TRADITIONAL & SYNTHETIC AIR COMPRESSOR OIL DEGRADATION

First and foremost, oil degradation is a general term used to describe the destructive mechanisms that cause physical and chemical changes. This damage can be done to traditional and synthetic air compressor oil while in service. Oil degradation results in a deterioration in fluid performance and a dramatic reduction in fluid service life. If ignored, oil degradation will progress and can lead to failures of critical compressor components. It is important to understand the mechanisms of oil degradation and their impact on fluid properties and performance. Additionally, it enables compressor users to proactively maintain fluid health, maximize fluid life, and avoid costly oil changes and major repairs.

OIL DEGRADATION MECHANISMS

Oxidation is primary oil degradation mechanism. It is the chemical reaction that naturally occurs between the oil and oxygen from the air. Rotary screw compressor fluid is extremely vulnerable to oxidation since the compressor’s design provides an extreme, oxygen-rich environment. Oxidation is an auto-catalytic series of chemical reactions that continuously produces acids. It also depletes additives and ultimately will form harmful varnish and sludge in many compressor fluids. Oxidation rates and acid production continuously accelerates as operating temperatures increase (doubles for every 180F increase). They also increase as acid levels (TAN) increase, as additive levels (antioxidants) decrease, and as fine metal catalysts accumulate in the fluid. Oxidation also impacts compressor internals by promoting corrosive wear, pitting and rust to unprotected metal surfaces.

Traditional & Synthetic Air Compressor Oil Additive Depletion

Additive Depletion is another harmful process that reduces the performance, protection, and service life of compressor fluids. Lubricant formulators rely heavily on performance enhancing additives. Their purpose is to control fluid service life, inhibit oxidation, and protect compressor internals from corrosion. While in service, additive levels continuously deplete which reduces the oil’s ability to resist oxidation and limits oil service life. Like oxidation, additive depletion is accelerated by catalysts like acids, water and fine metals. Monitoring fluid additive levels and replenishing the fluid’s additive package when necessary, helps maintain fluid chemistry and performance, and can dramatically extend fluid service life.

Contamination of air compressor fluids by foreign substances can be introduced via solids, liquids or gases. They can significantly accelerate fluid degradation and create a host of additional problems to air compressors. Rotary screw compressors have a “forced-contamination” design that continuously ingests atmospheric contaminants and forces them into the oil. Many of the airborne contaminants found in industrial environments are strong oxidizers that accelerate fluid oxidation and acid production. These contaminants include combustion exhausts, cooling tower chemicals, welding fumes, process vapors. Internally generated contaminants, like the acidic byproducts of oxidation, and fine metals (rust and wear particles), also add fuel to the auto-catalytic degradation cycle.

oil degradation maintenance cycle

Oil Degradation Cycle

The Oil Degradation Cycle is a self-propagating, auto-catalytic cycle that continuously accelerates at an ever increasing rate. Acids (produced from oxidation), and other contaminants (fine metal particles and water) are catalysts that accelerate fluid degradation, acid production and additive depletion. If not addressed, oil degradation will proceed unchecked until the fluid is no longer fit for continued service.

Synthetic Air Compressor Oil Degradation

Did you know that many fluids cannot survive temperatures, of 210 F or over? However, advanced synthetic fluids can withstand short-term temperature spikes as high as 250 F without fluid damage.

Source: Plant Engineering

synthetic air compressor oil degradation

Additive depletion is one of the leading causes of compressor fluid failure and replacement. Fluid oxidation and acid levels  increase until the fluid is unfit for continued service as additive levels decrease.

Proactive maintenance of compressor fluid additive levels, coupled with acid-control oil purification, dramatically impacts compressor fluid performance and service life.

Finally, learn more about The Truth About Air Compressor Oils and Additives by clicking here.

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