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Reclamation of Old Transformer Oil Using Kaolin Clay: July 2015

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Reclamation of Old Transformer Oil Using kaolin clay

Article · July 2015

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
Available online on http://www.rspublication.com/ijst/index.html ISSN 2249-9954

Reclamation of Old Transformer Oil Using kaolin clay


A. I. Hafez 1, N. S. Gerges1,K.I.El-nagar2, S. E. Mohamed 3& A. I. Hashem4
1- Central Chemical lab. Egyptian Electricity Transmission Company
2- National institute for standards
3-Egyptian Environmental Affairs Agency, Cairo, Egypt .
4- Chemistry Department, Faculty of Science, Ain-shams University, Cairo, Egypt.

ABSTRACT:

Kaolin clay used in this investigation was collected from kalabsha quarry in Aswan City
South Egypt. The analysis of kaolin revealed that it is enriched withaluminium and silicon
oxides as a major constituents and other trace element such as Fe and Ti. The using of kaolin
clay as sorbent material for the removal of acidity, water content and some impurities from
aged transformer oil by adsorption methodology was investigated using lab-scale refining
unit. Kaolin was found to improve the electrical and physical properties of aged transformer
oils. The changes in acidity, breakdown voltage, viscosity, specific gravity, water content
were discussed briefly. Nevertheless some of undesirable gases in aged oil (more than ten
years in service) were removed by using the lab-scale refining unit containing kaolin clay.
Keywords: - Transformer oils, kaolin, Refining unit.

1. INTRODUCTION:

Kaolin is a natural material has both rock and clay mineral term include quartz, smectites,
feldspars and micas. Kaolin is widely utilized in the paper, paint, rubber, ceramic and plastic
industries. Other applications in wine and vegetable clarifiers, oil absorbers, iron smelting [1-
3].
Transformer mineral oil is one of the expensive extracts of the crude oil, produced by its
refinement. Refining is the collective term for the processes involved in changing the crude
oil into fragments with the required properties for particular applications. Because of the
importance of the power transformers in electrical network, permanent taking care of
the oil quality is indispensable. Insulating oil in service is subjected to heat, oxygen and
electrical discharge, which may lead to its degradation .The main step in the regeneration of

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
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transformer oil is carried out using the adsorption process, which consists of removal of
theacidcomponents, water and oxidation products with an adsorbent material.
Currently, activated bauxite and bentonite are used as low cost adsorbents for the recovery of
aged oil in order to, maintain its properties to be to some extent like the new oil [4,5]. One of
the problems of the regeneration process with bauxite is the great volume of waste that is
discarded in landfill sites [6]. It is thusnecessary to examine the effectiveness of other raw
materials, especially from renewable sources, that possess adsorbent properties for removing
impurities in the treatment of insulating oil without any impacts on the environment. Oils,
which are essentially electrical insulators,are used in electrical power transformers, mainly
totransfer the heat and to increase the dielectricstrength of the insulating paper [7,8].
However,ageing, dust and metal particles, as well as humidity,deteriorate the isolating and
cooling properties of thetransformer oil, which increase the risk on equipmentand operators.
Degradation of transformer insulation,which in part defines the life span of a transformer,
ismonitored by sampling the transformer oil [9,10].
Therefore, oil test should be scheduled regularly inorder to determine its breakdown voltage.
This testhelps to increase the lifetime of the transformers andtherefore, new investment to
replace thesetransformers could be delayed. The transformer oiltest is mandatory in some
countries. Thermal,electrical, physical and chemical characteristics ofthe transformer oil are
typically tested.
In order to increase the equipment lifetime, oilsare usually replaced with fresh ones at regular
basis,which is not a cost effective solution. Bothenvironmental and conomical reasons
preventdiscarding the spent oils, after use. The used oilscontain a large proportion of valuable
base oil thatmay be reused, if undesirable pollutants are removed.
This is to say that transformer oil can be regeneratedand its original specifications can be
restored.The regeneration of the transformer oil is a greentechnology and could be done in
continuousoperation and is decomposed into different steps:
- Heat and filtration
- Adsorption process
- Fine filtration
- Degasification and dehydration
If oil is regenerated properly, its main propertiescan be highly improved. Among these
properties arethe density, viscosity, interfacial tension, breakdownvoltage, and neutralization
value.The main step in the regeneration of transformeroil is carried out using the adsorption

