Selection Strategy of Hydraulic Oil Additives Package under Different Working Conditions
In today's industrial field, hydraulic systems are widely used in various types of mechanical equipment, from large construction machinery to precision machine tools, from special equipment in high-temperature environments to key facilities in offshore engineering. As an important operating component of hydraulic systems, the performance of hydraulic oil directly affects the stable operation of the system and the service life of equipment. Hydraulic Oil Additives Package, as the core additives for enhancing the comprehensive performance of hydraulic oil, are particularly important for correct selection under different operating conditions.
What is a hydraulic oil compound additive?
Hydraulic Oil Additives Package are not single-component additives, but products formulated by combining multiple functional additives in specific proportions. These additives typically include antioxidants, rust inhibitors, anti-wear agents, extreme pressure agents, metal deactivators, anti-foaming agents, demulsifiers, etc., which work together to endow hydraulic oil with excellent comprehensive performance.
Antioxidants can effectively inhibit the deterioration of hydraulic oil due to oxidation during use and extend the service life of the oil. Hindered phenolic antioxidants interrupt the oxidation chain reaction by capturing free radicals; amine antioxidants prevent the further decomposition of peroxides to generate harmful free radicals by reacting with them.
The function of rust inhibitors is to form a protective film on the metal surface, preventing moisture and oxygen from coming into contact with the metal, thereby avoiding rusting. Common rust inhibitors include sulfonates, carboxylates, etc., which can adsorb on the metal surface to form a dense molecular film.
Anti-wear agents and extreme pressure agents play a crucial role in hydraulic systems when they are subjected to high loads. Under normal operating conditions, anti-wear agents reduce the friction coefficient and minimize wear by forming a physical or chemical adsorption film on the metal surface; extreme pressure agents, on the other hand, react chemically with the metal surface under extreme pressure conditions to form a reaction film with low shear strength, preventing direct contact between metal surfaces and avoiding scuffing and galling.
Metal deactivators can bind to the active check points on the metal surface, inhibiting the catalytic effect of metals on oil oxidation. Antifoaming agents are used to eliminate the foam generated during the circulation of hydraulic oil, ensuring the normal operation of the system; demulsifiers help the hydraulic oil quickly separate from the water mixed in it, maintaining the purity of the oil.
As a professional supplier of high-quality and high-performance hydraulic oil additive packages, UNPChemicals offers a variety of outstanding products. For example, the high-zinc hydraulic oil additive UNP AH502A, with its unique formulation, excels in applications where high zinc content is required to enhance certain performance; the low-zinc hydraulic oil additive UNP AH502B can precisely meet the requirements in working conditions where zinc content is somewhat restricted but some zinc-related performance is still needed; the zinc-free hydraulic oil additive UNP AH502C, in line with the current trends of strict environmental requirements or equipment sensitivity to zinc, achieves excellent comprehensive performance through its innovative zinc-free formulation, providing diverse options for various hydraulic systems.
Performance Requirements for Compounding Agents in Construction Machinery Hydraulic Systems
Construction machinery such as excavators, loaders, cranes, etc., operate in harsh working environments with complex and variable working conditions. They typically work outdoors, facing erosion from pollutants such as dust and muddy water, while also enduring high loads, frequent starts and stops, and impact loads.
High anti-wear performance
Taking excavators as an example, components such as pumps, valves, and cylinders in their hydraulic systems frequently operate under high pressure, resulting in intense friction between them. Therefore, hydraulic oil additives need to have excellent anti-wear properties and be able to form a strong and durable protective film on metal surfaces. Additives containing anti-wear agents such as zinc dialkyldithiophosphate (ZDDP) are common choices, which can effectively reduce wear under boundary lubrication conditions. However, in systems with environmental requirements or those containing special metal components (such as silver-containing components), ashless anti-wear agents, such as organic molybdenum compounds and borates, need to be selected to avoid potential corrosion problems caused by ZDDP.
