ongoing
research will not be enough to solve
all open issues and complain with
the Paris climate agreement. New
technologies, today’s unknown solutions
and new inventions are needed
to make a shift. We cannot say when
this shift will occur but the trends are
inexorable. Oil and gas industry is
used to up and downs and challenges
and is prepared to change again and
comply with the future requirements.
We have to rely on boundless
human imagination and inventiveness
for upcoming answers, it is
enough to see the solutions, science
and knowledge we have today that
five or ten years ago were unimaginable,
to gain confidence.

World Petroleum Council
The World Petroleum Council (WPC) is a neutral, nonpolitical
organisation with charitable status in the U.K.
and has accreditation as a Non-Governmental Organization
(NGO) from the United Nations (UN). The WPC is
dedicated to the promotion of sustainable management
and use of the world’s petroleum resources for the benefit
of all. WPC is UN accredited.
Headquartered in London, since 1933, the World
Petroleum Council, includes 65 member countries from
around the world, covering all five continents, representing
over 95% of the world’s oil and gas production
and consumption. WPC membership is unique as it
includes both OPEC and non-OPEC countries with representation
of National Oil Companies (NOC’s) as well
as Independent Oil Companies (IOC’s). Each country
has a National Committee made up from a representatives
of the oil and gas industry, academia and research
institutions and government departments. Governing
body is the Council consisting of representation from
each of the country national committees.
Croatian oil and gas industry is represented trough
the Croatian National Committee for World Petroleum
Council (CNC WPC), Zagreb, as a member of World
Petroleum Council, London.
Every three years, the World Petroleum Council
organizes the World Petroleum Congress, covering
all aspects of the industry including management of the
industry and its social, economic and environmental
impact. In addition all stakeholders including governments,
other industry sectors, NGOs and international
institutions have also joined the dialogue.
At the World Petroleum Council meeting, on July
9 2017, held in Istanbul before the opening of the 22
World Petroleum Congress, Mr Tor Fjearan was appointed
as a new WPC President for the period of three
years.
To find out more please visit: https://www.worldpetroleum.org/
About the author
Mrs. Petrović is a technology engineer by profession.
She graduated on Faculty of Technology at the University
of Zagreb in 1974. Since 1975 Mrs. Petrovic was
working in INA Plc., Croatian oil industry, starting in a
production department of Rijeka Refinery. After almost
30 years of refinery experience on different jobs and
positions Mrs. Petrovic moved to INA’s Headquarters
in Zagreb. From 2004 to 2014 Mrs. Petrovic had several
managerial positions in INA’s Business Divisions and
Functions: Director of Supply chain management Sector;
Director of Sustainable Development and Health,
Safety and Environment protection and Director of
Enterprise Relation Sector. Lately she works as Regulatory
Affairs Advisor.
Mrs. Petrović is involved in the various professional
associations and institutions such as Croatian national
committee of World council for oil and gas as Presidency
member; member of the Executive committee of
Scientific council for Energy at the Croatian academy of
science and art and president of Fuels branch of Croatian
society for fuels and lubricants.
Fuels&Lubricants No. 1 OCTOBER 2017 33

egida
Photo: Depositphotos
Big Data in Oil & Gas
How Data Analytics Can
Be Used To Improve
Business Results
Ivana Lukec
Big Data is the name used to
describe the theory and practice
of applying advanced computer
analysis to the ever-growing amount
of digital information that we can
collect, store and then reuse. Big
data analytics is today used widely in
large number of business areas, from
retail and finances to agriculture and
even healthcare. There is practically
no area where this discipline is not
used and the usage will in future only
continue to grow.
Oil and gas industry is, as well, accomodating
to increased number of
applications and software solutions
that are applying big data analytics.
Those software solutions are coming
from providers such as Microsoft,
Dell, IBM, ABB, OSIsoft and many
more.
With the fact that equipment and
process units are being increasingly
instrumented and that oil and
gas companies have to be strongly
focused on improvement of operational
efficiency, big data analytics
has become a key part of this drive
for continuous improvement.
The stored data are used as the
fuel to run system-wide reliability
models, which in turn identify and
quantify ability for process, performance
and margin improvement.
34 Fuels&Lubricants No. 1 OCTOBER 2017

