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A Suncor Energy business
Base Oils TrainingMichael Kaufman, M.Sc. (Eng.)
Technical Services Advisor
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Presenter Introduction: Michael Kaufman
B.Sc. in Engineering Chemistry
M.Sc. (Eng.) in Chemical
Engineering specializing inpolymer chemistry
Joined Petro-Canada Lubricantsin 2008
Started as R&D ProductSpecialist working on lawn care,PCMO and HDEO
Technical Services Advisor
since July 2010 Author/co-author of several
publications and conferenceproceedings
1
Michael KaufmanTechnical Services Advisor
(647) 477-3706
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DISCLAIMER
THE INFORMATION CONTAINED IN THIS
PRESENTATION IS PROPRIETARY AND FOR THE
SOLE USE OF PETRO-CANADA EMPLOYEESONLY. DO NOT DISTRIBUTE ANY INFORMATION
IN ANY FORM WITHOUT THE WRITTEN
PERMISSION OF THE AUTHOR.
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Agenda
Crude Oil
Refining Basics
Base Oil Quality API Groups
Petro-Canada Mississauga Refinery
Petro-Canada Base Oils Product Line
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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
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Crude Oil Reserves by Region
Top 10 Proven Crude Oil Reserves
Rank Country
Proven Reserves
(million barrels)1 Saudi Arabia 262,600
2 Venezuela 211,200
3 Canada 175,200
4 Iran 137,000
5 Iraq 115,0006 Kuwait 104,000
7 United Arab Emirates 97,800
8 Russia 60,000
9 Libya 46,420
10 Nigeria 37,200
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Top Oil Producing Nations
Top Oil Producers, 2010Includes crude oil, shale oil, oil sands and natural gas liquids
Venezuela
Kuwait
U.A.E.
Mexico
Canada
China
Iran United States
Saudi Arabia
Russia
Canadian production is 3.3 million barrels per day
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0
50
100
150
200
250
300
350
400
NorthAmerica
LatinAmerica
EasternEurope
WesternEurope
Middle East Africa Asia andPacific
1,0
00barrelsper
calendarday
World BASE OIL Refinery Capacity
Canada
United States
0
50
100
150
200
250
300
350
400
NorthAmerica
LatinAmerica
EasternEurope
WesternEurope
Middle East Africa Asia andPacific
,
barrelspercalendarday
World CRUDE Refinery Capacity
Canada
United States
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World Refinery Capacity
Source: OPEC Annual Statistical Bulletin 2010/2011
LubesNGreases 2011 Guide to Global Base Oil Refining
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
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Average N. American production from a barrel of crude oil.
Gasoline 44%
Distillate (home heat, diesel) 21%
Kerosene-type jet fuel 9%
Other (e.g., residual fuel oil, coke, asphalt) 25%
Lubricant feedstock 1%
So-called Lube Crudes will yield higher amounts of the
vacuum disti llates that go to make up lubricant Feedstocks, or
Feeds
Yields from Crude
Lubricant production = 1% of 89 Million BPD crude oil production = 890,000 BPD
Global Base Oil Refining Capacity = 950,000 BPD
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ParaffinicAppreciable 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.
Crude Oil Types
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Crude Oil Properties
Colour: Varies from clear to tar-
black
Viscosity: Ranges form water-like to
almost solid
Composition (weight%)Carbon 84%
Hydrogen 14%
Sulphur 1-5%Other (Nitrogen, Oxygen, Metals, Salts)
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Refining Basics
A refinery process known asAtmospheric
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 boilingfractions -vacuum gas oils - known as Feeds.
Vacuum gas oils are one of the main feeds in a
lubricants refinery
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Distillation of Crude
The value of crude oil can only be realized once it has been cleaned up (de-
watered and de-salted) and separated into various fractions of similar
hydrocarbons.
Crude Oil
Boiler
Gases/Naphtha
Lubricant
Asphalt/Residual
Diesel
Gasoline
Kerosene/Jet fuel
Rising vapours
condense and are
drawn off
Distillation Tower
Increasing
boiling
point
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2 Basics Refining Goals
Upgrade Composition
Regardless of refiningtechnology used, the intent is
to get rid of undesirable
molecules/character, such as
Unsaturates, Sulfur, Nitrogen,
& Aromatics
Enhance Physical Properties
Viscosity, Volatility & FlashPoint controlled through one
or more distillations.
Low-temperature properties
controlled through wax
conversion or removal
Refining Operations
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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
What Are Base Stocks?
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Quality API Groups
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API Groups: The American Petroleum Institute (API)
classifications for lubricant base-stocks:
Group Weight %
Sulfur
Weight %
Saturates
VI
I > 0.03 < 90 80 - 119II < 0.03 > 90 80 - 119
III < 0.03 > 90 120+
IV Synthetic PAOsV Other Synthetics (diesters, PAGs, etc.)
API Group Definitions
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API Groups Defined
API Base-Stock Groups. The American Petroleum Institute (API) hasdeveloped numerical classifications for lubricant basestocks, based onsulfur content, composition, and VI.