Good extreme pressure performance
When construction machinery is operating under heavy load, the instantaneous pressure of the hydraulic system is extremely high. Hydraulic Oil Additives Package must possess strong extreme pressure performance to handle such extreme working conditions. Extreme pressure agents such as polysulfides and phosphates are often used in such compound additives, which can react chemically with metal surfaces under high pressure to form a high-strength protective film, preventing failure phenomena such as scratches and abrasions on the metal surface. When a crane lifts heavy objects, the pressure of the hydraulic system rises sharply, and a compound additive with good extreme pressure performance can ensure the stable operation of the system and avoid component damage caused by excessive pressure.
Excellent anti-pollution ability
Impurities such as dust and sediment in the field operation environment can easily mix into the hydraulic oil. The hydraulic oil compound additive should have a certain ability to disperse and suspend contaminants, preventing impurities from depositing in the system, clogging the oil passages, or accelerating component wear. Meanwhile, the additives in the compound additive should be well compatible with the base oil, maintaining the stability of all properties of the hydraulic oil even in the presence of contaminants. The compound additive containing detergent-dispersant can disperse contaminants into tiny particles, keeping them suspended in the oil for easy removal through the filter.
Adaptable to a wide temperature range
Construction machinery may operate in the cold northern winter or the hot southern summer, and hydraulic oil needs to adapt to large temperature variations. The viscosity index improver in the compound additive enables hydraulic oil to maintain appropriate viscosity at different temperatures. At low temperatures, it prevents the oil from becoming too viscous, which could lead to difficult starting and poor pumping; at high temperatures, it avoids excessive reduction in oil viscosity, which could affect lubrication and sealing performance. In addition, the performance of antioxidants also needs to remain stable over a wide temperature range to effectively inhibit oil oxidation.
Key Points for Selecting Compounds in Precision Hydraulic Systems of Machine Tools
As precision machining equipment, machine tools have extremely high requirements for the precision, stability, and cleanliness of hydraulic systems. The selection of hydraulic oil compound directly affects the machining accuracy and surface quality of machine tools.
Low friction coefficient
In the hydraulic system of machine tools, to achieve precise motion control, hydraulic oil needs to have an extremely low coefficient of friction. This requires that the anti-wear agent in the compound not only reduces wear but also forms an ultra-smooth protective film on the metal surface, reducing the frictional resistance between components. Some compounds containing special organic additives can improve the frictional state of the metal surface at the micro level, achieving near-frictionless motion and ensuring that the movement accuracy of the machine tool table reaches the micron level.
High cleanliness retention ability
The internal oil passages of precision machine tools are complex and have small diameters, and any tiny impurities may affect the normal operation of the system. Hydraulic Oil Additives Package should have good detergency and dispersancy properties to prevent the formation of deposits such as sludge and varnish. At the same time, they should have good compatibility with the filtration system, not react adversely with filter materials, and ensure the filtration effect. Compound additives using polymer detergents and dispersants can disperse oxidation products and impurities into extremely fine particles, enabling them to pass through precision filters smoothly and keep the oil clean.
Excellent antioxidant performance
Machine tool hydraulic systems usually operate continuously for long periods, with high oil temperatures, making the oil prone to oxidation. The acidic substances and polymers produced by oxidation can corrode metal components, block oil passages, and reduce system performance. Therefore, Hydraulic Oil Additives Package for machine tools need to contain highly effective antioxidants, such as a high-performance hindered phenol and amine antioxidant compound system, which can inhibit oil oxidation at high temperatures for long periods, extend the oil change interval, and ensure the stable operation of the system.
Good air release and anti-foaming properties
During the operation of the machine tool hydraulic system, the oil comes into contact with air. If the air cannot be released in a timely manner, bubbles will form, affecting the system's response speed and stability. The anti-foaming agent and air release agent in the compound can effectively reduce the surface tension of the oil, causing the bubbles to quickly rupture and escape, ensuring that the oil is free of bubbles and maintaining normal pressure transmission and precise control of the system.
