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Lubricants and Greases Manufacturing Plants

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  • 1. Lubricants & greases manufacturing plantsOptimize and improve your performance
  • 2. International technology providerDesign, engineering and supply of lubricants and greases manufacturing plantsWith over 50 years of blending experience, in both new Key equipmentand revamped plants all over the world, Cellier, as an State-of-the-art equipment has been developed andActivity of ABB France, fully understands the complexity standardised by Cellier Activity to meet the specific requi-of running a lubes or greases manufacturing plant and rements of the lubricants and greases markets:in particular how to achieve inventory using Just In Time(JIT) principles integrated with the production of many −− Automatic Batch Blenderfinished products and packing combinations. −− Drum Decanting System −− In-Line Blending systemOur services include: −− Simultaneous Metering Blending system −− High-yield grease reactor and peripherals−− Conceptual design −− Pigged pipe lines−− Basic engineering −− Pigged manifold−− Detail engineering−− Equipment design and supply All the equipment can be skid mounted. In addition to the key−− Installation and start-up by ABB’s own expert team equipment noted above, our capability includes the design and−− Training and technical assistance delivery of raw material and finished product storage, transfer−− Software telemaintenance services and distribution units as well as filling and packaging systems.Design Process ControlCellier Activity has developed specific software for the design Cellier Activity has developed Lubcel™, a specific processof new plants or modernisation of existing ones. The design control software for lubricants and grease manufacturingis optimised to give the shortest Return On Investment (ROI) plants helping you to achieve the compliance with qualitytime and to guarantee the plant performance. procedures and a total traceability of operations.3-D view of a grass-root plant2 International technology provider | Lubricants and greases manufacturing plants
  • 3. Process and know-howIncreasingly stringent product-quality requirements are the PORTFOLIO BLENDING UNITS SIZING • Blending batch sizestandard for today’s lube oil market. Formulations are forever ANALYSIS • Blending facilities design • Cycle times / work loadincreasing in number and complexity. In addition to theseproduction constraints, the Lube Oil Blending Plant (LOBP)has to face up to the highly competitive lubricants market. DESIGN RAW MATERIALS BALANCE • Bulk storage sizing FINISHED PRODUCTS STORAGE • Unloading facilities design • Dedicated tank sizing • Packaged additives storage • Holding tank sizingCompetitive cost is of primary importance as is customer and handling design • Raw materials transfersservice especially for the industrial lubricants market. Ability toguarantee, at short notice, delivery for the exact quantity re- FILLING FACILITIES SIZING FINISHED PRODUCTS TRANSFERquired by the customer is the daily challenge of every modern • Balance per pack • Filling orders numbers • Transfers requirements • Transfers system designLOBP. • Change / rinsing over time • Filling lines design (lines / manifolds / pumps, etc.)In this environment, only an optimised LOBP design canensure customer satisfaction and supplier profitability. ENGINEERING PROCESS DOCUMENTS OTHER ENGINEERING DOCUMENTS • PFS • Layouts • Equipment listA blending plant typically includes five main areas: • Process description • Typical PIDs−− Raw materials storage ORGANISATION / ECONOMICS−− Blending units • Plant organisation CONCEPTUAL • Manning level−− Finished-product storage (bulk) • Operational cost DESIGN BOOK−− Filling and loading−− Packed finished products warehouse and dispatchThese areas are closely interconnected and as such an The design methodology specifically developed by Cellieroptimised design needs to cover the complete plant. Design Activity for complex batch production plants, and supportedis based on the actual customer production requirements and by specific design tools, can be applied at the different stepsconstraints which include: of the project from feasibilty study up to turn-key unit design.− − Production portofolio (product slate, required production, Dynamic simulation of production portofolio can be imple- formulas, grade/ pack distribution) mented which is of special interest to further optimise areas− − Batch size distribution (Economic Order Quantity or with great load variations such as truck loading gantries. Customer Order based)− − Product compatibility This know-how applies also to the manufacture of greases.− − Raw material characteristics and delivery mode− − Products Lead time and peak demand. Lubricants and greases manufacturing plants | Process and know-how 3