Technology Corner
PHOTO: Bigstock
Process units and
equipment are being
increasingly instrumented,
so big data
analytics has become
a key part of this drive
for continuous
improvement.
Both tactical and strategic decisions
can be made with confidence and
speed.
With the correct advanced reliability
modeling tool, refiners are able
to use big data analytics to improve
process monitoring, control, and
to optimize operation while helping
to target important problems
such as product and/or quality loss,
energy loss, byproduct generation,
efficiency improvement and safety
problems. With the explosion of
available data, much of this data
relates directly back to equipment
performance and reliability. Refiners
are as well able to make better
CAPEX decisions, to allocate redundant
systems and spares where they
will have the biggest financial impact
and to optimize buffering with the
process design and the logistics.
Royal Dutch Shell as one of the
largest oil and gas companies - one
of the “supermajors” which also
include BP, Chevron, Total and
ExxonMobil - and the world’s fourth
largest company by revenue, for
some time has been developing the
idea of the “data-driven oilfield” in
an attempt to bring down the cost
of drilling for oil. Shell is also known
to widely use big data for monitoring
equipment. Sensors are used for
collecting equipment data to evaluate
its performance and comparing
it to aggregated data. This “big” data
is then used to determine whether
parts need to be replaced and when.
Shell does the same thing with its
exploration equipment which minimizes
the time equipment spends
offline due to breakdowns. Consequentially,
overheads are reduced.
Big data are also used to increase
the efficiency of the transport, distribution
and retail of oil and gas.
However, as in any industry, application
of big data analytics in process
industry has its challenges that are
mostly related to the varying quality
of industrial data. Common factors
affecting the quality of process data
are measurement noise, missing
values, outlying observations, multirate
data, measurement delay, and
drifting data are the common factors
affecting the quality of process data.
The satisfactory performance of
these models can be achieved only
if such challenging issues are addressed.
Therefore, big data analytics can
be summarized into three dimensions
in oil and gas industry: surveying,
forecasting and maintaining
which helps producer understand
the “bigger picture” of the business.
Big data analytics allow for the
close examination and monitoring
of the separate aspects of this bigger
picture. Models can be built and
analyzed to determine how minor
modifications in one area can make a
big impact in another. The more data
an organization has about its business
components the more realistic
a portrait of reality it can create, and
thus, the better-backed decisions it
can make.

Fuels Corner
Fuels and Fuels Processing
Overview of the most relevant articles related
to fuels and fuels processing
Ante Jukić
For a number of years the main
issue in fuel research is the
consideration of biomass as a
raw material for fuel production
Biomass
For a number of years, the main issue in fuel research
is the consideration of biomass as a raw material
for fuel production, and this is followed by the modelling
and optimization of the production processes. Thus,
most-cited and most-downloaded papers in this area
deal with the above-mentioned topics. Knowing the
detailed composition of biomass is of crucial importance
to the process and later product properties. In review
article: Composition, properties and challenges of algae
biomass for biofuel application: An overview (Fuel, 181,
2016, 1-33), the common issues concerning taxonomical
classification, habitat environment, carbon reserve
capacity, production, use, and main advantages and
disadvantages of algae or algae biofuel are addressed.
Further, more than 135 characteristics related to the
chemical, phase and mineral composition and properties
of algae and algae ash are evaluated and compared
to those of terrestrial biomass, coal and their ashes. As a
result specific benefits and obstacles connected with the
composition and properties of algae and algae ash are
discussed. The present data demonstrate that the high
contents of inorganic matter with unfavorable modes of
element occurrences (chlorides, sulphates, carbonates,
oxalates, nitrates and some oxyhydroxides, phosphates
and amorphous material) in algae and algae ash provoke
the most critical technological and environmental challenges
during algae processing for biofuel application
and especially during algae thermochemical conversion.
There are very informative and following titles:
An overview of the organic and inorganic phase composition
of biomass (Fuel, 94, 2012, 1-33), Effects of torrefaction
process parameters on biomass feedstock upgrading
(Fuel, 91, 2012, 147-154), A review on the pretreatment
of lignocellulose for high-value chemicals (Fuel Processing
Technology, 160, 2017, 196-206).
Pyrolysis
Considering the processes, pyrolysis biomass is currently
being prominent by its attractiveness, and the
headlines we recommend are as follows: Historical Developments
of Pyrolysis Reactors: A Review (Energy Fuels,
31, 2017, 5751-5775), Combustion, performance and
emission analysis of a DI diesel engine using plastic pyrolysis
oil (Fuel Processing Technology, 157, 2017, 108-
115), Catalytic pyrolysis of biomass for biofuels production
(Fuel Processing Technology, 91, 2010, 25-32), Characteristics
of hemicellulose, cellulose and lignin pyrolysis
(Fuel, 86, 2007, 1781-1788), Pyrolysis of Wood/Biomass
for Bio-oil: A Critical Review (Energy Fuels, 20, 2006,
848-889).

