Reclamation of Old Transformer Oil Using Kaolin Clay: July 2015
Reclamation of Old Transformer Oil Using Kaolin Clay: July 2015
Reclamation of Old Transformer Oil Using Kaolin Clay: July 2015
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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
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
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:
Acid and
impurities removal
cartridge
Vacuum
Chamber
Heater
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).
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
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
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
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.
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
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.
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.
Carbon monoxide (CO) 318 235 122 0.0 0.0 350 – 570
Carbon dioxide (CO2) 1829 1334 1267 1198 1185 2500 – 4000
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.
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.
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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