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The Correlation Between Hydraulic Oil Additive Packages and Equipment Energy Efficiency Improvement
In the field of industrial production, hydraulic systems, as the core power transmission components of various heavy equipment, precision machine tools, and construction machinery, their operating efficiency directly determines the production capacity level, energy consumption cost, and operational efficiency of the entire production process. Hydraulic oil, as the core medium of hydraulic systems, its performance directly affects the overall operating state of the system, while hydraulic oil additives, as the core components for improving the comprehensive performance of hydraulic oil, are even more crucial for achieving energy efficiency improvement in equipment.
1.What is a hydraulic oil additive package?
Hydraulic oil additive package refers to a compound additive product formulated by combining multiple single-function hydraulic oil additives in a scientific ratio, which can be directly mixed with base oil to prepare hydraulic oil products that meet various industry standards and are suitable for different operating conditions.Compared with single additives, hydraulic oil compound additives, through strict scientific compounding and comprehensive performance verification, can achieve synergy among components, simultaneously meet the performance requirements of hydraulic oil in multiple aspects such as anti-wear protection, oxidation stability, rust and corrosion prevention, and viscosity control. There is no need for enterprises to conduct compounding work on their own, significantly reducing the technical difficulty and quality risks of hydraulic oil blending, and effectively improving the stability and consistency of hydraulic oil performance.
The core functions of hydraulic oil compound additives revolve around the stable operation and energy efficiency optimization of hydraulic systems, mainly covering key performance aspects such as anti-wear protection, viscosity adjustment, improvement of oxidation stability, anti-rust and anti-corrosion, anti-foaming, anti-emulsification, etc. Different types of compound additives target the requirements of different working conditions, with clear differences in performance emphasis. For example, hydraulic oil compound additives used in industrial heavy equipment focus on enhancing anti-wear performance and load-bearing capacity, those used in precision machine tools prioritize viscosity stability and system cleanliness, while those used in outdoor construction machinery need to balance high and low temperature resistance and anti-water pollution capabilities.
UNPChemicals, a professional supplier deeply rooted in the lubricant additive industry for many years, specializes in the research, development, production, and supply of high-quality, high-performance hydraulic oil additives. Relying on strict R&D control standards, a complete testing and verification system, and a large amount of actual operating condition application data, it has established a comprehensive product system covering different application scenarios, which can fully meet the energy efficiency optimization and stable operation requirements of various hydraulic equipment. Its core products cover three major series, precisely matching the differentiated needs of different industries and operating conditions.
All hydraulic oil additive products under UNPChemicals have undergone rigorous laboratory performance testing and actual operating condition application verification. The R&D process strictly adheres to national industry standards such as GB/T 11118.1 to ensure that the product performance meets the standards and is stable and reliable. Relying on years of in-depth industry experience, UNPChemicals can provide customized additive solutions based on the specific equipment types and operating conditions (such as operating pressure, working temperature, load level, etc.) of customers, helping customers maximize the energy efficiency of hydraulic systems and reduce enterprise operating costs.
2.Impact of Friction Coefficient Optimization on Energy Consumption of Hydraulic Systems
The energy consumption losses of hydraulic systems are mainly divided into three categories: volumetric losses of hydraulic pumps, frictional losses along pipelines and local losses, and frictional losses of hydraulic components (valves, cylinders, motors, etc.). Among them, frictional losses account for 30%-50% of the total energy consumption losses of the system and are one of the core factors affecting the energy efficiency of hydraulic systems. The friction coefficient of hydraulic oil directly determines the magnitude of frictional resistance on the contact surfaces of hydraulic components. Therefore, optimizing the friction coefficient of hydraulic oil through hydraulic oil additives is a key technical approach to reducing system frictional losses and improving equipment energy efficiency.
In a hydraulic system, core components such as hydraulic pumps, cylinders, and directional valves all have precision mating surfaces, which will experience relative sliding or rotation during operation. If the friction coefficient of the hydraulic oil is too high, it will lead to an increase in frictional resistance on the contact surfaces of the components, which not only accelerates component wear but also requires a large amount of power to overcome the frictional resistance, resulting in significant energy consumption waste. Conversely, if the friction coefficient is too low, it may cause slippage on the mating surfaces of the components, affecting power transmission efficiency and even damaging seals and causing leakage problems. Therefore, the ideal friction coefficient of hydraulic oil should fall within a reasonable range of "low friction, no slippage", which can effectively reduce frictional resistance while ensuring the stability and reliability of power transmission.
