Nitrogen GeneratorThe Advantages of Skid Mounting

Building on our experience of skid-mounting process vessels for grease manufacture, we can provide skid mounting for a wide variety of equipment, to permit rapid on-site installation and commissioning.

Not only do we mount process vessels, but can mount other forms of equipment, such as the nitrogen generator shown on the right. 

Generally, we use UK based sub-contractors for this work unless circumstances dictate otherwise.

 

 


Skid that doubles as a spill trayQatar Bentone Unit Close Front View


Most skids are based on channel steel with tread-plate welded on top.  Whilst this meets the structural needs for moving and supporting equipment, it served little purpose beyond that.  We can build an improved version that has a closed bottom and open removable tread plate on the top.  This acts as a spill tray or mini-bund that contains the fluid, allowing it to be recovered conveniently rather than having to deal with a more major clean-up operation with the fluid having to be disposed of as waste.

Examples:-

Qatar Lubricants (2012):Qatar Kettle Skids

 

 

 

 

 

 

Qatar Lubricants Bentone Kettle (2011):Qatar Bentone Unit

 

 

 

 

 

 

Base Oil Metering Skid for Turkey (1992):Base Oil Metering Skid

 

 

PAST PROJECTS

Grease manufacturing plants and other similar projects...


Grease Plant for Qatar (2012) - Second PhaseGeneral View

This comprises a 3 Tonne Autoclave and two 5 Tonne Finishing Kettles to give the plant a 3000 Tonne per annum capacity on a single shift system, higher on double shifts.  The three vessels can also run independently as stand-alone kettles. Post-processing is based on a mobile mill, grease filter and de-aerator.

We have used faster and more powerful agitation on this plant than in its predecessors, which gives a more complete reaction in a shorter time, allowing the benefits normally attrubuted to under-driven contactors without their disavantages.

Some of the support equipment, for example the thermal oil heater and mezzanine floor were sourced independently by the client to maximise their cost beneft.

Charging the Autoclave

Closer Up

 

 

 

  

  


Bentone Grease Unit for Qatar (2011)Bentone Kettle in Qatar

This is the first phase of a full scale grease plant outside of Doha.  The unit comprises a 2 Tonne skid mounted double motion kettle with pump, mill, access platform and control panel.  The panel features variable speed drives for the gate, inner agitator and pump, amongst the control equipment.

This unit embodied the chief advantage of the skid mounted system as it allowed rapid erection on-site with the minimum of specialist equipment. 


Complex Grease Turbomixer Pilot Plant (2009) Complex Pilot Plant

Based on a skid mounted Scanima Turbomixer, originally for the food industry, this plant makes 20 - 30 Kg batches of grease with a higher yield than its conventionally agitated counterparts with the majority of formulae.  Having completed R&D work for a US Client, it has now been sold to a manufacturer in Liverpool.  

 


Marine Fuel Blender for Trinidad & Tobago (2002)Marine Blender 2

This was done by renovating a self-powered Fisher Blender and mounting it on a bi-directional trailer for mobile bunkering at Point Lisas, Trinidad.  The chief advantage of this unit is that it does not need an electrical supply and thus can be used in a flammable atmosphere or in the vicinity of flammable liquids.  

 


Lithium Grease Plant for Kuwait (1998)Kuwait Plant Shipment

This was built to replace a Grease Plant destroyed in the Gulf War; as the customer was an experienced Grease Maker, he had a strong design input and the plant was built to match his grease formulae and methods.

It featured the largest kettle we had built to date, being 5 Tonnes in capacity and offered a design upgrade over its predecessor, such as:

  • Contra-rotating paddles
  • Water-cooled hopper for high ambient temperature operation
  • De-aerator with variable orifice

Brake Fluid Plant for Trinidad & Tobago (1992)Brake Fluid Plant

This plant was designed to blend two-pack DOT 3 fluids into a finished product in a moisture free environment provided by a nitrogen blanket that was desiccated in silica gel columns.

It featured:

  • Stainless Steel contact surfaces
  • Raw Material barrel siphoning
  • Raw Material and finished product buffer tanks
  • Variable speed mixer
  • Volumetric flow metering
  • Skid mounting

 

2000 Tonnes Per Annum Grease Plant for Turkey (1991)Grease Plant in Turkey

It was designed to be capable of manufacturing:

  • Lithium Grease (Std and Complex)
  • Calcium Grease (Hydrated and Anhydrous)
  • Aluminium Stearate Grease
  • Bentone Grease
  • Sodium Grease

It was capable of making any grease type that could be done in a single stage process vessel.


1000 Tonnes Per Annum Grease Plant for Trinidad & Tobago (1985)Lithium Plant Trinidad

It was designed to be capable of manufacturing:

  • Lithium Grease (Std and Complex)
  • Anhydrous Calcium Grease
  • Aluminium Stearate Grease
  • Bentone Grease
  • Sodium Grease

It is capable of making most grease types that could be done in a single stage process

 

 

 

Hydrous Calcium Grease characteristics and the manufacturing basics: 

Low cost water-repellent grease

The key advantages include:

  • Water resistant
  • Made from cheap and widely available commodity raw materials

Limitations:

  • Poor high temperature performance and degrades irreversibly if melted

Manufacturing Principle:

React Hydrated Lime with fatty acids in oil to about 130°C under pressure to avoid water boiling off, then cool slowly whilst adding more oil to bring it to the right consistency (thickness).  Once complete, can be filtered or de-aerated before packaging.  Milling is not required.