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
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process, whichconsists of the removal of the acid components,water and oxidation products
with an adsorbent.
Currently, activated bauxite is used as an adsorbentfor the recovery of aged oil in order to
regenerate theoil, maintaining the properties of new oil with lowcost [11]. One of the
problems of the regenerationprocess with bauxite is the great volume of wastethat is
discarded in landfill sites [12].
Traditionally, mineral oil, synthetic esters and silicon oils have been used in transformers.
More recently, the environmentally friendly sunflower oil hasbeen usedas transformer oil for
special purposes [13-16]. The life time assessment and evaluation of the condition of a
transformer is of high importance for the users and manufacturers. The end of life of the
transformer is defined as the decrease in the tensile strength of the isolating paperto approx
50% of the starting value [17-21].
In this investigation, we wish to report on constructing and using a lab-scale refining unit
containing kaolin as sorbent for treatment of aged transformer oil (more than ten years in
service). The variations of acidity, breakdown voltage, viscosity, specific gravity, water
content and some undesirable gases of the treated oil are measured.

2. EXPERIMENTAL:

2.1- Refining unit:


The refining unit consists of three components;
1- Vacuum chamber and pump.
2- Acidity and impurities removal cartridge.
3- Fine filter.
All essential parts of the unit (vacuum pump, transfer pump, valves, fine and coarse filters
and heaters) were handmade assembled as shown in Figure (1):

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
Available online on http://www.rspublication.com/ijst/index.html ISSN 2249-9954

Acid and
impurities removal
cartridge

Vacuum
Chamber

Heater

Figur(1): Typical photograph of the constructed refining unit.

The schematic diagram of refining unit is shown in Figure (2) as follow:

Figure (2): The schematic diagram of refining unit


2.2 Materials:
2.2.1 Aged Transformer Oil:
Aged Transformer oil was collected from high voltage transformer after more than ten years
operation with the properties listed in Table (1).

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
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Table (1) :physico-chemical characteristics of the used aged oil.


Limits(1)
Standard ≤ > 72.5
Exp. Results > 170
Method 72.5 ≤ 170
K.V.
K.V. K.V.
Specific Gravity at 15ºC ASTM D1298 0.866 ≤ 0.91 (2)
Color ASTM D1500 >8 < 2 Clear not turbid
Water Contentppm at BS 148 - IEC 48 < 25 < 15 < 10
Impurities ASTM D1796 +Ve NIL
20ºC 60733
Total Acidity (mg KOH/g) ASTM D974 - 0.31 < 0.3 < 0.2 < 0.15
Break down Voltage Kv IEC 60156 15 > 30 > 40 > 50
Oil) IP 1 (2)
Kinematics Viscosity (CST) ASTM D445 10.45 ≤ 12
/2.5 mm
Flash Point openºC ASTM D92 140 Maximum decrease 10%
Copper Corrosion ASTM D130 ---- NIL
(1) Acceptable limits for mineral insulating oils in-service: According to IEC 60422:2005.
(2) Acceptable limits for mineral insulating oils: According to ASTM D3487.

2.3. Kaolin clay:

Kaolin used in this investigation was collected from kalabsha quarry in Aswan City South
Egypt, and mainly consists of Al, Si, Fe, Ti and other trace elements. The typical and grinded
forms of kaolinare shown in Fig. (3).

Figure (3): Typical and grinded forms of kaolin.


2.4. Treatment process:
The treatment process was performed using one liter of the aged transformer oil with
different doses of kaolin at different temperatures and time in the lab scale refining unit.
The amounts of kaolin used were put in acid and impurities removal cartridge. The aged oil
samples were heated and passed through the cartridge for different time and temperature in
stages of half an hour each. The oil was then introduced to vacuum chamber to remove
undesirable gases after treatment. The treated oil was finally collected in the treated oil tank.
Samples of the treated oil were then withdrawn and analyzed applying the standard methods
of test.