Stability Control of Hydraulic Oil Compound under High Temperature Environment
In some industrial sectors, such as steel smelting, glass manufacturing, cement production, etc., hydraulic systems need to operate in high-temperature environments. High temperatures accelerate the oxidation, degradation, and evaporation of hydraulic oil, posing a severe challenge to the stability of Hydraulic Oil Additives Package.
Application of Heat-Stable Antioxidants
Under high-temperature conditions, the consumption rate of ordinary antioxidants accelerates, failing to meet the long-term antioxidant requirements of oil products. Therefore, it is necessary to select antioxidants with excellent thermal stability, such as hindered phenolic antioxidants containing special functional groups, which can maintain a stable molecular structure at high temperatures and continuously exert antioxidant effects. Some high-temperature-resistant amine antioxidants are also commonly used in such compound additives, synergistically enhancing the overall antioxidant performance of oil products with hindered phenolic antioxidants.
Improvement of anti-evaporation performance
High temperatures can lead to increased evaporation losses of hydraulic oil, which not only affects the viscosity and performance of the oil but may also cause environmental pollution. Additives with high boiling points and low volatility, such as certain high molecular polymers, can be added to hydraulic oil compound agents to reduce the evaporation rate of the oil. By optimizing the formulation of the compound agent, enhancing the interaction between the base oil and additives, and strengthening the overall stability of the oil, performance degradation caused by evaporation can be reduced.
Prevent coking and carbon deposition
At high temperatures, certain components in hydraulic oil may undergo polymerization and cracking reactions, forming coke and carbon deposits, which can block oil passages and valve ports, affecting the normal operation of the system. The detergents and dispersants in the compound additive also play important roles in high-temperature environments. They can disperse the precursors of coke and carbon deposits into tiny particles, preventing their aggregation and growth, and keeping the system clean. Some additives with special structures can also inhibit the high-temperature polymerization reaction of the oil, reducing the formation of coke and carbon deposits at the source.
Viscosity adjustment adapted to high-temperature working conditions
High temperatures can cause the viscosity of hydraulic oil to decrease, affecting its lubrication and sealing performance. The viscosity index improver in the compound additive must have good thermal stability and still be able to effectively adjust the oil viscosity at high temperatures to keep it within an appropriate range. Some new types of viscosity index improvers use special molecular structure designs, which have better shear resistance and thermal stability, and can meet the requirements of hydraulic systems for viscosity stability in high-temperature environments.
Anti-corrosion and anti-rust design of Hydraulic Oil Additives Package in marine engineering
Marine engineering equipment, such as offshore drilling platforms and ship power systems, is long-term exposed to the high humidity and high salinity marine environment, where hydraulic systems face serious corrosion risks. Therefore, the anti-corrosion and anti-rust design of hydraulic oil additives for marine engineering is crucial.
Selection of High-Efficiency Rust Inhibitor
To address salt corrosion in the marine environment, rust inhibitors with strong resistance to chloride ions should be selected. Some sulfonate-based rust inhibitors containing special functional groups can form a dense and firm protective film on the metal surface, effectively blocking the penetration of chloride ions and preventing metal rusting. Some carboxylate-based rust inhibitors also have good adaptability to the marine environment, as they can chemically adsorb onto the metal surface to form a stable anti-rust film.
Resistance to seawater emulsification
Seawater can easily mix into the hydraulic system. If the hydraulic oil emulsifies with seawater, it will seriously reduce the lubrication and anti-rust properties of the oil. Therefore, Hydraulic Oil Additives Package for marine engineering need to have excellent anti-seawater emulsification performance. Demulsifiers play a crucial role in this, as they can promote the rapid separation of oil and water, maintaining the purity of the oil. At the same time, other additives in the compound should work in synergy with the demulsifier to ensure that the hydraulic oil can still perform its various functions normally in the presence of seawater.
