2. Fluid Solutions
Your partner in planning and manufacturing
latest state of the art Lube Oil Blending Plants
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3. LUBE OIL – DEFINITION AND PRODUCTION
PROCESS
DEFINITON
A lubricant is a substance introduced to reduce friction between moving
surfaces . It may also have the function of transporting foreign particles.
CHARACTERISTIC
High boiling point - low freezing point – high viscosity index – thermal
stability – corrosion prevention – high resistance to oxidation
PRODUCTION PROCESS
“Lubricating oil is produced by ‘Blenders and Compounders’ who combine
base oil with 1% to 20% application-specific chemical additives, which
enhance the performance of the base oil. The ‘compounded’ Lubricating oil
is then packaged and sold to end users.”*
*General lube oil definition
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4. Fluid Solutions – The Company
Based on a small Engineering Company, Michael Krapalis started
in the dispenser business 1981.
The development of the first fully automatic 24 Valve dispensing system
for paint at the new plant “Contilack - Oberhausen Germany” was ready in 1982.
Later on, 1985 Fluid Verfahrenstechnik was founded.
Here the development of the Fluid dispenser type 1405 and Industrial was born.
Until 1990 Fluid delivered the dispenser and control/ software technology for:
Füll Systembau GmbH
The today name “Fluid Solutions”, with international character evolved at the
beginning of 2003.
Based on more than 25 years of experience in the planning and construction of
components and systems for all recipe-controlled branches.
Fluid Solutions is now focused on consulting and concepts, strategies and the
complete engineering including delivery and assembly especially for the Lube Oil
Business
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5. Fluid Solutions – The Company
• Focused especially on the Lubricants market
(Lube Oil Blending and Grease Production
Plants)
• Customer support starting from programming via
engineering up to the running production system
• Latest technology, innovation and specialization
for conceptual design and engineering of
complete LOBP’s with focus on efficient core
equipment.
• Complete production concepts including storage,
production, handling systems and logistics
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6. Lubrication Projects Fluid Solutions
• ESSO, Hamburg
– 2 units AMBB each 30 additive components heated for pre-batches
up to 600 Kg in mobile Containers.
- 12 automated drum dispenser by robot with integrated “los in weight system” connected to each blender
• Fuchs(Hispano Chemica), Barcelona
– Fully automated movable 30 component additive dispenser for each 10 blenders.
– IBC and drum storage for additives
• DEA/ Texaco - Shell, Hamburg
– 2 units fully automated batch blender(ABB) with each 30 valves
• Statoil, Sweden
– 3 units AMBB each 28 components heated for pre-batches
and finished products up to 1.000 Kg in mobile Containers
– Automated handling system for the mobile container
– IBC and drum storage for additives
• Q8, Belgium
– 2 units AMBB each 28 components heated for pre-batches
and finished products up to 1.000 Kg in mobile Containers and 1 3.000 Kg batch vessel
– Automated handling system for the mobile container
– IBC and drum storage for additives.
• SWD, Duisburg
– 1 units AMBB each 36 components heated for pre-batches and finished products
up to 1.000 Kg in mobile Containers including automated mixing
– Automated handling system for the mobile container
– IBC and drum storage for additives
– 5 blender connections
• Fuchs Kaluga Russia
– 40.000 to LOBP
– Basic Engineering
– Detailed Engineering
– Automation material flow
• Bautec Lubmin
– 40.000 to LOBP
– Basic Engineering
– Detailed Engineering
– Automation material flow
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7. Fluid Solutions – The Company
Range of supply and services
Management consulting Provides proven, modern, flexible
Front End Engineering and expandable designs
Design Experience for modern lube oil
EPCM Project Management blending plant is proven
Process & Detail Design Key equipment like ABB, AMBB,
Procurement/Fabrication SMB; Transfer Equipment,
Installation Automation, … works as high
Commissioning performance Building Block in Lube
Training Oil Blending & Grease Plants
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8. Engineering Skills – EOQ calculation
The customers requirements are the origin for the engineering
process
The definition of type, number and size of blending equipment
will be calculated according to economical sources (Economic
order quantity calculation – EOQ)
Results will be adapted to real life circumstances and lead to
optimized storage, blending and filling capacities
Innovative designs will follow out of the calculation method
Optimized in-plant logistics
This procedure is very successful in debottlenecking of
existing Lube Oil Blending Plants
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9. Engineering Skills
The Process
Economical Order Quantity
calculation leads to optimized
Process Flow
Beginning from the storage of
raw materials and ending with
the filling lines, the material flow
diagram illustrates the complete
production process.
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10. Engineering Skills
The Layout
In a first step the management rules
for the plant are defined. They
contain data about working time,
the engaged blenders, pumps and
information about the capacities of
mixers and tanks and has lead to
a process flow diagram
In the second step the plant first
layout is made. It leads to meet
the optimal recommendations.
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11. Fluid Solutions
Key Equipment
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12. KEY EQUIPMENT
DDU – Drum Decanting Unit
Characteristics
Fast return on investment. Process flow diagram
Automatic handling of additives up to 5000 Cst.
Fast automatic decanting 3 m³/h (viscosity 3000Cst).
No impact from changes in density, viscosity and temperature of the products on the dosing result.
Skid mounted DDU-Module for easy integration in existing production units.
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13. KEY EQUIPMENT
AMBB – Automatic Mini Batch Blender
Characteristics
Latest state of the art technology for batches smaller than 5 m³ and for preblends
Highest dosing accuracy
Fast movers are hard piped with all its advantages (no contamination, exact dosing)
Additives could be connected to the AMBB via flexible containers (Flexsystainers) or drums with
its own dosing equipment to achieve highest accuracy with no pipeline contamination
Maximum product variety and flexibility due to unlimited amounts of Flexsystainers
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14. KEY EQUIPMENT
ABB – Automatic Batch Blender
Characteristics
used for batches between 5 and 30 m³ volume
raw material dosing via load cells
mixed in batch process
easy to clean – short setup times when product changes
easy to adjust the batch after quality analysis
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15. KEY EQUIPMENT
SMB – Simultaneous Metering Blender / ILB – In-Line Blender
Characteristics
used for fast movers production
raw material dosing via regulating valves and mass flow meters
mixed in continuous production process
fast dosing – fast blending time
SMB: all raw materials will be dosed in sequence and will be finished in storage tanks
ILB: all raw materials will be dosed in parallel and leads to finished product immediately
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16. KEY EQUIPMENT
Transfer – pigging equipment
Hose Manifold Matrix Manifold
Characteristics
avoids contamination in raw material and finished product transfer
maximum flexibility by using manifolds by minimum pipework
clean pipes – no material loss in pipes
maximum safety by using Matrix technique
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17. KEY EQUIPMENT
Automation
Characteristics
complete production control leads to
safe production
same quality for all batch types
documentation of complete process conditions
maximum flexibility with shortest reaction times
connection to ERP system (e.g. SAP) possible as option
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18. Our expertise in Lube Oil Production
• High quality Engineering and Delivery for the
complete Lube Oil Blending Plant (LOBP) –
storage, blending, transfer, filling, packing
• Definition of working and delivery packages in
the project
• Available for a complete range of lube oil
production applications
• Available in a wide range of production sizes
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