  • 4. Lube Oil Blending PlantCellier has developed specific processing equipment to meet the lubricant marketrequirements and quality constraints.Automatic Batch Blending Simultaneous MeteringThe Cellier Automatic Batch Blender represents a techno- Blendinglogically advanced blending option especially adapted tocomplex formulations, extended products slate and blend-to- Simultaneous Metering Blending (SMB) is similar to the ILBorder policies which are part of modern lubricants production but coupled with a sequential control and mode of operation.requirements. It combines the advantage of the ILB in terms of production capacity but also the advantage of the sequential controlThe principal advantages of Automatic Batch Blending related to flexibility and contamination.systems as compared to conventional batch blending are : Advantages:−− High level of blending accuracy and repeatability−− High RFTI (Right First Time Index ), no re-blend − − High throughput capability−− Reduced manpower requirements − − Low inter-contamination through rinsing being part of−− Enhanced blending flexibility the blend−− Quick blend turnaround − − Reduced number of dosing modules compared to conven-−− Low contamination tionnal ILB (typically 4 vs. 9) meaning reduced investment−− Minimum (virtually zero) slop generation. − − Simpler control − − Possible batch interruption enabling direct drum decantingFlexibility in batch size, product formulation, raw material or manual additions.handling and process sequences yield to a powerfullblending tool in the fields of lubricants, lubricant additives orfuel additives. Drum Decanting System Cellier Drum Decanting System (DDS) is designed to pumpIn Line Blending liquid products (even viscous) stored in drums or small containers and to incorporate them in formulation processesIn Line Blending (ILB) is especially adapted to large through- (chemical industry, lubricants, etc.).put production with a limited number of products andcompatibility groups and when immediate product availability The DDS perfoms the following functions:is required or intermediate storage is difficult (such as shiploading). −− empties a drum or mini-container −− doses a quantity of productAdvantages: −− rinses the emptied drum and −− recycles the rinsing product.−− Product immediately available (on spec)−− Large throughput−− High level of blending accuracy and repeatability−− Low manpower requirements.4 Lube Oil Blending Plant | Lubricants and greases manufacturing plants
  • 5. 1 2 3 41 Simultaneous Metering Blending systems with pigged lines | 2 In-Line Blending systems | 3 Drum Decanting System | 4 Automatic piggable manifoldPigging systems Pigging ManifoldUsed for many years in certain industries, pipe pigging Interconnecting the large number of source tanks withtechnology can be used where a large variety of products different possible destinations (filling, loading, etc.) hasare transfered. always been a major problem of Lube Oil Blending Plants. The unsafe and unpractical old “snake-pit” can now beAdvantages: replaced by a closed and compact piggable manifold ensuring safe interconnection without cross-contamination or product− − Optimisation of installation costs by reducing the number loss. of lines− − Operating and cleaning costs reduced by a significant Advantages: decrease of rinsing liquid quantities− − Line flexibility increased, simultaneous multi-connections, − − Automatic operation reduction of cleaning time between two batches − − Compactness and optimized space requirement− − Quick, automatic and safe pipe cleaning system − − Flexibility: multidirectional connections, bidirectional− − Completely closed system pigging, dedicated/pigged lines, different diameters)− − No more dead zones, complete line cleaning −− Fast cycle time− − No waste generation. −− Equipment availability and cleanliness, easy maintenance. Lubricants and greases manufacturing plants | Lube Oil Blending Plant 5