Lube Corner
Lubricants and Lubrication
Engineering
Recommendation of the most relevant articles related
to materials research, friction reduction, machine health
monitoring, wear and environmental protection
Ante Jukić
Benefits of friction reduction
Unlike fuel, lubricants and lubrication research
takes place in a much more subject matter. Nevertheless,
the traditionally biggest field is various materials
research, and then there is a constantly growing area of ​
environmental protection that is being considered by
saving energy and increasing energy efficiency, the use
of renewable raw materials and vegetable oils, green
chemistry, and so on. The study Global energy consumption
due to friction in passenger cars (Trib. Int., 47, 2012,
221-234) presents calculations on the global fuel energy
consumption used to overcome friction in passenger cars
in terms of friction in the engine, transmission, tires, and
brakes. Friction in tribocontacts was estimated according
to prevailing contact mechanisms such as elastohydrodynamic,
hydrodynamic, mixed, and boundary
lubrication. Coefficients of friction in the tribocontacts
were estimated based on available information in the
literature on the average passenger car in use today, a car
with today’s advanced commercial tribological technology,
a car with today’s best advanced technology based
upon recent research and development, and a car with
the best technology forecasted in the next 10 years. The
following conclusions were reached. In passenger cars,
one-third of the fuel energy is used to overcome friction
in the engine, transmission, tires, and brakes. The direct
frictional losses, with braking friction excluded, are 28%
of the fuel energy. In total, 21.5% of the fuel energy is
used to move the car. Reductions in frictional losses will
lead to a threefold improvement in fuel economy as it
photo: https://unsplash.com/
38 Fuels&Lubricants No. 1 OCTOBER 2017

