Base Oils Training

Michael Kaufman, M.Sc. (Eng.)

Technical Services Advisor
A Suncor Energy business

Presenter Introduction: Michael Kaufman

Michael Kaufman
Technical Services Advisor
(647) 477-3706
mkaufman@suncor.com

B.Sc. in Engineering Chemistry

M.Sc. (Eng.) in Chemical
Engineering specializing in
polymer chemistry
Joined Petro-Canada Lubricants
in 2008
Started as R&D Product
Specialist working on lawn care,
PCMO and HDEO
Technical Services Advisor
since July 2010
Author/co-author of several
publications and conference
proceedings

DISCLAIMER
THE INFORMATION CONTAINED IN THIS
PRESENTATION IS PROPRIETARY AND FOR THE
SOLE USE OF PETRO-CANADA EMPLOYEES
ONLY. DO NOT DISTRIBUTE ANY INFORMATION
IN ANY FORM WITHOUT THE WRITTEN
PERMISSION OF THE AUTHOR.

Agenda
Crude Oil
Refining Basics
Base Oil Quality API Groups
Petro-Canada Mississauga Refinery
Petro-Canada Base Oils Product Line

Petroleum Source
In its unrefined state petroleum is referred to as Crude
Oil
Crude is a complex mixture of light and heavy
hydrocarbons and other compounds
Undesirable impurities include Sulfur, Nitrogen, Oxygen, and
Metals

Base oils are obtained from refined crude oil

Crude Oil Reserves by Region

Top 10 Proven Crude Oil Reserves
Rank
1
2
3
4
5
6
7
8
9
10

Country
Saudi Arabia
Venezuela
Canada
Iran
Iraq
Kuwait
United Arab Emirates
Russia
Libya
Nigeria

Proven Reserves
(million barrels)
262,600
211,200
175,200
137,000
115,000
104,000
97,800
60,000
46,420
37,200

Top Oil Producing Nations

Top Oil Producers, 2010
Includes crude oil, shale oil, oil sands and natural gas liquids

Venezuela
Kuwait
U.A.E.

Russia

Mexico

Canada
Saudi Arabia
China

Iran

United States

Canadian production is 3.3 million barrels per day

6

World Refinery Capacity

World BASE OIL Refinery Capacity

400
350
300

Canada

250

United States

200
150

1,000 barrels per calendar day

100,000 barrels per calendar day

World CRUDE Refinery Capacity

400
350
300

Canada

250

United States

200
150

100

100

50

50

0
North
America

Latin
America

Eastern
Europe

Western Middle East

Europe

Africa

Asia and
Pacific

North
America

Latin
America

Eastern
Europe

Western Middle East

Europe

World Refinery Capacity = 89 million barrels per day

World Base Oil Refinery Capacity = 0.95 million barrels per day
Base oil refining capacity = 1% of total fuels refining capacity

Source:

OPEC Annual Statistical Bulletin 2010/2011

LubesNGreases 2011 Guide to Global Base Oil Refining

Africa

Asia and
Pacific

Yields from Crude

Average N. American production from a barrel of crude oil.
Gasoline

44%

Distillate (home heat, diesel)

21%

Kerosene-type jet fuel

Other (e.g., residual fuel oil, coke, asphalt)
Lubricant feedstock

9%
25%
1%

So-called Lube Crudes will yield higher amounts of the

vacuum distillates that go to make up lubricant Feedstocks, or
Feeds
Lubricant production = 1% of 89 Million BPD crude oil production = 890,000 BPD
Global Base Oil Refining Capacity = 950,000 BPD
8

Crude Oil Types

Paraffinic
Appreciable wax content. Minimal asphalt.
Favored for Paraffinic Base Oil production

Naphthenic
Minimal wax; minimal asphalt
Largely used as feedstock for refrigeration, transformer or niche
process oils

Mixed
Contains wax and asphalt
Can be used to produce base oils, but in low yields

Asphaltic
Primarily asphaltic residue; high S and N content
Suitable for high-viscosity base oil manufacture ie cylinder stock.
9

Crude Oil Properties

Colour:

Varies from clear to tarblack

Viscosity: Ranges form water-like to

almost solid
Composition (weight%)
Carbon
84%
Hydrogen
14%
Sulphur
1-5%
Other (Nitrogen, Oxygen, Metals, Salts) <0.2%