Hydraulic oil compound additives can precisely regulate the friction coefficient of hydraulic oil and effectively control friction losses by adding special anti-wear and friction-reducing additives (such as zinc salts, sulfur-phosphorus additives, ashless anti-wear agents, etc.). Taking the core product of UNPChemicals as an example, its high-zinc hydraulic oil compound additive UNP AH502A contains highly active zinc salt anti-wear components, which can form a dense anti-wear protective film on the contact surface of hydraulic components, converting direct metal-metal contact into protective film-protective film contact and significantly reducing the friction coefficient; The ashless hydraulic oil compound UNP AH502C uses a new type of ashless anti-friction component, which can optimize the friction coefficient while avoiding the adverse effects of ash deposition on components, and is suitable for the operating requirements of precision equipment.
3.Matching Relationship between Viscosity Characteristics and Hydraulic Pump Efficiency
As the core power source of a hydraulic system, the operating efficiency of a hydraulic pump directly determines the overall energy efficiency level of the hydraulic system, and the viscosity characteristics of hydraulic oil are one of the core factors affecting the efficiency of the hydraulic pump. The efficiency of a hydraulic pump mainly includes volumetric efficiency and mechanical efficiency, where volumetric efficiency depends on the leakage of hydraulic oil, and mechanical efficiency depends on the frictional resistance of hydraulic oil, both of which are closely related to the viscosity of hydraulic oil. Therefore, optimizing the viscosity characteristics of hydraulic oil through hydraulic oil compound additives to achieve precise matching with the efficiency of the hydraulic pump is an important technical means to improve the energy efficiency of the hydraulic system.
The viscosity characteristics of hydraulic oil mainly include core indicators such as kinematic viscosity, viscosity index, low-temperature viscosity, high-temperature viscosity, etc. Among them, the kinematic viscosity at 100°C (mm²/s) is the core parameter for measuring the viscosity of hydraulic oil, and it is also an important basis for the selection of hydraulic pumps and the formulation of hydraulic oil. According to the relevant provisions of GB/T 265 "Determination of Kinematic Viscosity of Petroleum Products", the kinematic viscosity test of hydraulic oil must strictly control the temperature at 100°C ± 0.05°C, and the test results shall be retained with four significant figures. Hydraulic pumps of different types and specifications have clear requirements for the kinematic viscosity of hydraulic oil at 100°C. If the viscosity does not match, it will lead to a significant decrease in the efficiency of the hydraulic pump and a notable increase in energy consumption.
Specifically, the matching relationship between viscosity and hydraulic pump efficiency is mainly reflected in the following two aspects:
Firstly, the impact of excessively high viscosity. If the viscosity of hydraulic oil is too high, it will lead to a decrease in its fluidity, an increase in the resistance when the hydraulic pump sucks in the hydraulic oil, and is likely to trigger the "cavitation" phenomenon; meanwhile, the flow resistance of the hydraulic oil inside the pump increases, the mechanical friction loss rises, resulting in a decrease in the mechanical efficiency of the hydraulic pump. In addition, excessively high viscosity will also increase the frictional loss along the pipeline, reduce the transmission efficiency of the hydraulic oil within the system, and cause an increase in overall energy consumption. For example, if a gear pump uses hydraulic oil with excessively high viscosity, its mechanical efficiency will decrease by 10%-20%, and the system energy consumption will increase by more than 15%.
Second, the impact of excessively low viscosity. If the viscosity of hydraulic oil is too low, it will lead to a decrease in its sealing performance, an increase in internal leakage of the hydraulic pump, and a reduction in volumetric efficiency; meanwhile, the hydraulic oil will fail to form an effective oil film protection on the contact surfaces of components, which will exacerbate component wear, shorten the service life of the hydraulic pump, and indirectly increase equipment maintenance costs and energy consumption. For example, if a plunger pump uses hydraulic oil with excessively low viscosity, its volumetric efficiency will decrease by 8% - 15%, and the increased leakage will result in wasted power.
