Why To Choose Synthetic Compressor Oil?

26 Jun 2024

Index:

• Introduction
• Understanding Compressor Oils
• What is Synthetic Compressor Oil?
• Performance monitoring
• Key Advantages of Synthetic Compressor Oil
• Applications of Synthetic Compressor Oil
• Considerations When Choosing Synthetic Compressor Oil
• Environmental Impact
• Conclusion

Compressor oils are the flowing bloodline of any kind of compressors. They not only lubricated the internal parts, but also helps in optimizing the performance of the equipment as well as modulates the life span expectancy of the equipment as well as its internal spares.

Specifically talking about industrial revolution, compressor oils have followed a path of being formulated from mineral oil groups to recently preferred and adopted synthetic variants. We might face questions of higher end-to-end product pricings of synthetic type over mineral type (conventional market grades), but the same can be established and settled in customer’s belief by proving the optimization in terms of overall life cycle cost, maintenance downtimes, man-machine interface, etc.

Understanding Compressor Oils

Compressor oils play a critical role in the functioning of compressors by providing lubrication, reducing friction, and dissipating heat. There are two main types of compressor oils: mineral-based and synthetic. Mineral oils are derived from refined crude oil, while synthetic oils are chemically engineered from synthesized compounds.

What is Synthetic Compressor Oil?

Synthetic compressor oil is formulated using chemically modified base oils, which offer enhanced properties compared to traditional mineral oils. The synthetic base oils are often combined with advanced additives to further improve their performance. This combination results in a lubricant that can withstand extreme operating conditions, providing superior protection and efficiency.

As lubricants play an important role in meeting your environmental responsibilities, today and in the future. The transition from mineral to synthetic lubricant not only guarantees the best performance in all conditions, it increases the sustainability of your compressed air system and reduces your CO2 footprint.

Advantages of synthetic compressor oils over standard conventional/mineral type compressor oil can be listed as below:

Apart from performance advantages, there might be some disadvantages or we can mention as a threat of adoption into real time application scenario which can be listed below and can be countered by some of the value-oriented pitch-ins or practices:

Higher product pricing

Synthetic compressor oils generally comes at higher end-to-end cost than conventional oils, however their extended life span and enhanced performance can offset the initial product cost.

Compatibility concerns

Synthetic compressor oils generally are not being recommended to be used by mixing-up or topping-up with other compressor oils due to probable compatibility issues however proper draining-cleaning-flushing-charging practices can eliminate the same fear and helps to get optimum and durable performance out of it.

It is very easy to mention regarding operational service duration of any lubricant, but to measure and implement the same practically needs some processes which falls under monitoring services. Similarly, compressor oils’ performances can be monitored and measured via physically as well as chemically via below mentioned methods:

Performance monitoring

Via oil health analysis at laboratory

1. Appearance & colour of the oil
   Via visual & ASTM D 1500
2. Viscosity @40 deg C & 100 deg C
   Via ASTM D 445
3. Viscosity index
   Via ASTM D 2270
4. Flash point
   Via ASTM D 92
5. TAN value
   Via ASTM D 664
6. Elemental analysis
   Via ASTM D 5185
7. Contaminants
   Via ASTM D 5185

Via on-site physical monitoring

1. Total compressor running hours
2. Delivery pressure & temperature
3. Oil flow temperature at pipelines
4. Changeover of filters & separators
5. Regular oil condition monitoring

Key Advantages of Synthetic Compressor Oil

1. Enhanced Lubrication and Protection

   Synthetic compressor oils have a uniform molecular structure that provides consistent lubrication across a wide range of temperatures. This ensures that the compressor components are well-protected against wear and tear, reducing the risk of mechanical failure and extending the life of the equipment.

2. Superior Thermal Stability

   One of the standout features of synthetic oils is their excellent thermal stability. They can operate efficiently at high temperatures without breaking down, unlike mineral oils which tend to oxidize and form sludge. This property is particularly important for compressors that run continuously or under heavy loads, as it helps maintain optimal performance and efficiency.

3. Reduced Oil Consumption

   Due to their superior formulation, synthetic oils tend to have lower volatility compared to mineral oils. This means they are less likely to evaporate at high temperatures, reducing the need for frequent top-ups and minimizing oil consumption. This not only saves money but also reduces the environmental impact of oil disposal.

4. Improved Energy Efficiency

   Synthetic compressor oils can reduce energy consumption by minimizing friction and improving the efficiency of the compressor. The uniform molecular structure of synthetic oils allows for smoother operation, which in turn reduces energy loss and lowers operating costs.

5. Extended Oil Change Intervals

   The superior stability and resistance to oxidation of synthetic oils mean that they do not degrade as quickly as mineral oils. This allows for longer intervals between oil changes, reducing maintenance downtime and costs. In industrial settings, this can translate to significant savings in terms of both time and money.

6. Enhanced Resistance to Contamination

   Synthetic compressor oils often come with advanced additive packages that provide better protection against contaminants such as water, dirt, and chemicals. These additives help maintain the oil's purity and performance, ensuring that the compressor operates efficiently even in harsh environments.

Applications of Synthetic Compressor Oil

Synthetic compressor oils are suitable for a wide range of applications, including:

• Industrial Compressors: Used in manufacturing plants, refineries, and power generation facilities where compressors operate under extreme conditions.
• Automotive Compressors: Utilized in air conditioning systems and turbochargers that require high-performance lubricants.
• Commercial Compressors: Found in refrigeration units, HVAC systems, and other commercial applications that demand reliable and efficient operation.

Considerations When Choosing Synthetic Compressor Oil

While synthetic compressor oils offer numerous benefits, it's important to choose the right product for your specific application. Here are some factors to consider:

1. Compatibility with Equipment

   Ensure that the synthetic oil you select is compatible with your compressor's design and materials. Some compressors may have seals or components that are not compatible with certain synthetic oils, leading to potential damage.

2. Operating Conditions

   Consider the operating conditions of your compressor, such as temperature range, load, and environmental factors. Choose a synthetic oil that can perform well under these conditions to ensure optimal performance and protection.

3. Manufacturer Recommendations

   Always refer to the compressor manufacturer's guidelines and recommendations when selecting oil. Using an oil that meets or exceeds the manufacturer's specifications can help ensure reliable operation and avoid voiding warranties.

4. Cost vs. Benefits

   While synthetic oils tend to be more expensive than mineral oils, their extended life, reduced maintenance needs, and improved efficiency often justify the higher initial cost. Consider the long-term savings and benefits when making your decision.

Environmental Impact

Synthetic compressor oils not only offer performance advantages but also have a positive impact on the environment. Their longer life and reduced oil consumption mean less frequent oil changes and lower disposal volumes, which helps reduce environmental contamination. Additionally, many synthetic oils are formulated to be more biodegradable and less toxic than traditional mineral oils, further minimizing their environmental footprint.

Conclusion

Choosing synthetic compressor oil is a wise decision for those looking to enhance the performance, efficiency, and longevity of their compressors. The superior lubrication, thermal stability, and extended oil change intervals of synthetic oils provide significant advantages over mineral oils. By selecting the right synthetic oil for your application and following the manufacturer's recommendations, you can ensure that your compressor operates smoothly and efficiently, saving time and money in the long run.

In an era where reliability, efficiency, and sustainability are paramount, synthetic compressor oils stand out as the preferred choice for many industries and applications. Whether you are operating industrial compressors in a manufacturing plant or maintaining commercial refrigeration systems, synthetic oils offer the performance and protection needed to keep your equipment running at its best.