10

Refining Basics
A refinery process known as Atmospheric
Distillation boils off all the low-boiling materials which
are then condensed and used as fuels.
A second distillation process, Vacuum Distillation,
under reduced pressure produces high boiling
fractions -vacuum gas oils - known as Feeds.
Vacuum gas oils are one of the main feeds in a
lubricants refinery

11

Distillation of Crude
The value of crude oil can only be realized once it has been cleaned up (dewatered and de-salted) and separated into various fractions of similar
hydrocarbons.
Gases/Naphtha

Rising vapours
condense and are
drawn off

Gasoline

Crude Oil

Kerosene/Jet fuel
Diesel
Lubricant

Boiler
Asphalt/Residual
Distillation Tower
12

Increasing
boiling
point

Refining Operations
2 Basics Refining Goals
Upgrade Composition
Regardless of refining
technology used, the intent is
to get rid of undesirable
molecules/character, such as
Unsaturates, Sulfur, Nitrogen,
& Aromatics

13

Enhance Physical Properties

Viscosity, Volatility & Flash
Point controlled through one
or more distillations.
Low-temperature properties
controlled through wax
conversion or removal

What Are Base Stocks?

Base Stocks are the individual cuts of product from refinery distillation towers.
Base Stocks of different viscosities are the fundamental building blocks of
finished lubricants.
When used internally to formulate finished lubricant products
Base Stocks

When used alone or blended together into a saleable product

Base Oils

14

Quality API Groups

15

API Group Definitions

API Groups: The American Petroleum Institute (API)

classifications for lubricant base-stocks:
Group

16

Weight %
Sulfur
> 0.03

Weight %
Saturates
< 90

VI
80 - 119

II

< 0.03

> 90

80 - 119

III

< 0.03

> 90

120+

IV

Synthetic PAOs

Other Synthetics (diesters, PAGs, etc.)

API Groups Defined

17

API Base-Stock Groups. The American Petroleum Institute (API) has

developed numerical classifications for lubricant basestocks, based on
sulfur content, composition, and VI.

Group I: Is the lowest quality level with VIs in the range 80-100+, but
usually below 100. Solvent refined stocks fall into this category. PetroCanada does not manufacture these.

Group II: Applies to stocks with low impurity levels, and VIs from 100 to119.
Our HT base-stocks are Group II.

Group III: Applies to basestocks of saturated hydrocarbon composition,

very low impurity levels, and very high VI (VHVI), above 120. Our HC/IDW
stocks fall into this category.

Group IV: Refers to fully synthetic base-stocks, (e.g. PAOs).

Group V: All base stocks not included in Group I-IV (Naphthenic pale oils,
ester, poly-alkylene glycol and other non-PAO synthetics)

Purity (% saturate level)

Petro-Canada
Group II

100
Group III+
Group II

Group III

90
Group I

80
90

18

Petro-Canada
Group III (VHVI)

100

110
120
Viscosity Index

130

Increased Performance

Performance vs Degree of Refining

Next Generation
Lubricants are
demanding increasingly
higher quality base oils

Group III (Isomerization /

Wax Conversion)
The grey zone of Gp II+

Group II (Hydrogenation)
Group I (Solvent Refined)
Increased Refining Technology

19

Mississauga Lubes Refinery

20

Petro-Canada Lubricants

State of the art lubricants facility

15,600 bpd Overall Capacity
13,600 bpd Group II
2,000 bpd Group III
7th largest Group II/III* base oil
refinery in North America
* Only Group III producer in N.A.
11th largest Group II/III base oil
refinery in the world
2012 LubesnGreases Data
21

History
Lubricants Refinery History
The original refinery on this site was built by British
American Oil to produce fuels and lubricants for the
Allied Forces in World War II.
The original plant was built in 1943 and contained 2
small crude refining units, a thermal cracker to make
aviation gasoline, a small lubricants unit to produce
lubricating oils for automobiles, and an asphalt plant.
The business was purchased by Gulf Canada in 1968
and finally by Petro-Canada in 1985.
In 1993, Petro-Canada converted this plant from a full
petroleum refinery into a lubricants facility and was
awarded the first ISO9001 certification in the industry.
22

