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Thickener viscosity improver plays a crucial role in the performance of lubricating oils in a wide range of industrial settings. In recent years, a number of novel additives with superior efficacy and market acceptance have been developed, although conventional VI enhancers still hold a significant market share due to their performance and low cost.
The following is a brief overview of the key categories of thickener viscosity improvers:
They are the most extensively employed viscosity index enhancers in lubricants. Polymers such as ethylene-propylene copolymer, polymethylmethacrylate, and others work by expanding or flattening specific oil sections to sustain or increase lubricant viscosity at elevated temperatures. At low temperatures, these polymer chains contract or assume a coiled shape, letting the oil fluidize easily. When heated, they stretch out and boost the viscosity of the oil, which means that no expansion equals better fluidity even at higher temperatures. Polymeric VI improvers are extensively used in industrial oils, engine oils, and hydraulic fluids due to their great performance and low cost. They are even praised for their superior performance in thick oils and applications. In recent years, however, as more industries shift toward lower viscosity classes of lubricants that meet modern energy standards, these polymeric additives have also come under some criticism. Some formulators have noted that under extreme shear conditions, such as those witnessed in highly loaded gear systems, polymeric VI improvers behave unpredictably. This can include significant and permanent viscosity loss over time, leading to oil starvation and equipment damage if not mitigated. To counteract this, enhanced polymeric additives that boast shear stability through chemical modification have gained traction. Now, these advanced polymers are designed with shorter, branched polymer structures that hinder shear-induced folding of the polymer chains, which had caused viscosity loss in previous formulations. The rise of low-SMR oils has also directed attention to these improved additives, as reduced thickness in oils necessitated greater protection, which in turn resulted in more strenuous operating circumstances for the lubricants. Thus, advanced polymeric VI improvers with better shear stability have become indispensable in contemporary formulations.
Although polymeric VI improvers dominate the thickness viscosity improver marketplace, a small but important minority of adherents is known to be asphalt-based VI improvers. These substances coalesce and modify the internal structure of hydrocarbon oils, primarily crude oil fractions, to enhance its viscosity characteristics across temperature ranges. They boost low-temperature fluidity by raising oil viscosity to hinder excessive thinning at elevated temperatures. Conversely, during high-temperature situations, their unique thixotropic (shape-recovering) nature allows low-viscosity oil flow with minimal resistance. Oilfield and heavy industrial applications frequently employ asphaltic VI improvers. They are frequently used in extreme conditions where oil shear stability is critical for minimizing dilution and other forms of viscosity alteration. The oil industry sector deserves particular mention. Asphaltic VI improvers such as petroleum resins are incorporated into refinery-process lubricants and crude oil transportation lines. High shear forces typical of these systems demand a robust Viscosity index improver capable of holding back the oil's natural tendency to thin under duress. Without effective modification from asphaltic VI improvers, crude oil demonstrating significant viscosity reduction might come to a halt in extremely high shear regions. This would cause a dangerous situation threatening equipment integrity and ending supplies. Asphaltic VI improvers serve critical roles in oil transportation and industrial lubricants by enhancing viscosity under extreme working conditions.
Multimodal viscosity index improvers are a new generation that combines the benefits of both polymeric and asphaltic improvers. These novel additives are engineered with multiple polymer lengths and thixotropic features to boost viscosity across the spectrum of low to high temperatures. Multimodal VI improvers serve to simultaneously solve the problems usually addressed by different additives in creating a lubricant with desired viscosity properties. A single multimodal improver can boost low-temperature fluidity while maintaining thickness at elevated temperatures, minimizing thinning under high shear forces. This dual action accommodates a wider viscosity range than traditional polymers or asphaltic improvers. Multimodal additives are emerging as promising substituents due to the rise of multigrade lubricants aiming for more expansive service profiles and longer lifecycles in industry. They are particularly applicable in modern industrial environments where machinery operates under variable loading and thermal conditions, necessitating greater oil thickness fluctuations. With multimodal VI improvers, oils remain sufficiently resilient at low and high operational temperatures without excessive shear dilution. These novel substances are also helpful in formulating green lubricants as services lengthen without frequent replacement.
Modern engine oils employ thickener viscosity improvers to protect against excessive thinning during different thermal conditions, from engine startup to peak functioning. For instance, Multi-grade oils' numbers mean how thick they are at various temperatures. This is known as viscosity grading: the cold number represents oil thickness when the engine is off; the hot number signifies the oil rating at working temperature. Without VI improvers, oil would become either extremely thick upon cold startup or dangerously thin under peak heat during engine use. Fortunately, these additives help maintain a stable mid-range viscosity where performance is goal. That assures proper engine lubrication at every operational stage, crucial for maximizing safety and minimizing wear. These applications exemplify the significance of VI improv to oil formulators. Before widespread adoption, automotive oils were monogrades. However, they suffered excessively in oil dilution and equipment destruction. The key to creating durable multigrades was pioneering VI improvers with adequate shear stability. As temperature rises, good shear-resilient additives should not fold or break down. Premium oils function without a reduction in viscosity regardless of engine heat. Multi-grade oil certifications denote reliable performance. Engine risks arise from poor-quality oil. Lubrication starvation leads to corrosion. VI improvers are indispensable for sacrificing highway speeds and sustaining extended intervals between oil changes. Thus, with proper formulations containing effective viscosity-modifying agents, petroleum firms meet reliability standards.