Group I: Is the lowest quality level with VIs in the range 80-100+, butusually below 100. Solvent refined stocks fall into this category. Petro-Canada 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/IDWstocks 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)
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Pur
ity(%s
aturateleve
l)
80
90
100
Viscosity Index
90 100 110 120 130
Group II
Group I
Group III
Petro-Canada
Group IIPetro-Canada
Group III (VHVI)
Group III+
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Increased Refining Technology
Group I (Solvent Refined)
Group II (Hydrogenation)
Group III (Isomerization /Wax Conversion)
In
creasedP
erforman
ce
The grey zone of Gp II+
Next Generation
Lubricants are
demanding increasingly
higher quality base oils
Performance vs Degree of Refining
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Mississauga Lubes Refinery
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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
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History
Lubricants Refinery History
The original refinery on this site was built by British
American Oil to produce fuels and lubricants for theAllied 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 producelubricating 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.
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VacuumDistillation
CrudeOil
Atmospher icDistillation
Grp II Base Oils
Atmospher icDistillation
Dewax
2nd StageHTU
Gas
Oil
Wax
Hydrogen
40N
VacuumDistillation
1st StageHTU
45N / 50N
LightBlock
60N
100N
350N
Commissioned in 1979
Produces Pharmaceutical Grade White Oils
Starting in 1991
Produces Group II Base Oils
MediumBlock
*60N
200N
650N
*Base stock consumed internally
Hydro Treating Base Oil Train
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Commissioned in 1996
CDW unit uti lizes 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
CDW Base Oil Train (Phoenix)
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Vacuum
Distillation
Hydro-IsomerizationWax Conversion
Atmospheric& VacuumDistillation
CrudeOil Hydro-Cracker High PressureHydro-Treater
AtmosphericDistillation
100N
325N
65N
Group II/II+Base Oils
Medium Viscosity Index (MVI) - Mode
20N40N
Hydro Isomerization Dewaxing Process
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Vacuum
Distillation
Hydro-IsomerizationWax Conversion
Atmospheric& VacuumDistillation
CrudeOil Hydro-Cracker High PressureHydro-Treater
AtmosphericDistillation
VHVI 4
VHVI 8
VHVI 2
Group IIIBase Oils
High Viscosity Index (HVI) - Mode
20N40N
Hydro Isomerization Dewaxing Process
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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
Quality of HT/HC Base Stocks
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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
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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)
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Process Oils
Paraflex Process Oils
Marketed in applications that require the use as raw materialsin 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
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PURETOL White Mineral Oils
Highest quality oils from the worlds largest manufacturer of WhiteMineral Oils. Sold in bulk only.
Meet the requirements of:
USP/NF United States Pharmacopoeia/National Formulary EP European Pharmacopoeia
DABX German Pharmacopoeia
JP Japanese Pharmacopoeia
Code of Federal Regulations (US Government)
21 CFR 172.878 direct food contact
21 CFR 178.3620 (a) indirect food contact
NSF International registered (select grades)
3H Release agent (direct food contact)
HX1 Lubricant ingredient (incidental contact)
Certified Kosher, Pareve and Halal
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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)
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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
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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.
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Paraflex HT (Canada)
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Paraflex HT (US)
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Purity FG WO
O
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Purity Base Oils
Property
ASTM
Test
Method L60 L65 1020 1017 1003 1810 2204 3501 5300
API Base Oil Category API 1509E.1.3 II II II II II+ II II II II
Density @ 15C, kg/L D4052 0.857 0.830 0.858 0.847 0.840 0.864 0.865 0.860 0.870
Viscosity
@ 40C, cSt D445 11.0 9.78 21.2 20.6 21.2 34.8 41.7 67.6 101
@ 100C, cSt D445 2.75 2.6 4.16 4.24 4.4 5.69 6.4 8.87 11.4
Viscosity Index D2270 83 95 94 109 118 102 102 104 99
Pour Point, C D97 -21 -36 -21 -21 -21 -18 -18 -15 -12Flash Point, C D92 179 180 205 210 224 226 235 250 268
Cold Crank Simulator
@-25C, cP D5293 1950 1385
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Purity VHVI Base Oils
Property
ASTM
Test
Method VHVI 2 VHVI 4 VHVI 6 VHVI 8
API Base Oil CategoryAPI 1509
E.1.3 III III III III
Density @ 15C, kg/L D4052 0.833 0.832 0.839 0.847
Viscosity
@ 40C, cSt D445 9.9 21.1 33.1 51
@ 100C, cSt D445 2.64 4.48 6.00 8.20
Viscosity Index D2270 101 127 128 127Pour Point, C D97 -39 -24 -18 -15
Flash Point, C D92 187 230 240 258
Cold Crank Simulator
@-35C, cP D5293 3000
@-20C, cP D5293 1550 3189
VolatilityEvap. Loss, Noack, wt% D5800 60 11.7 9.0 4.6
GCD wt% @ 371C D6417 62
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Questions?
Michael Kaufman
Technical Services Advisor(647) 477-3706