Lube Corner
will reduce both the exhaust and cooling losses also at the
same ratio. By taking advantage of new technology for
friction reduction in passenger cars, friction losses could
be reduced by 18% in the short term (5-10 years) and by
61% in the long term (15-25 years). This would equal
worldwide economic savings of 174,000 million euros
and 576,000 million euros, respectively; fuel savings
of 117,000 million and 385,000 million litres, respectively;
and CO 2
emission reduction of 290 million and
960 million tonnes, respectively. The friction-related
energy losses in an electric car are estimated to be only
about half those of an internal combustion passenger
car. Potential actions to reduce friction in passenger cars
include the use of advanced coatings and surface texturing
technology on engine and transmission components,
new low-viscosity and low-shear lubricants and additives,
and tire designs that reduce rolling friction.
In passenger cars one-third
of the fuel energy is used to
overcome friction in the
engine, transmission, tires,
and brakes.
Machine health monitoring
Analysis of lubricating oil is an effective approach in
judging machine’s health condition and providing early
warning of machine’s failure progression. In the paper:
Lubricating oil conditioning sensors for online machine
health monitoring - A review (Trib Int 109, 2017, 473-
484) a comprehensive review of the state-of-the-art
online sensors for measuring lubricant properties (e.g.
wear debris, water, viscosity, aeration, soot, corrosion,
and sulphur content) is presented. These online sensors
include single oil property sensors based on capacitive,
inductive, acoustic, and optical sensing and integrated
sensors for measuring multiple oil properties. Advantages
and disadvantages of each sensing method, as well
as the challenges for future developments, are discussed.
Research priorities are defined to address the industry
needs of machine health monitoring.
Wear
We also recommend the following, though specific, very
interesting and attractive research studies: Development
of an interactive friction model for the prediction of lubricant
breakdown behaviour during sliding wear (Trib. Int.
110, 2017, 370-377), The influence of surface hardness on
the fretting wear of steel pairs - Its role in debris retention
in the contact (Trib. Int. 81, 2015, 258-266), Characterisation
of soot in oil from a gasoline direct injection engine
using Transmission Electron Microscopy (Trib. Int. 86,
2015, 77-84), The Influence of Base Oil Properties on the
Friction Behaviour of Lithium Greases in Rolling/Sliding
Concentrated Contacts (Trib Lett 65, 2017, 128), Study
of Permanent Shear Thinning of VM Polymer Solutions
(Trib Lett 65, 2017, 106), A critical assessment of surface
texturing for friction and wear improvement (Wear
372-373, 2017, 21-41), On the mechanism of tool crater
wear during titanium alloy machining (Wear 374-375,
2017, 15-20), Influence of lubricant formulation on rolling
contact fatigue of gears - interaction of lubricant additives
with fatigue cracks (Wear 382-383, 2017, 113-122),
Improvement of wear resistance of some cold working tool
steels (Wear 382-383, 2017, 29-39), Vibration and wear
prediction analysis of IC engine bearings by numerical
simulation (Wear 384-385, 2017, 15-27).

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Fuels&Lubricants No. 1 OCTOBER 2017 41

Symposium of Petroleum
Laboratories in the Region
Sixth year in a row laboratories in the region are
gathering to exchange experience and build the
powerful and influencing network.
Tihana Gorenc
Photo: Drew Hays on Unsplash
42 Fuels&Lubricants No. 1 OCTOBER 2017

Lab Corner
PHOTO: www.pixabAy.com
6th Symposium of petroleum laboratories in the region
was held in Poreč, Croatia from 11th to 12th May, 2017.
The Symposium is an annual event in organisation of one
of representative laboratory or laboratory related institutions
from the country in the region. This year Symposium
had 78 participants from ten regional countries.
The main objective of the Symposium is exchange of
experience and knowledge which are closely related to
the Good laboratory practice (GLP), optimisation of
laboratory activities and organisation of proficiency testing
schemes.
The original idea to connect petroleum laboratory
representatives in region came from Mr. Ice Rikaloski
from OKTA, Macedonia. First Symposium was held in
Ohrid, Macedonia, then next five from Novi Sad Serbia,
Sarajevo Bosnia and Herzegovina, Kotor Montenegro
to Petrol Slovenia. With each new Symposium number
of participants grew and in time Universities and related
intuitions joined. It created synergy between laboratory
experiences and scientific achievements in the field.
Through mutual cooperation and networking, laboratories
are directly influencing the improvement in
quality of products on the market, improvement in
measurement’s precision and improvement in cooperation
with regional state bodies, customs, control houses,
laboratory equipment suppliers and Universities.
This year Symposium was organised by INA Refining
and Marketing laboratories and it was opened with
presentation related to 90 years of Sisak refinery. Among
others, presentation related to their activities were presented
by INA Central testing laboratory, INA Quality
control laboratory Rijeka refinery and INA Upstream
laboratory.
The main topics of this year Symposium were: possibilities
of development of petroleum laboratory related
to environmental requests, quality control, technical
competence and participation on the market; principles
of LEAN and FMEA methodologies; experiences in
accreditation of petroleum products laboratories and
flexible scope of accreditation; interpretation of Calibration
certificates and opportunities for higher precision in
measurement and methodology of forming the prices of
laboratory analysis.
Next Symposium will be organised by Makpetrol in
Ohrid, Macedonia in May 2017.