Hydraulic oil compound additives can precisely optimize the viscosity characteristics of hydraulic oil by adding functional components such as viscosity index improvers, pour point depressants, and tackifiers, ensuring that indicators such as kinematic viscosity and viscosity index meet the operating requirements of hydraulic pumps and achieving precise matching with the efficiency of hydraulic pumps. For example, the UNP AH502B low-zinc hydraulic oil compound additive, when added with a high-efficiency viscosity index improver, can increase the viscosity index of hydraulic oil to over 140, ensuring its viscosity remains stable under high-temperature (above 100°C) operating conditions and avoiding leakage problems caused by viscosity reduction; Under low-temperature conditions, it can effectively lower the pour point of hydraulic oil, improve fluidity, prevent the occurrence of "cavitation" phenomenon, and ensure the efficient and stable operation of hydraulic pumps.
In addition, hydraulic oil compound additives can effectively improve the viscosity-temperature characteristics of hydraulic oil. By increasing the viscosity index, they reduce the impact of temperature changes on the viscosity of hydraulic oil. For example, under high-temperature working conditions (such as metallurgical equipment and construction machinery operating outdoors in summer), the viscosity of ordinary hydraulic oil will drop significantly, leading to an increase in leakage; while hydraulic oil with UNPChemicals compound additives, due to its higher viscosity index, maintains stable viscosity in high-temperature environments, ensuring that the efficiency of the hydraulic pump is not affected by temperature and maintaining the efficient operation of the system. Under low-temperature conditions (such as outdoor equipment in northern winters), the compound agent can effectively lower the pour point of hydraulic oil, improve its fluidity, prevent the hydraulic pump from experiencing efficiency decline due to difficult suction, and reduce energy consumption waste.
4.Improvement Effect of Compound Agent on the Response Speed of Hydraulic System
The response speed of a hydraulic system refers to the time it takes for the actuating elements (such as cylinders, hydraulic motors, etc.) to complete the specified actions after the hydraulic system receives a control signal. The speed directly affects the operating efficiency and running accuracy of the equipment. In the field of industrial production, especially in scenarios such as automated production lines, precision machine tools, and construction machinery, insufficient response speed of the hydraulic system will lead to a decrease in equipment operating efficiency, a reduction in product accuracy, and may even affect the continuity of the production process, indirectly increasing energy consumption and production costs. Hydraulic oil compound can effectively improve the response speed of hydraulic systems and enhance the operating efficiency and energy efficiency of equipment by optimizing multiple core performance indicators of hydraulic oil.
The main reasons for the insufficient response speed of the hydraulic system include three aspects: First, the viscosity stability of the hydraulic oil is poor, with excessive viscosity fluctuations when the temperature changes, resulting in unstable flow speed of the hydraulic oil within the system; Second, the cleanliness of the hydraulic oil is insufficient, with impurities and deposits clogging pipelines or valves, hindering the flow of the hydraulic oil; Third, the anti-emulsification and anti-foaming properties of the hydraulic oil are poor, leading to the generation of bubbles or emulsification within the system, affecting the timeliness and stability of power transmission. Hydraulic oil compound additives can specifically address the above issues and improve the response speed of the hydraulic system from multiple dimensions.
First, the hydraulic oil compound ensures the stability of hydraulic oil viscosity under different temperature conditions by optimizing its viscosity characteristics, thereby increasing the flow rate of the hydraulic oil. As previously mentioned, the UNPChemicals hydraulic oil compound contains a high-efficiency viscosity index improver, which can increase the viscosity index of the hydraulic oil to over 140. Within the temperature range of -20°C to 120°C, the viscosity fluctuation is controlled within ±10%, ensuring a stable flow rate of the hydraulic oil within the system and reducing response delays caused by viscosity fluctuations.For example, in the hydraulic system of precision machine tools, hydraulic oil formulated with UNP AH502C ashless hydraulic oil compound has a stable viscosity, which can shorten the response time of the hydraulic system by 0.2 - 0.5 seconds, improve the machining accuracy of equipment by 10% - 15%, and significantly enhance the operating efficiency.
