LUBE OIL BLENDING PLANT ULTIMATE SOLUTIONS
There are two main raw materials for the production of lubricants:
• Lube base stock
LUBE BASE STOCK:
One of the products is base stock, which processed further, provides us with base oil. The base oil is the lubricant that is used to lubricate machines. This base oil needs to have certain chemicals called additives added to it to enhance its performance as a good lubricating agent. These additives together perform diverse functions but each additive has a specific use and together they give the lubricant its character. Depending on the engine the lubricants are to be used; the ratio of base oil to additives varies from 85:15 to 90:10.
BASE OILS: Base oil is highly refined crude oil or in some cases a synthetic composition and they account for roughly one present of the total output of petroleum products from crude. It is essentially a by-product obtained during the refining of crude and is obtained along with the heavier ends. Different operating conditions like moisture, dust, exposure to air, high/low temperature, high pressure, corrosion, etc. dictate which base oil and which additives should be used.
TYPES OF BASE OILS
THE PUMPING SOLUTION:
Linus Projects Supply base oil pump and lubricant dosing pump. The gear pump is a self-priming bi-directional positive displacement rotary pump, fitted with Teflon coated dry running 'DU' bush bearing.
The three-piece design makes the pump easy cleanable, easy maintainable simply by removing four dome nuts on the back cover.
The Pump is with mechanical seal The mounting bracket converts the pump to foot mounting & facilities to align the pump with the electric motor of appropriate ratings on the base plate at the same frame height.
The feed rate for the base oil pump will be around 20m3/hr to 50m3/hr at a pressure of 4 Bar to 10 Bar
Unfiltered liquid enters the basket housing and passes down them.
Solids are retained inside of basket mesh which is removed when the unit is serviced.
Basket Filters and strainers are normally supplied with a spring arrangement at the top of the filter element.
This will ensure any type of bypass & confirm the position of the basket filter even in case of reverse flow.
A fluid bypass around the basket is prevented by an optional “O” ring seal between the basket rim and the housing inside diameter.
For base oil basket filter provided with 200-micron mesh and For blending vessel basket filter provided with 50-micron mesh
The Platform structure is designed for blending vessels.
Steel platforms are self-supporting, prefabricated structures made from partially welded components.
They are made from standard rolled and cold-formed steel sections, which are reinforced using stabilizing rods with tensioners.
In order to use the platforms, it is necessary for the space to have a height of at least 4.5 meters. Our design has a minimum ceiling height of 2.1 meters.
It is possible to equip the platforms with various accessories, such as elevators, chutes, mesh, labels, lighting, etc.
We provided a 2mt mechanical hoist on the platform
LUBRICANT BLENDING SOLUTION:
Blending vessel fabricated out of Mild Steel/Stainless steel IS 2062 material having an open top and partially dished bottom.
The blender is provided with a top Lid which is hinged to the main blender. A ball valve is fitted at the bottom for discharge along with a sample valve.
An MS Jacket is welded around the main blender complete with inlet, outlet, drain & vent fittings. The vessels are provided with a temperature probe with all necessary fittings.
Our blender is specifically designed for different grades of lubricant as per ASME standards, all types of products can be manufactured in the same blender such as engine oil, gear oil, hydraulic oil, special purpose oil, marine oil, and viscosity improver.
Each blender will be provided with an additive dozing bunker. The drive consists of an electric motor coupled to a heavy-duty gearbox by couplings. The output shaft of the gearbox is coupled to a stool housing complete with bearings, oil seals, and gland packings. The blending vessel is suitable for withstanding a temperature of 200˚C. It is duly insulated with rock wool and cladded with GI sheets.
LOAD CELL FOR AUTOMATION: METTLER TOLEDO BRAND
The blending vessel is supplied with a high-quality precision load cell system which is suitable for automatic performance and batch control of the plant typically known as ABB technology.
Load cells having the following advantages
Built-in Safety against vessels tilting and build forces
Allows vessels expansion & contraction, which occurs due to thermal effect.
Flexible copper earthing strip to protect the load cell from lightening or welding current
In-built Load Cell cable protection plate & Overload protection plate with Heat Insulation Pad
INSULATION MATERIAL FOR HEATING LINE:
Linus Projects Supply high-quality Rockwool and aluminum sheets along with the plant for insulation of hot oil lines and blenders etc.