Synergistic effect of corrosion-resistant additives
In addition to rust inhibitors, some corrosion-resistant additives, such as metal deactivators and corrosion inhibitors, can also be added to the compound agent. Metal deactivators can bind to the active check points on the metal surface, reducing the activity of the metal and inhibiting its reaction with corrosive substances; corrosion inhibitors, on the other hand, slow down the corrosion rate by forming an adsorption film or reaction film on the metal surface. These additives work together to form a multi-layered protection system, enhancing the corrosion resistance of the hydraulic system in the marine environment.
Protective film resistant to seawater initialize
Wave impacts and water initialize in the marine environment can damage the protective film on the surface of hydraulic system components. Hydraulic oil compound agents should be able to form a protective film with a certain degree of toughness and wear resistance on the metal surface, which can remain intact even under the action of seawater initialize and continue to play an anti-corrosion and anti-rust role. Some additives containing special polymers or nanomaterials can enhance the strength and adhesion of the protective film and improve its resistance to seawater initialize.
Under different operating conditions, the correct selection of hydraulic oil additives is the key to ensuring the efficient and stable operation of hydraulic systems. Whether it is the complex operating conditions of construction machinery, the high-precision requirements of machine tool precision systems, the stability challenges in high-temperature environments, or the anti-corrosion difficulties in offshore engineering, it is necessary to comprehensively consider the performance indicators of additives based on the specific characteristics of the operating conditions and make precise selections. UNPChemicals' series of products provide a reliable choice for your selection of hydraulic oil additives under different operating conditions, helping your hydraulic system operate stably, reducing equipment maintenance costs, and extending equipment service life.
The Price of Hydraulic Oil Additives Package
The price of Hydraulic Oil Additives Package varies depending on factors such as brand, specification, composition, and sales channels. If you are interested in Hydraulic Oil Additives Package, please feel free to contact us.
Supplier of Hydraulic Oil Additives Package
UNPChemicals is a professional supplier of high-quality and effective Hydraulic Oil Additives Package. We offer several remarkable products, namely High zinc hydraulic oil additives UNP AH502A,Low Zinc Hydraulic Oil Additives UNP AH502B,Zinc-free Hydraulic Oil Additives UNP AH502C,etc.
High zinc hydraulic oil additives UNP AH502A are a type of chemical additive used in hydraulic oils that contain high levels of zinc dialkyldithiophosphate (ZDDP). ZDDP is a well-known anti-wear agent that also provides antioxidant, anti-corrosion, and anti-foam properties. The zinc in these additives plays a crucial role in forming a protective film on metal surfaces within the hydraulic system, thereby reducing wear and extending the life of the system components.
Low Zinc Hydraulic Oil Additives UNP AH502B are a class of advanced lubricant additives designed to enhance the performance of hydraulic oils with reduced zinc content.These additives are formulated to provide a balance of anti-wear,extreme pressure,and antioxidant properties,making them suitable for modern hydraulic systems that demand high performance with lower environmental impact.
Zinc-free Hydraulic Oil Additives UNP AH502C are a new class of environmentally friendly lubricant additives designed for hydraulic systems.These additives are formulated to provide the same level of performance as traditional zinc-containing additives but without the heavy metal content,reducing the environmental impact of hydraulic fluids.
Professional Lubricant Additive Manufacturer
UNPChemicals,aka Luoyang Pacific United Petrochemical Co., Ltd., focuses on the application and development of special lubricating grease additives such as MODTC, MODTP, molybdenum amide, thiadiazole metal deactivators, and phosphate esters. With nearly 30 products in seven series, including extreme pressure anti-wear additives and special grease additives, it is a global manufacturer of special lubricating grease additives and a national high-tech enterprise with great influence and leading role in the industry. If you are looking for Lubricant Additive or technical information, feel free to contact UNPChemicals.