Secondly, hydraulic oil additives improve the cleanliness of hydraulic oil and reduce the formation of impurities and deposits by adding functional components such as detergents and dispersants, antioxidants, etc. During long-term operation, hydraulic oil generates impurities such as sludge and metal debris due to oxidation and component wear. Such impurities easily clog pipelines and valve orifices, impede the flow of hydraulic oil, and cause a delay in the response of the hydraulic system. UNPChemicals hydraulic oil additives contain high-quality detergents and dispersants, which can evenly disperse sludge and impurities in the hydraulic oil, preventing their deposition;Meanwhile, antioxidants can delay the oxidation and aging process of hydraulic oil, reduce sludge formation, keep the hydraulic system pipelines unobstructed, ensure smooth flow of hydraulic oil, and improve the system's response speed.
In addition, hydraulic oil compound additives can effectively improve the anti-foaming and anti-emulsification properties of hydraulic oil, preventing the formation of bubbles or emulsification within the system. During the operation of the hydraulic system, contact between hydraulic oil and air can generate bubbles. If the anti-foaming performance of the hydraulic oil is poor and the bubbles cannot be eliminated in a timely manner, it will lead to inconsistent power transmission, causing the "cavitation" phenomenon and delaying the system's response speed. If water enters the hydraulic oil, an emulsification reaction will occur, and the fluidity of the emulsified hydraulic oil will significantly decrease, also affecting the system's response. UNPChemicals Hydraulic Oil Compound Agent adds special anti-foaming agent and demulsifier, which can quickly eliminate bubbles in hydraulic oil, control the demulsification time within 30 minutes, ensure that the hydraulic oil still maintains good fluidity even when mixed with water, avoid response delay caused by bubbles and emulsification, and improve the stability and response speed of the hydraulic system.
5.Summary and Recommendations
Hydraulic oil compound additives are closely and inherently related to the improvement of the energy efficiency of hydraulic equipment. By optimizing the friction coefficient and viscosity characteristics of hydraulic oil, improving the response speed of the hydraulic system, they can reduce the energy consumption losses of the hydraulic system from multiple dimensions, enhance the operating efficiency, stability, and service life of the equipment, and help enterprises reduce operating costs and enhance market competitiveness.
As a professional hydraulic oil additive supplier with years of in-depth industry experience, UNPChemicals, relying on strict R&D control standards, a comprehensive product system, and rich practical application experience in various working conditions, has launched core products such as UNP AH502A, UNP AH502B, and UNP AH502C, which can precisely meet the requirements of hydraulic equipment in different industries and working conditions, providing enterprises with additive solutions that combine energy efficiency optimization and operational stability.
The following suggestions are put forward regarding the selection and use of hydraulic oil compound additives for enterprises:
1.Select suitable compound products based on equipment type and operating condition requirements: Different types of hydraulic pumps, different loads, and temperature conditions have varying requirements for hydraulic oil performance. Enterprises should select the appropriate type of compound (e.g., UNP AH502A for heavy-load equipment and UNP AH502C for precision equipment) based on equipment parameters and actual operating conditions to avoid energy efficiency decline caused by product mismatch.
2.Strictly follow the mixing ratio standard when preparing hydraulic oil: The mixing ratio of hydraulic oil compound and base oil directly affects the comprehensive performance of hydraulic oil. Enterprises should strictly adhere to the mixing ratio standard provided by UNPChemicals, avoid over- or under-mixing, ensure that the performance of hydraulic oil meets the standard, and achieve the goal of energy efficiency optimization.
3.Regularly test the performance of hydraulic oil and promptly replace aged oil: Hydraulic oil will gradually age and its performance will decline during long-term operation. Enterprises should regularly test core indicators such as kinematic viscosity, friction coefficient, and cleanliness of hydraulic oil. When the indicators exceed the standard range, promptly replace the hydraulic oil to ensure that the hydraulic system always operates in a highly efficient state.
4.Select a professional compound supplier: Professional suppliers can provide comprehensive product inspection reports, customized solutions, and after-sales technical support. For example, UNPChemicals can optimize compound formulations, provide on-site technical guidance, and help customers maximize the energy efficiency of their hydraulic systems based on their specific needs.
As the industrial sector's requirements for equipment energy efficiency continue to rise, the importance of hydraulic oil additives will become increasingly prominent. Selecting high-quality and well-suited hydraulic oil additives can not only improve the energy efficiency of hydraulic equipment but also extend the equipment's service life and reduce maintenance costs, providing strong support for the sustainable development of enterprises.
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.