Recommended Process Vessel(s)

  • Ideal:  Use pressurised autoclave for the heated half of the process and finishing kettle for the cooling half
  • Cost Effective:  Use a single pressure grease kettle for the whole process

Anhydrous Calcium Grease characteristics and the manufacturing basics: 

Low cost water-repellent grease

The key advantages include:

  • Water resistant
  • Made from cheap and widely available commodity raw materials
  • Can be made in food-grade form by using correct base oils

Limitations:

  • Poor-ish high temperature performance

Manufacturing Principle:

React Hydrated Lime with mono-valent acid inn oil to about 140°C, then cool slowly whilst adding more oil to bring it to the right consistency (thickness).  Once complete, can be filtered or de-aerated before packaging.  Milling is not required.

Recommended Process Vessel(s)

  • Ideal:  Use pressurised autoclave for the heated half of the process and finishing kettle for the cooling half
  • Cost Effective:  Use a single grease kettle for the whole process

Bentone (also known as Organo-Clay or Non-Melting) Grease:

High temperature Grease

The key advantages include:

  • Very good high temperature performance - does not melt
  • Made from widely available commodity raw materials

Limitations:

  • Can age-harden
  • De-gels if mixed with mono-soap grease
  • Can dry into clay residue at high temperature when exposed to air

Manufacturing Principle:

Mix organo-clay with oil, mill then package.  Some Organo clays do not require heat, others need moderate heating, perhaps to about 80°C

Recommended Process Vessel(s):

  • Unheated or heated mixer

Lithium Complex Grease

High temperature version of Lithium Grease - the de-facto high temperature bearing grease

The key advantages include:

  • Does not melt until at least 260°C
  • Shear stable
  • Made from widely available commodity raw materials

Limitations:

  • None, but if one sets the height bar high, one could argue that it is not as water resistant as calcium and aluminium greases

Manufacturing Principle:

React Lithium Hydroxide with mono and bi-valent acids, holding for a while at just over 100°C to allow complexing to happen, then heat up to almost 200°C to drive off water content.  Only dilute with a small amount of oil when cooling or complex will break up leaving a mono-soap structure.  Mill and then optionally, filter and de-aerate.

Recommended Process Vessel(s):

  • Ideal:  Use pressurised autoclave, ideally fitted with bottom entry turbomixer or disperser to prevent unreacted bi-valent acid buildup for the heated half of the process and finishing kettle connected to both heating and cooling circuits for the cooling half
  • Cost Effective:  Use a single grease kettle for the whole process, but cooling circuit as well as heating circuit will be needed to prevent extended cooling down timescale

Aluminium Complex Grease

High Temperature, highly water-resistant grease

The key advantages include:

  • Does not melt until at least 260°C
  • Highly water resistant
  • Adheres well to metal
  • Can be made for food processing applications if the right base oil is used

Limitations:

  • Can get hot at high speeds
  • Requires specialist raw material (Aluminium donor, e.g. Kolate)
  • Can be difficult to eliminate unreacted acid unless samples are checked with an infra-red spectrometer

Manufacturing Principle:

Aluminium donor is reacted with mono and bi-valent acids in oil with heat up to just over 200°C.  Unreacted acid needs to be checked for before cooling down by using an infra-red spectrometer.  Do not add a significant amount of oil during cooling or complex structure is liable to break down.  Do not mill. Filtering and de-aeration can be done as an option.

Recommended Process Vessel:

  • Heated Grease Kettle - pressure is not needed

Calcium Sulphonate Complex Grease

High Temperature, highly water-resistant grease with good shear stability

The key advantages include:

  • Does not melt until about 300°C
  • Highly water resistant
  • Thickener doubles as a EP additive and corrosion inhibitor giving the grease a high performance, even without additives
  • High specific gravity makes it possible to do a negative buoyancy grade, advantageous in marine applications where it will sink rather than float on water, reducing pollution issues.

Limitations:

  • Can get hot at high speeds
  • Requires specialist raw material in the form of Calcium Suphonate, problem can be made worse as some calcium sulphonate manufacturers also make the grease, meaning your main raw material supplier may also be your main competitor! Effective fume extraction/vapour control needed to minimise air pollution

Manufacturing Principle:

React calcium sulphonate with mono and bi-valent acids and alcohol.  Must be held at just below alcohol's boiling point for two hours for complexing to happen, then heat up to almost 200°C to drive off water content.  Do NOT dilute with oil when cooling or complex will break up leaving a mono-soap structure.  Do not mill.  Filtering and de-aeration can be done as an option.

Recommended Process Vessel:

  • Heated and cooled Grease Kettle, ideally with bottom entry turbomixer or high speed disperser to prevent thickener accumulating at the bottom of the kettle.  Also the bottom entry unit helps ensure the temperature is the same everywhere in the kettle, which is important for the two hour hold during complexing.  Pressure is not needed