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
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3. Results and Discussion:


Experimental work revealed that kaolin has approximately the same constituents of
bentonite and bauxite that are the most substances used in reclaiming the transformer oils
[22]. Therefore the kaolin was chosen to use as reclaiming substance.
The electrical, chemical and physical properties of insulating oil can be considerably
improved by its filtering, degassingand dehydration.
During its operation, transformer-insulating oil is absorbing moisture over itsfree surface in
the expansion vessel and it becomes polluted by absorbingdirty particles, fibers, soot,
undesired gases and aging products. Therefore, oil upgrading hasto eliminate these
contaminants.
The abovementioned contaminants can be removed by filtering, degassing and dehydration
of insulating oilto the extent depending on moisture content and reducing the acidity by an
acid adsorbent agent.
3.1 Structure and chemical composition of kaolin:
3.1.1- X-ray analysis:
Kaolin collected fromkalabsha quarry in Aswan city South Egypt was analysed using; Energy
Dispersive X-ray spectrometer (EDX) ISIS Link Instrument P/C. Oxford Co,which is
attached to a SEM. Figure (4) shows the spectrum of kaolin sample.It is evident that kaolin
sample was enriched by some inorganic elements whose amounts are represented by the
peaks in Figure (4).
There are traces of (Fe) and small amount of titanium ions. Thepresence of (Al) and (Si)
ions as indicated in Figure (4) confirms that the sample is enriched by these two elements .

Figure (4): X-ray chart of kaolin sample

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
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3.1.2- Thermogravimetric analysis (TGA):


Thermogravimetric analysis of kaolin sample was performed using
ThermogravimetricdeterminatorLeco: Mac-500.ST.Joseph, Michigan-USA. This apparatus
provides a continuousmeasurement of sample weight at a range oftemperatures
between ambient and 900 oC. The samples were heated in an alumina cell to 900 oC at
heating rate of 10oC/min with nitrogen as the circulating gas.
The diagram obtained (Fig. 5) shows four characteristic stages of decomposition. The first
stage starts at 55 °C and ends at 90°C with weight loss of 5.3 %. This could be recognized as
due to the moisture content of kaolin sample. The second stage which related to the main
decomposition of the sample occurs in one step of decomposition starts at 90°C and ends at
220°C with weight loss of 11% representing the hydrated hydroxide [Al(OH)3.xH2O] and
others. The third stage of decomposition is related to the carbonization process which occurs
up to 600 °C with a weight loss of 32%.The fourth stage is related to calcination stage which
started at 600 oC and ended at 900oC with weight loss of 37%.

Figure (5) : TGA of kaolin.


3.2. Effect of kaolin treatment on acidity number of oil:
The degradation of oil produces some organic acids such as carboxylic acids that will either
dissolve in the oil or volatilize into the headspace of transformer. Dissolved acids may
cause damage to the paper and copper windings, while volatile acids corrode the top
of the unit. As a result, all of the necessary conditions exist properly in a power
transformer for the degradation of the oil.
The effect of kaolin on the removal of acidity is represented by Figures (6-9). These Figures
indicate that the acidity decreases by increasing the amount of adsorbent material (kaolin) at
different temperatures and stages of refining (stage time is ½ hour). The maximum decrease
of acidity was at kaolin dose of 20% for 4 stages, it reached 0.02mg KOH /g of oil.
According to ASTM No. D 3487, the total acidity is 0.31mgKOH/g of oil maximum.aged
transformer oil either before purification or before treatment has a total acidity of

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
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0.31mgKoH/g of oil, which mean that it is over the ASTM limits but total acidity decreased
to treated oil 0.02 mgKOH/g [ 23] .

0.2
0.18
0.16

Acidity Value
0.14
0.12 at 30 ºC

0.1 at 40 ºC

0.08 at 50 ºC
0.06 at 60 ºC
0.04
0.02
0
0 5 10 15 20 25

Amount of adsorbent material %

Figure (6) : Variation of total acid value with kaolin dose (1 stage)

0.16

0.14

0.12

0.1
Acidity value

0.08 at 30° c
at 40° c
0.06 at 50° c
at 60° c
0.04

0.02

0
0 5 10 15 20 25

Amount of adsorbent material%

Figure (7) : Variation of total acid value with kaolin dose (2 stages)

0.14

0.12

0.1
Acidity value

0.08
at 30° c

at 40° c
0.06
at 50° c

at 60° c
0.04

0.02

0
0 5 10 15 20 25

Figure (8) : Variation of total acid


Amountvalue with
of adsorbent kaolin
material % dose (3 stages)

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International Journal of Advanced Scientific and Technical Research Issue 5 volume 4, July-August 2015
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0.09