  • 6. Greases manufacturing plantCellier provides expertise and in-house technologies to optimize your greasesmanufacturing process.ABB designs greases manufacturing units meeting your In-line manufacturing processspecific needs. These units integrate saponification In the in-line greases manufacturing process, the saponifi-reactors offering excellent performance in terms of cation, dehydration and finishing phases are completedmixing, thermal transfer, easy cleaning and maintenance. continuously. The in-line process offers:They also include satellite solutions conferring flexibilityand modularity to your plant: in-line dosing (flowmeters, − − flexibility,loss-in-weight), transfers of finished products using − − reduced cycle time,pigged lines and production monitoring systems. − − improved process control.Application Heating/coolingAll types of grease - simple, complex or mixed - lithium, The key to the process control, productivity and quality lieslithium/calcium, aluminium, etc. with or without additives. in the mastering of thermal exchange systems. An accurate heating/cooling system for the heating of oil and chemicalBatch manufacturing process components and the cooling of the finished product enables:The batch greases manufacturing process includes thefollowing phases: − − reduced heating/cooling times, − − fine product temperature regulation with +/- 1°C accuracy,− − metering and addition of reactants (fatty acids, base oils, − − high pressures and high velocities of the heating/cooling water, alkali), medium,− − saponification run in a reactor/kettle operating at atmos- − − elimination of thermal shocks, pheric pressure or as a pressurized kettle to convert the − − reduced operational costs. fatty acid to soap and disperse the soap throughout the mixture, Process control− − dehydration to remove the reaction water, The module of the Lubcel™ software developped for grease− − homogenisation or milling to break agglomerated process control is perfectly adapted to the requirements of particles, adjust the grease consistency and produce a greases manufacturers. It is based on: smooth and stable product,− − cooling − − ABB expertise in the control of continuous and batch− − in-line deaeration to remove air entrapped prior to filling. processes, − − choice of reliable and accurate measurement, control andTo add special properties to the grease, other ingredients may regulation instruments,be introduced, such as oxidation inhibitors, anti-corrosion − − customization of the control system according to theand anti-wear agents. This additivation step is completed in process needs.a finishing kettle where the deaeration of the product may becompleted. and provides common control tools for both greases and lubricants manufacturing processes.6 Greases manufacturing plant | Lubricants and greases manufacturing plants
  • 7. 1 2 3 41 Grease reactors | 2 Dosing hopper with bag emptying | 3 Filling line | 4 Control room with production monitoringBenefits Cellier Activity delivers complete units from the storage and− − High dispersion and thermal yields delivery systems of raw materials to the filling and packaging− − Easy cleaning systems, including utilities production.− − Reduced investments costs− − Minimised operational costs The units can be delivered as skidded units, fully assembled− − Flexible and multipurpose units for the production of and ready for operation, including valves, fittings, control current greases. instruments, utilities and thermal insulation, for ease of instal-− − Excellent process repeatability and quality control. lation and to meet customer layout constraints. Lubricants and greases manufacturing plants | Greases manufacturing plant 7
  • 8. Extended process controlLubcel™: Process control and plant scheduling softwareLubcel™ Syncel graphics moduleLubcel™ is a powerful control system for batch production Syncel graphics module is a SCADA system sharing commonmonitoring and management which perfectly fits the require- database with the Lubcel™ solution. It includes a completements of lube oils or grease manufacturers. Lubcel™ ensures integrated synoptic screen maker.the entire management of raw materials, product formulation,sub-recipes and recipes, resources, inventories, production Workshop capabilitiesbatches and cleaning sequences. Parameter setting enables Lubcel™ enables the management of manual operationsLubcel™ to optimize the production. through deported industrial PC, WIFI tablets PC.Lubcel™ can be extended to encompass the control and Warehouse modulesupervision of all the operations within the plant, from raw Lubcel™ enables the management of packed additives, IBCmaterial reception and storage to product dispatch (blending, containers including bar coding scanner and printer solutions.intermediate storage, transfers, filling and warehouse). It is aplant-wide control system integrating sub-systems such as Advanced short-term scheduling modulegraphics, workshop capabilities, warehouse management, Lubcel™ indicates the daily load for each blending or fillingadvanced schedule features. It has no limits in communicating resource (ABB, SMB, ILB…) or workshop (reception, blen-with other systems such as lab or business systems (ERP). ding, filling). This