Technical News
ACEA & API Approved
Lubricants What’s in a name?
Lubrizol
Introduction
When engines were first developed, engine lubricants
only needed to reduce friction, avoid direct contact
between two moving components and inhibit corrosion
whilst operating in relatively high temperatures.
It wasn’t until the inclusion of new additives in the
1930s and 40s that lubricants were able to achieve
service life beyond 100 to 200 hours. During that period
in the USA, the Society of Automotive Engineers (SAE)
began testing and classifying various oils by viscosity and
pour rate at 100 °C. This resulted in SAE 30 becoming
the first standardised lubricant. The American Petroleum
Industry’s (API) first oil category, API SA, was also
introduced for use in vehicles built before 1930.
Since then, the demands on engine lubricants for passenger
cars have become much more involved and complex.
Motor manufacturers have virtually reinvented
gasoline and diesel internal combustion engine technology
to address global emission regulations and the need
for fuel economy.
Changes and Developments
Power densities have doubled in the past 20 years. Turbochargers
and exhaust gas after-treatment systems are
now commonplace and engine operating temperatures
are higher. These all place additional stress on lubricants,
so that now lubricant technology has to track hardware
innovations from car manufacturers.
The rate of development has been such that the process
of lubricant standardisation has accelerated dramatically
since the early 1990s. For example, ACEA (Association
des Constructeurs Européens d’Automobiles)
was formed in 1991, followed by ILSAC, (International
Lubricants Standardization and Approval Committee)
in 1992. Together with the API these organizations
cover North America, Europe and Asia and have significant
influence on lubricant classification and standards.
With vehicle manufacturers now supplying global
rather than just domestic markets, the API and ACEA
oil classification systems have an even more important
role to maintain standards, compatibility and compliance
in export markets. One example is where cars are
produced in Asia or North America but sold in Europe
(or vice versa). Another is the impact on oil formulation
and specifications because of after-treatment systems
compatibility as gasoline vehicles dominate the USA,
whereas in Europe around half are diesel.
Likewise, as engine hardware technology develops,
the new oil specifications introduced by ILSAC; API and
ACEA ensure lubricants meet both the needs of motor
manufacturers, and those of the consumer. This is of
44 Fuels&Lubricants No. 1 OCTOBER 2017

particular importance when purchasing service-fill lubricants
for vehicles that are out of warranty and no longer
serviced by a main dealer.
However, this necessary, rapid evolution of engine oil
means that selecting the correct lubricant for a particular
car is not only more complex, but has never been more
vital, as incorrect use can lead to significant damage.
PHOTOs: LUBRIZOL
API & ACEA Classifications
API and ACEA oil classifications exist to help trade users
and consumers make an informed choice about the correct
lubricant and its performance. However, it is easy to
understand how confusion may arise as the latest ACEA
2016 oil sequences include eight separate lubricant
categories for passenger cars and light duty engines and
API has nine!
These specifications are the minimum standard for oil
performance and tightly defined, even down to the grade
of the base oil.
ACEA & API are There to Help
To guide purchasers, both API and ACEA have very
clear product marking systems and both are usually applied
on the oil packaging.
Products labelled as ‘equivalent oil’ or ‘blended to
ACEA or API’ specifications might be serviceable products,
but they are not certified by API unless they carry
either their ‘starburst’ certification mark or the service
symbol ‘donut’.
ACEA doesn’t currently operate a lubricant certification
system, but encourages manufacturers to register
their lubricants and self certify them as compliant with
the specifications and ACEA’s CEC tests.
Independent non-franchised dealers, garages and
technical service centres can get it wrong, either by accident
or through poor practice. It is often impractical and
costly to stock bulk containers for a multitude of different
oils to service vehicles aged from three to 30 years;
each with different lubricant needs.
A poorly operating workshop might therefore choose
to compromise and stock just two oils such as an ACEA
C3 for vehicles fitted with after-treatment systems and
an ACEA A3/B4 for those without.
Ultimately, using the correct lubricant is a question of
education and information. The backbone is the API and
ACEA lubricant classifications, which define industry
standards and ensure that the correct maintenance
regime and lubricants can be selected accurately. For
their part, brands and manufacturers are simplifying the
lubricant/vehicle matching process with online selection
guides (some even matching to vehicle registrations).
Clearly, from a consumer perspective, there is a reliance
on the expertise of the service technician. Ignoring
or failing to appreciate the importance of using the right
oil for the right engine can be very costly, involving replacement
after-treatment systems, key engine components
or even entire engines.
ACEA and API are there to help and when lubricants
claiming both performance levels are used you can be
sure to benefit from the best of both worlds.