0.08

0.07

0.06

Acidity value
0.05
at 30° c
0.04
at 40° c
at 50° c
0.03
at 60° c

0.02

0.01

0
0 5 10 15 20 25
Amount of adsorbent material%

Figure (9) : Variation of total acid value with kaolin dose (4 stages)
3.2. Colour:
The colour of a sample is determined by direct comparison with a set of colour standards
using “Colorimeter as colorimeter degree according to ASTMD1500/03”.The colour of an oil
sample is used mainly as a guide to thedegree of refinement of the oil when it is new. If the
sample isfrom a transformer that has been in service then the colour canbe followed over a
period of time to indicate the possible condition of the oil. It should be pointed out that
the colour ofthe oil by itself should never be used to indicate the dielectricquality of the oil
[5]. However it can be used to determinewhether more definitive tests should be done
to determinespecific characteristics of the sample that are more related tothe performance of
the oil .The clarity of the sample can also give possible suggestionsfor further tests.
Cloudiness of the sample can indicate thepresence of water, which in turn will decrease the
dielectricstrength of the sample.
Figures (10-13) represent the variation of oil colour with amount of adsorbent material
(kaolin) at different temperatures through the four stages of treatment. There is a significant
improvement in the colour of the treated oil resulting from increasing the amount of
adsorbent material (kaolin), at the working temperatures. The colour of oil was changed from
more than 8 degree of aged oil to 1 degree after 4 stages as can be seen from the Figures.

Figure (10) :Variation of colour with kaolin dose (1 stage)

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Figure (11) :Variation of colour with kaolin dose (2 stages)

Figure (12) :Variation of colour with kaolin dose (3 stages)

Figure (13): Variation of colour with kaolin dose (4 stages)


Also figure (14) show thecolour oil sample photograph of untreated and treated oil at
different reclaiming stages

Untreated oil Treated 1 stage Treated 2 stage Treated 3 stage Treated 4 stage
Figure (14 )Colour of treated and untreated transformer oil for different sages

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3.3. BREAKDOWN VOLTAGE:


This characteristic is very significant and is usually investigated first and its value should be
held at the highest possible level. The lowering of this value mainly indicates the growth of
the water content in oil[ 24] .
The breakdown voltage of aged and reclaimed oil was measured by petrotestMegger
OTS100AF according to IEC60156. Figures (15-18) show the variation of breakdown voltage
of oil by the increasing the amount of adsorbent material. The value was changed from 15
Kvfor aged oil to 74Kvfor reclaimed oil by such material at temperature 60 0C after the four
stages treatment.

Figure (15) : Variation of breakdown voltage with kaolin dose (1 stage)

Figure (16) : Variation of breakdown voltage with kaolin dose (2 stages)

Figure (17) : Variation of breakdown voltage with kaolin dose (3 stages)

Figure (18): Variation of breakdown voltage with kaolin dose (4 stages)

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3.4. Viscosity:
The viscosity of dielectric coolants within the range of normal operating temperatures
is important because it can impact both the cooling and performance of some internal
components. The oil closed to the windings in the field transformer flows up at
higher temperature while the oil at lower temperature flows to bottom from the wall.
The heat is scattered from windings in this way. So, transformer oil with lower viscosity has
better cooling effect. The increase of viscosity, which has negative effect on load and
efficiency, is adverse to the safe operation of the unit. Therefore, it is essential to
control the viscosity of transformer oil in service. The viscosity of aged and treated oil was
measured by “viscometer Koehler”K2337.Table (2) shows the variation of viscosity of oil
during the four stages of treatment at 60 0C for 20% adsorbent material (kaolin).
Table (2) : Variation of oil viscosity during the four stages of treatment.

No. of Stage 1 Stage 2 Stages 3 Stages 4 Stages


Viscosity(CST) 11.1 10.9 10.8 10.8

3.5. Moisture:
Moisture is generated at temperatures over 80°C from deterioration of the oil and still
generates above 170°C. Hydrogen is generated from degradation of the oil at
temperatures above 120°C and still generates at temperatures over 140°C. Carbon
monoxide and dioxide are generated significantly in the aged oil at temperatures greater than
110°C [5-7]. Figures (19-22) show the variation of water content of oil by the increasing the
amount of adsorbent material. The value was changed from 48ppm for aged oil to 9 for
reclaimed oil by such material at temperature of 60 0C during the four stages treatment.