Industrial lubricants similarly benefit. These fluids are crucial as mechanical constituents work up to their rated facility limits. Hence, bringing minimum lubrication levels is imperative. Huge electric motors and gearboxes encounter wide loading differentials under industrial conditions. Here, heavy-duty gear oils rely on pour-point depressants and viscosity index enhancers to resist extreme ranges of mill work. Such products find evident payoffs from multimodal viscosity index improvers. Industrial oils encounter heterogeneous shears that make basic lubricating films in peril. VI improvers withstand these detrimental forces without disastrous oil dilution. Manufacturing hub machineries labor under screen layers of load from production. Mode variants of lubricating oil safeguard constituent assembly intricacies from abuse under such toil. Machines operate with thin films of oil under enormous pressure and friction that could destroy parts if less protected. Sage industrial lubricant oil formulators prioritize selecting robust multimodal viscosity index improvers as a matter of first principle for safeguarding machine integrity.
Hydraulic fluid operating in heavy construction machinery encounters worlds away pressures. Their safety margins demand utmost thicker viscosity improvers. The operating states of these fluids vary considerably. Mining trucks are dragged by ladened trailers and sunset without etuding. In contrast, excavators digging ditches barely hold their own weight. Despite such pressure discrepancies, hydraulic oils maintain lubricating viscosity levels between the least and most stressed. Mission accomplished by multimodal viscosity index improvers that confer thickening when needed and thinning when not. Construction units opening walls need efficient fluid lends easily extending many feet behind at low pressures yet coping with surge pressures reaching hundreds of feet. Proportionately most employed fluids possess sizeable viscosity differentials between such tauntauns. Poor efficiency fluids incur losses, and constituents suffer cavitation hazard. Proper fluids safeguard against harm by easily bearing transitional variations in pressure and flow. Multimodal VI improvers stand in between this fluctuation like friendly giants.
Polymeric thickener viscosity improvers are formulated primarily from synthetic polymer compounds. The most utilized materials include:
Ethylene and propylene copolymers
Ethylene-propylene copolymers are the poll stars of viscosity index enhancers. They are simply modified by mixing ethylene, a gaseous envelope, and propylene, a byproduct of crude processing, under extreme conditions of heat and pressure. The resultant polymer chain coiled can elongate and bend, unlike its peers, granting superb thickness.
Styrene-conjugated diene block copolymers
Like the famed daisy flower bouquet, styrene-conjugated diene block polymers are put up in structures by repeatedly alternating two contrasting monomers: styrene in nabobs and dienes, which for the umpteenth time are long-chain alkenes. The soap creates unique tapered block copolymers having viscosity-stabilizing versatility through periodic styles.
Other synthetic polymers
Forms that bear diverse appearances but play the same role, such as polymethylmethacrylate and polyethylene vinyl acetate, are also used.
Nonetheless, it should be considered how these improvers are manufactured to ensure durability. Key parameters include materials used, molecular size distribution, covalent bonds within polymer structures, and promoting sturdy peaks.
Ingredient selection
Above have already listed materials by which these improvers are made. Notably, copolymers of ethylene and propylene specifically stand the heat owing to bond covalent. Styrene-conjugated diene block copolymers also bear the intellectual redundancy, thanks to ionic and hydrogen bonds within the structure.
Molecular size distribution
Typically, these improvers have polymers of various sizes. That helps in providing a functional range for the product. It as well means that different polymers will act differently with change in temperature.
Covalent bonds
Well, the stronger the bonds, the longer polymer structures can remain functional. These bonds mainly incorporate hydrogen bonds and disulfide bonds.
Cross-linking
At times, polymers in thickener viscosity improvers are crossed, where two covalent bonds link a polymer chain to another. That increases the product's elasticity and thus durability.
The viscosity index improver must be compatible with the thickened oil for the desired outcome to happen. This means that choosing the product should be based on the type of oil, be it mineral, synthetic, or biolubricant oil, and the refinery stock.
Different products exhibit varying effectiveness at specified temperatures. Therefore, one must choose a product capable of ensuring optimum performance at minimum and maximum temperature extremes. The product should also maintain its efficacy at thermal peaks.
One of the phenolic characteristics of these improvers is shear stability. This means that regardless of the shear forces, the substance should not undergo polymer breakdown. Usually, this leads to viscosity loss, which is detrimental to the lubrication system. A good product also resists dilution.
When these improvers were first introduced, they had some secondary effects, such as cloud points and deposit formation. Some of them even cause oil-related degradation. That is why it is preferable to go for products that exhibit minimal or no secondary effects.
This further goes to ensure that the oil behaves optimally during the oil's pouring and fluidity process. Prefer products with good low-temperature viscosity to avoid issues like pumpability and filtration.
As much as this is not a primary consideration, especially for businesses, one should go for eco-friendly products. Those that offset negative effects on aquatic life.
Thickener viscosity improvers mainly help enhance the temperature of hydraulic fluids.
Yes! They also boost fluidity.
They are the most effective in maintaining proper viscosity throughout a wide range of temperatures.
Improvers reduce friction, thus enhancing efficiency.
The higher the index, the more oils can resist aging.