Events Calendar
2017
2018
October 25 - 27, 2017
November 13 - 16, 2017
November 15 - 16, 2017
November 29 - 30, 2017
January 9 - 11, 2018
UEIL Annual Congress
Bologna, Italy
www.ueil.org
ADIPEC - The Abu Dhabi International Petroleum Exhibition & Conference
Abu Dhabi, UAE
https://www.adipec.com/
4th ICIS & ELGI Industrial Lubricants Conference
Vienna, Austria
www.icisbaseoils.com/mebaseoils2017
The 2017 European Base Oils & Lubricants Interactive Summit
Antwerp, Belgium
www.wplgroup.com/aci/event/base-oils-lubricants-summit
21st International Colloquium Tribology, TAE
Stuttgart / Ostfildern, Germany
https://www.tae.de/kolloquien-symposien/tribologie-reibung-verschleiss-undschmierung/international-colloquium-tribology
January 29 - 31, 2018 11th European Gas Conference 2018
Vienna, Austria
www.europeangas-conference.com/
February TBA, 2018
March 5 - 6, 2018
22nd ICIS World Base Oils and Lubricants Conference
London, UK
www.icisworldbaseoils.com
ICOPGE 2018: 20th International Conference on Oil, gas & Petrochemical
Engineering
Rome, Italy
www.waset.org/conference/2018/03/rome/ICOGPE
April 16 - 17, 2018 3rd World Congress & Expo on Oil, Gas & Petroleum Engineering 2018
Dubai, UAE
scientificfederation.com/petroleum-engineering-2018/
April 17 - 18, 2018
April 21 - 24, 2018
UNITI Mineral Oil Technology Congress
Stuttgart, Germany
www.umtf.de
ELGI 30th Annual General Meeting
London, UK
www.elgi.org
May 7 - 8, 2018 Petrochemical & Refining Congress 2018
Berlin, Germany
http://prceurope.com/
June 11 - 12, 2018
August 9 - 10, 2018
ICOPGE 2018: 20th International Conference on Oil, Gas & Petrochemical
Engineering
Copenhagen, Denmark
https://www.waset.org/conference/2018/06/copenhagen/ICOGPE
9th International Conference and Expo on Oil and Gas
Madrid, Spain
https://oil-gas.conferenceseries.com/
October 17 - 19, 2018 The 51st GOMA Symposium - FUELS 2018
Opatija, Croatia
www.fuels.goma.hr
46 Fuels&Lubricants No. 1 OCTOBER 2017

Expect more
Measuring viscosity
with an SVM is easy,
fast and accurate.
- More than viscosity: Multiple parameters
from just one syringe
- Low sample and solvent volume
- Unbeatable ease of operation
- Wide temperature range for both
viscosity and density
- One measuring cell for the entire viscosity,
density and temperature range
Fuels&Lubricants No. 1 OCTOBER 2017 47
Get in touch: www.anton-paar.com/svm

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48 Fuels&Lubricants No. 1 OCTOBER 2017

LET US TAKE CARE
OF EVERYTHING