All insulation shall be done by ROCKWOOL mattress 50 mm thick as required of Density 100Kg/ cu mtr of reputed make and cladded with aluminum/GI sheet 24 gauge. This part of the job shall be done on the site. The material shall be supplied loose and the client has to organize the same at the site under our guidance. Insulation of pipelines below blenders to filling lines to be done on-site.
BOILER FOR UTILITY PURPOSE:
Linus Projects Supplies high-quality fuel-efficient burners with boilers both for steam and thermic fluid.
The main heater unit consists of a double jacketed external shell made of sturdy M.S. Sheets with an Aluminum reflector to preheat the combustion air and provide heat insulation.
Specially designed multi-start, concentric helical coils assembly made from B.S, 3059,
Part I, 9 Gauge, Boiler Tubes for longer life and high-temperature operations.
Pressure jet burner assembly on/Off Design Make – RIELLO ITALY with integral Oil Pump & Combustion blower assembly with the motor.
LUBRICANT PACKAGING SOLUTION FULLY AUTOMATIC:
A. BOTTLE UNSCRAMBLERS:
Linus Projects Supply a high-speed bottle unscrambler machine that is used to straighten the bottles and make them inline to conveyors for packaging purposes this is the first machine in the line.
The machine has a unique rotary pocket system to enable high speed, highly reliable unscrambling unmatched in the industry. Rotary Pockets gently grip every bottle and maintain full control until discharged. In addition, they can invert your bottle 180 degrees, multiple times if needed, to let you perform additional tasks, such as ionized air rinsing or bottle coding, without taking up any more space on your packaging line.
B. LABELING MACHINE:
Linus Projects Supply high-speed labeling solution. The Automatic Self-Adhesive Sticker Labeling Machine is one of the most users friendly. The machine is used for two sides labeling on the flat surfaces of different sizes of the flat containers. It is capable of labeling up to 100 containers per minute depending on products and label size. The automatic model is equipped with a belt spacing device resulting in a simple "No change parts required".
The flat containers positioned & curate spacing between two containers by the belt spacing device and a belt drive mechanism hold the container from top of the container for two sides labeling on flat container at the labeling point, an electronics product sensor sense container & relies a label from self-adhesive label roll. If machine is equipped with batch printing device in that case batch printing device prints the batch no. & other matter on label during label is stationary means time between sensing of two label. Then the labeled container moves further through a rubber pressing belt & stationary rubber pad that ensures neat & perfect fixing of label
C. LINEAR / ROTARY FILLING MACHINE:
Linus Projects Supply high-speed Linear filling machine and rotary filling machine depending on client's requirement, usually, a rotary filling machine give highspeed than a linear filling machine.
Minimal adjustment is required to set different capacities from 500ml to 5litres with varying container contours. The entire range can be set on the same machine without any change parts.
Working Principle: Each machine has its own pumping system to connect the machine with the main/buffer tank of the product. The volume to be filled is measured by the measuring system, which consists of multi-piston positive displacement volumetric devices. the flow of liquid is measured and converted into electronic pulses by digital encoders and controlled by the reputed make of PLC (Programmable Logic Controller). Client to provide buffer tank.
The facility is provided for each nozzle to set fast flow “cutoff” and “final flow cutoff” with an interval between the two to be decided on the basis of filling speed and volume to be filled. Volumes can be present for each nozzle with increments of 1ml up to 5 liters. All settings can be done on the HMI (Human Machine Interface) keypad, which is provided on the control panel.
Filling Speed:-The estimated filling speed for 8 nozzle machines shall be as follows:
500ml @ 60-70 fills per minute
1 liters @ 50-40 fills per minute
5 liters @ 30-20 fills per minute
D. AUTOMATIC CAPPING MACHINE:
Linus Projects Supply high-speed Linear capping solution.
The machine comprises of Cap Vibrator for cap orientation & capping unit. The caps fed in the vibratory hopper are properly oriented here.
The properly oriented caps are brought out through the chute and supported at the end by spring-loaded fingers the containers as it comes out of the filling station moves to the capping unit, which in it picks up the cap and goes towards the capping head.