short-term scheduling module is a powerful tool for smoothing the load.Lubcel™ is able to be integrated with the majority of PLCsor controllers. With Lubcel™ you will achieve the total process Histcel historics modulecontrol and plant scheduling software integration of your Lubcel™ enables information from the previous year’s pro-production system. duction data records to be retrieved for data tracking purpose and to perform analysis or to get some trends. The results of multi-criteria searches can be exported in Excel format files in order to manipulate the records with standard tools.1 Synoptic screen for the monitoring of a piggable manifold | 2 Synoptic screen for the monitoring of raw materials transfer through pigged lines 1 28 Extended process control | Lubricants and greases manufacturing plants
  • 9. Typical Lubcel™ architecture Lubricants and greases manufacturing plants | Extended process control 9
  • 10. Modernisation of existing plants StockWhy modernise and improve performance ?− − To comply with highest international quality standards.− − To enhance productivity and lower production costs.− − To increase production capacity. 50 %− − To enlarge product portfolio. Additive−− To ensure a better customer service. Saving Reblend 95 %− − To increase control and interface by automation and plant- 2% wide process control system.Improvement factorsThe technologies developped and implemented by CellierActivity improve the efficiency of existing plants. 50 % 75 %Modern blending tools− − Variable batch size. Operators Slop− − Dosing accuracy.− − Reduced and repeatable cycle time. Typical savings resulting from an LOBP upgradePigging technology / contamination control during transfers− − Quick product change without slop generation. Key Performance Indicators (KPIs) improve by the reduction of− − Minimisation of cross-contamination. minimum batch volume and reblend index.High-connectivity control system A better productivity is obtained by an optimal resource− − Elimination of human errors. allocation. It results in time savings by efficient, reliable and− − Operation traceability. automated rinsing and transfer (pigging) procedures as well as− − Connectivity to corporate network (ERP). in raw material savings (additives and base oils).Results and capabilities Additional benefits are a laboratory workload reduction andMajor benefits of a plant upgrade are product and process a drastic slop reduction (virtually zero at blending stage) andflexibility. Your plant becomes market responsive allowing: product loss.− − high quality products,−− inventory reduction,− − Just-In-Time operations.1 Automatic Batch Blenders as skidded units before shipment | 2 Tank farm 1 210 Modernisation of existing plants | Lubricants and greases manufacturing plants
  • 11. Worldwide referencesThrough our capability to meet the real needs of the lubricants industry andour unique position as specialist in the supply of turnkey production units,Cellier Activity enjoys a leading position in this market.The major international petroleum companies have chosen Cellier Activity.AMOC EgyptAGIP ItalyBP Castrol Australia, Belgium, China, India, Iran, Iran, Singapour, South AfricaCHEVRON USACOPEC ChileENGEN RSAENOC UAEEXXON MOBIL China, Egypt, France, Hong Kong, Japan, Singapour, Tunisia, UKGALP PortugalIDEMITSU JapanINDIAN OIL IndiaINFINEUM Italy, SingaporeLUBRIFIN RomaniaLUKOIL RomaniaQ8 BelgiumLUBRIZOL France, India, UKNAFTEC AlgeriaNIPPON OIL JapanPERTAMINA IndonesiaPSO PakistanRAK OIL UAEREPSOL SpainSHELL Belgium, Canada, France, Japan, Philippines, Russia, Singapore, TrinidadSINOPEC ChinaTOTAL Belgium, China, France, India, Saoudi Arabia, Spain, Vietnam Lubricants and greases manufacturing plants | Worldwide references 11
  • 12. Contact usABB France Note: FRABB_PA_CE036-V032011EN We reserve the right to make technical changes orProcess Automation Division modify the contents of this document without priorCellier Activity notice. With regard to purchase orders, the agreed700 bd. Jean-Jules Herbert particulars shall prevail. ABB does not accept anyP.A. des Combaruches responsibility whatsoever for potential errors or possible lack of information in this document.73100 Aix-Les-Bains, FrancePhone: +33 (0)479 35 05 65 We reserve all rights in this document and in theFax: +33 (0)479 88 37 71 subject matter and illustrations contained therein.E-Mail: info.cellier@fr.abb.com Any reproduction, disclosure to third parties or utilization of its contents – in whole or in parts – iswww.abb.com/industries forbidden without prior written consent of ABB. All copyrights and trademarks are the property of their rightful owners. Copyright© 2011 ABB All rights reserved