The role of Synthetic Lubricants in Industrial Applications
Synthetic lubricants may be three to four times more expensive than mineral-based oils, but the payback is huge due to their longer service life and the efficiencies they can deliver. It’s useful to understand the advantages of synthetics and the range of synthetics available for different applications.
In on-highway engine oils, it has been observed that the primary driver of the trend toward lower-viscosity synthetics has been because of the requirement for better fuel economy. However, this may not be a concern in industrial equipment, but synthetics will deliver very similar energy efficiency improvements.
Synthetics also give you a wider operating temperature range than conventional oils. At lower temperatures, synthetics deliver better fluidity and reduce the risk of wax crystallizing out of the oil.
Another major benefit, and perhaps the biggest, is better oxidation resistance, which leads to longer drain intervals and less frequent oil changes which then translates to improved operating efficiency and potential cost savings for your industrial plant.
Together, these benefits result in overall improved operating efficiencies. With a synthetic, the wide operating range allows you to leave the same oil in all year round—and maybe even longer, due to the oxidation resistance and longer drain intervals. Not only do you get a longer life out of the oil, but you also reduce inventory complexity, and save on labor and downtime associated with seasonal oil changes.
One of the major differences between industrial synthetics and engine oils is the wider range of base stocks used for different applications. Synthetic engine oils are derived primarily from polyalphaolefin (PAO) or Group III base stock, and are typically compatible with their mineral oil counterparts, which reduces the risk of cross-contamination when switching from a conventional to a synthetic oil.
Silicones represent another class of base oils. Some air compressors utilize silicone fluids because they have excellent oxidation resistance, as well as a favorable viscosity index (meaning temperature changes do not cause changes in viscosity).
Despite all these benefits, switching over to synthetic oil in an industrial application must be carried out with caution and care. You need to identify the synthetic base stock to make sure it’s compatible with the fluid you’re replacing or do a thorough job of flushing out the older oil. If you can keep a synthetic in a component three or four times as long as the comparable mineral oil—and keep it free of particulates and contaminants that entire time — you will not only see performance benefits but also account for overall savings.
As always, let Caltex Lubricants guide you in the selection and proper handling of synthetics for your industrial applications.