History Continued

Two Production Units Provides Enhanced Supply

HTU - HydroTreating Unit (Two-Stage)

USP White Oils and API Group II Base Oils
Pharmaceutical Grade Products
Higher Cycloparaffin content

Commissioned in 1979
Began White Oil Production in 1991

CDW Catalytic Dewaxing Unit (Hydro-Isomerization)

API Group II+ & Group III Base Oils
Lower Volatility (GF- 5 / PC -11 ready)
Higher VI (shear stability)
Enhanced Low Temperature Properties

Commissioned in 1996
Capacity expanded by 50% in 2006

23

Hydro Treating Base Oil Train

Commissioned in 1979
Produces Pharmaceutical Grade White Oils
Starting in 1991

Produces Group II Base Oils

Hydrogen

Grp II Base Oils

40N
Atmospheric
Distillation

45N / 50N

Vacuum
Distillation
Dewax

Crude
Oil

Gas
Oil
Vacuum
Distillation
1st Stage Atmospheric
Distillation
HTU

Wax

Light
Block

Medium
Block

60N

*60N

100N

200N

350N

650N

2nd Stage
HTU

24

*Base stock consumed internally

CDW Base Oil Train (Phoenix)

Commissioned in 1996
CDW unit utilizes Isomerized Dewaxing to produce high
quality Group II+ and III Base Stocks
Total wax molecular conversion enhances low pour properties
Capacity expanded by 50% in 2006

25

Hydro Isomerization Dewaxing Process

Medium Viscosity Index (MVI) - Mode
Atmospheric
& Vacuum
Distillation
20N
40N

Atmospheric
Distillation
Vacuum
Distillation

Hydro-Isomerization
Wax Conversion

Group II/II+
Base Oils
65N
100N
325N

Crude
Oil

26

Hydro-Cracker

High Pressure
Hydro-Treater

Hydro Isomerization Dewaxing Process

High Viscosity Index (HVI) - Mode
Atmospheric
& Vacuum
Distillation
20N
40N

Atmospheric
Distillation
Vacuum
Distillation

Hydro-Isomerization
Wax Conversion

Group III
Base Oils
VHVI 2
VHVI 4
VHVI 8

Crude
Oil

27

Hydro-Cracker

High Pressure
Hydro-Treater

Quality of HT/HC Base Stocks

The processes we use ensure:

Low Toxicity: Virtually no aromatics, sulphur-, oxygen-

or nitrogen-containing compounds and therefore the

base stocks are relatively benign
Dermatological Safety: Many of our base stocks are

made to meet medicinal credentials

Environmental soundness: Our base stocks have

inherent to readily biodegradability in standard tests

28

Benefits of HT vs CDW Base Stocks

Hydro-Treated Base Stocks (HT)
Excellent oxidative stability
Improved additive solubility
Pharmaceutical grade white
oils

Hydro-Isomerization (CDW)
Lower volatility
Higher VI
Improved shear stability
Better low temperature
properties (pour point, cold
crank, etc)

Disadvantages of Petro-Canada Group II+/III Base Stocks

Lower solubility due to lower aromatic content
Less seal swell
Upper viscosity limit
HT maximum viscosity: ~100 cSt @ 40C
CDW maximum viscosity: ~8 cSt @ 100C
29

Petro-Canada Base Oils Offering

PARAFLEX
Process oils (drums, IBC, bulk)

PURITY FG WO
NSF registered white mineral oils (pails, drums, IBC, bulk)

PURITY & PURITY VHVI

Base oils used for lubricant blending (bulk only)

PURETOL
USP/NF, EP, NSF registered white mineral oils (bulk only)

KRYSTOL
Technical Grade mineral oils (bulk only)

Miscellaneous
Defoamer Oils, Mineral Seal Oil, Wash Oil (bulk only)
30

Process Oils

Paraflex Process Oils

Marketed in applications that require the use as raw materials
in the manufacturing of products such as chemicals, rubber,
plastic, leather and polishes

Purity FG WO
Marketed to food processing, pharmaceutical and agricultural
industries that require a white mineral oil available in pails,
drums and totes (IBCs)

Purity & Purity VHVI Baseoils

Marketed as a base blend fluid for lubricant needs
Can be Group II or Group III
Sold in bulk quantites only