Figure (19) : Variation of moisture with kaolin dose (1 stage)

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Figure (20) : Variation of moisture with kaolin dose (2 stages)

Figure (21) : Variation of moisture with kaolin dose (3 stages)

Figure (22) : Variation of moisture with kaolin dose (4 stages)

3-7-Dissolved Gas Analysis (DGA):ASTM D3612


The dissolved gases in the oil play an important role in the transformer operation because of
the probability of explosion. There is a limit for every gas in the transformer oil according to
its load.
The gases in the aged and treated oil were analyzed by Gas Chromatograph "DANI Auto
sampler GC1000" and the results are listed in Table (3). It is obvious that the amounts of
gases in the reclaimed oil are within the standard limits of operation.

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Table (3): Analysis of gas in the aged and treated oil.


ppm
Gas 1 2 3 4 Alert limits
Aged
Stage stages Stages Stages
Hydrogen (H2) 23 22 23 23 23 100 – 700

Oxygen (O2) 11971 14975 21241 23671 26374 -

Nitrogen (N2) 75167 7334 70360 6998 68219 -

Carbon monoxide (CO) 318 235 122 0.0 0.0 350 – 570

Carbon dioxide (CO2) 1829 1334 1267 1198 1185 2500 – 4000

Methane (CH4) 754 11 2 0.0 0.0 120 – 400

Ethane (C2H6) 4223 245 94 0.0 0.0 65 – 100

Ethylene (C2H4) 10827 611 136 0.0 0.0 50 – 100

Acetylene (C2H2) 178 78 0.0 0.0 0.0 1–9


Total Dissolved Combustible
16324 967 377 23 23 720 – 1920
Gas (TDCG) =

4- Elemental analysis of aged and reclaimed oil:


The elemental analysis of (C, H, N and S) were determined by LecoTruspect (CHN)
Analyzer, Leco Corporation 3000 LAKE View AVE.ST. Joseph,MI-USA. The results are
listed in Table (4).
Table (4)The elemental analysis of aged and reclaimed oil

Sample Aged 1 Stage 2 Stages 3 Stages 4


Element % Oil Stages

C 85.65 85.11 85.10 84.90 84.91


H 13.03 13.11 13.41 13.7 13.9
N 0.22 0.21 0.20 0.20 0.19
S 0.32 0.31 0.29 0.24 0.24

The data represented by Table (4) reveal that the carbon element in oil slightly reduced by the
reclamation stages. The reduction in carbon element by the treatment may be attributed to the
elimination of carbon impurities produced.The results indicate also that there is a significant
reduction in sulphur content at the third and fourth stages of treatment.
5- Environmental Impacts:
Used transformer oil is considered as a hazardouswaste environmentally, because of its
chemical reaction, toxicity, flammability, or ability of explosion.

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Aged transformer oil contains some toxic chemicals resulting from additives which as used
to improve oil properties such asheavy metals, organic materials (e.g. phenol).
Specialsynthetic transformer oils, are very toxic, carcinogenic, soluble in water and penetrate
in the soil andunderground water.
The reusing of transformer oil by reclaimation using kaolin can solve the above mentioned
problems of aged oil disposal. Nevertheless, kaolin after reclaimation can be reused after
ignition at 750 0C at which temperature kaolin returns back to its constituents. Figure (23)
shows the typical image of kaolin after using and ignition.

A B
Figure (23): Typical image of kaolin after using (A) and ignition (B)
Also Figure (24) shows the X-ray spectrum of used kaolin after ignition. The spectrum shows
the same peaks as kaolin before using. As can be seen from the spectrum of kaolin after using
and ignition it contain Al, Fe and Ti elements which are the most elements used in the
reclaiming of oil.
This indicates that the used kaolin can be recycled and used for further treatment processes.

Figure(24) : X-ray spectrum of kaolin after using and ignition.

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6. CONCLUSION:
High improvement of breakdown voltage occurs after using kaolin reclaimed transformer oil
and changed from 15 to 72 kV. Also some improvements have been achieved such as water
content changed from 48 to 9 ppm and total acidity changed from 0.37 to 0.01mg/g of oil.
Economically the actual cost for treated oil is negligible with respect to oil price.
kaolin is available with no costs .
Environmentally, after kaolinreclamation process for the used transformer oil, the kaolin can
be recycled by ignition and used in further treatment processes.

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