The caps are subsequently tightened through the magnetic clutch system. The capped bottles finally emerge out of the machine through a discharge conveyor. The speed can be adjusted through the VFD on the conveyor Necessary Mechanism shall be provided for no bottle – no cap. The torque can be set on the PLC of the filling machine. The capping machines will be supplied with parts for one pack size along with Eight feet long and 150 mm wide conveyor. An additional change part will be required for each pack for any change in the dimensions of the containers which shall be charged extra. The machine Power Requirement:3 Phase, 415V Volts AC., 50 Hz. Load: 2 Hp
E. AUTOMATIC INDUCTION SEALING MACHINE
The technology of heating sealing the aluminum-plastic multiplex material by electromagnetic induction sealing machine manufactured of this principal becoming necessary equipment of medicine, pesticides, high-quality viscous oil, cosmetics, grease other trade require high-quality air sealing for plastics and other non-metal bottles.
The latest I.G.B.T. Solid State Induction Cap Sealing System Model LP- 2 for neck sizes up to 38mm is suitable to seal 70 to 80 bottles per min. & for a neck range, up to 53mm is suitable for 40 to 50 bottles per min.
Working principle: The machine is complete with the principle of metal objects can bring blow waves to heat under the action of the high-frequency electromagnetic field. Make aluminum foil hot and melt the binding under aluminum foil then agglutinate to the mouse of the bottle, thus accomplishing the constant quick non-contact sealing operation.
F. CARTON TAPPING SOLUTION:
Linus Projects Supply sophisticated design carton taping machine.
Carton Taping Machine is put on the in-feed rollers & given a gentle push when the motorized conveyor takes over & starts pulling the carton forward. Here the top & bottom tape dispensers stick the BOPP-type self-adhesive tape onto the Top & Bottom flaps of the cartons simultaneously along with rollers pressing the tape for a tight seal. When the taping is over, the cutter blades cut off the tape & the sealed cartons pass through to the outfeed rollers for delivery.
we are offering a Regular Carton Sealing Machine. These are designed and manufactured under the supervision of our professionals using high-grade quality raw materials in adherence with industry standards. The offered machines are widely used for packaging various sizes and shapes of boxes.
Low maintenance/High performance/Corrosion resistance/Longer functional life.
AUTOMATIC DRUM AND IBC PACKAGING SOLUTION:
Linus Projects Supply sophisticated design palletized drum filling or IBC packaging machine.
This Automatic Palletized Drum Filling Machine is designed to handle drums or IBCs with bungs and caps removed. This machine will convey, visually locate the fill holes, fill then discharge a full pallet of drums automatically. It will do the same for an IBC. The next downstream station will automatically place each bung and cap onto every drum.
Depending on the product and volume delivered, this machine can fill each 55-gallon drum in less than one minute.
IBC FILLING LINE:
This is a fully automatic IBC filling system. No operator is necessary. Each IBC conveys into the fill station and then stops, signaling the lance to enter the container and automatically tare the load. This system allows several pallets loads of empty IBCs to accumulate prior to the filling station. A powered roller conveyor is on the scale and another is after the fill station for cap & label application. There are additional conveyors after to accumulate full loads.
FULL AUTOMATION CONTROL OF PLANT:
Linus Projects supplies a centralized automation system for the entire plant which is controlled by one person inside the control room with almost zero human interference involved.
A complete PLC based SCADA is provided for monitoring and controlling the flow of base oils to the Blenders. A recipe management system is provided for the feeding of up to 100 formulations.
OPERATION SEQUENCE & LOGIC Selection & Settings:
Selection of Storage tank & Blender for transfer done through HMI and PLC.
The setting of parameters like the weight of each ingredient along with the recipe management system.
The setting of other parameters like time specs. Etc.
Operation starts from HMI:
Start the operation by selecting the above parameters.
Respective valves & pumps will be operated in that sequence after fulfillment of required interlocks.
Operation sequencing will be done as per the valve status.
Valve, Motor and Pump status will be displayed on the HMI with Color animation
The current value of weight will be displayed continuously.
Fault & alarms will be displayed when arrives with date & time stamping. Also, it will be stored
Data will be logged in the HMI (Which can be used for future analysis)
Manual ON/OFF is also possible through HMI (Individual opening/closing of the valves)