31

PURETOL White Mineral Oils

Highest quality oils from the worlds largest manufacturer of White
Mineral Oils. Sold in bulk only.
Meet the requirements of:
9 USP/NF United States Pharmacopoeia/National Formulary
9 EP European Pharmacopoeia
9 DABX German Pharmacopoeia
9 JP Japanese Pharmacopoeia
9 Code of Federal Regulations (US Government)
21 CFR 172.878 direct food contact
21 CFR 178.3620 (a) indirect food contact

9 NSF International registered (select grades)

3H Release agent (direct food contact)
HX1 Lubricant ingredient (incidental contact)

9 Certified Kosher, Pareve and Halal

32

PURETOL WMO Testing

1. Carbonizables
Slight difference between USP/NF and EP

2. Solid Paraffin, FTIR, Acidity, Sulphur compounds,

Polynuclear Aromatics
3. Biodegradability, Toxicity, Mutagenicity, Sensitivity,
Irritation studies
special attention is required for cosmetics customers

4. Residual Solvent (PAH, low ppm range. USP467)

5. DMSO Extractables (IP346)

33

PURETOL Applications
Pharmaceutical
Ointment bases, petrolatum
Laxatives
Capsule and pellitilizing aids

Health and Beauty Applications (HABA)

Cosmetics
Baby Oil, sunscreen and haircare products

Plastics and Elastomers

Process aid for PVC, polystyrene, polyolefin and thermoplastic
elastomers

Other
Adhesives (hot melt and pressure sensitive)
Textile fabric lubricant
Cleaners and polishes
34

KRYSTOL Technical Grade WMOs

21 CFR 178.3620 (b)
Polyaromatic testing required

Certified Kosher, Pareve and Halal

Adhesives, textiles, plastics
Where food and/or skin contact is not critical

Sold in bulk only.

35

Paraflex HT (Canada)

36

Paraflex HT (US)

37

Purity FG WO

38

Purity Base Oils

Property
API Base Oil Category
Density @ 15C, kg/L
Viscosity
@ 40C, cSt
@ 100C, cSt
Viscosity Index
Pour Point, C
Flash Point, C
Cold Crank Simulator
@-25C, cP
@-20C, cP
@-15C, cP
Volatility
Evap. Loss, Noack, wt%
GCD wt% @ 371C

39

ASTM
Test
Method
API 1509
E.1.3
D4052

L60

L65

1020

1017

1003

1810

2204

3501

5300

II
0.857

II
0.830

II
0.858

II
0.847

II+
0.840

II
0.864

II
0.865

II
0.860

II
0.870

D445
D445
D2270
D97
D92

11.0
2.75
83
-21
179

9.78
2.6
95
-36
180

21.2
4.16
94
-21
205

20.6
4.24
109
-21
210

21.2
4.4
118
-21
224

34.8
5.69
102
-18
226

41.7
6.4
102
-18
235

67.6
8.87
104
-15
250

101
11.4
99
-12
268

1950

1385

<1350

4500
2200

6800
3400

D5293
D5293
D5293
D5800
D6417

3480
62.2
67.0

20
25.0

24.8
15.0

15.5
2.7

15.0
8.0

10.2
2.0

3.0

3.0
<1

Purity VHVI Base Oils

Property
API Base Oil Category
Density @ 15C, kg/L
Viscosity
@ 40C, cSt
@ 100C, cSt
Viscosity Index
Pour Point, C
Flash Point, C
Cold Crank Simulator
@-35C, cP
@-20C, cP
Volatility
Evap. Loss, Noack, wt%
GCD wt% @ 371C

40

ASTM
Test
Method VHVI 2
API 1509
E.1.3
III
D4052
0.833
D445
D445
D2270
D97
D92

9.9
2.64
101
-39
187

D5293
D5293
D5800
D6417

VHVI 4

VHVI 6

VHVI 8

III
0.832

III
0.839

III
0.847

21.1
4.48
127
-24
230

33.1
6.00
128
-18
240

51
8.20
127
-15
258

1550

3189

9.0
<1

4.6
<1

3000

60
62

11.7
<1

Questions?

Michael Kaufman
Technical Services Advisor
(647) 477-3706
mkaufman@suncor.com