MICROBIAL IMPLICATION ON BIO BASED HYDRAULIC FLUID

ASBTRACT

This study was used to determine the microbial implication of biobased fluid. Lard used in this was processed after been purchase from local sellers within Umuahia metropolis. After the samples were cultured on solid media using pour plate techniques. The bacteria species were identified as Staphylococcus aureus, Escherichia coli and Salmonella species while the fungi species include Aspergillus niger and Aspergillus flavus. The Total Viable Staphylococcus aureus ranges from 1.01x105 and 1.32x105 cfu/ml respectively. While the total fungal count (TFC) Aspergillus niger and Aspergillus flavus of organism suspension at day 0, day 3 and day 6 range from 0.34x105 and  0.64x105 cfu/ml, the pH of each of the bacterial organism suspension at day 0, day 3 and day 6 incubation ranges from 7. 00 and 7.41 respectively are seen in Table 4.4a. while the pH of each of the fungal organism suspension at day 0, day 3 and day 6 incubation were 7.12 to 7. 22 respectively. The Optical Density of each of the bacterial organism suspension at day 0, day 3 and day 6 incubation 0.267 to 1.531respectively.  The physicochemical parameter of hydraulic fluid. From the result viscosity at 300c.

TABLE OF CONTENTS

Title page                                                                                                                    i

Certification                                                                                                               ii

Declaration                                                                                                                 iii

Dedication                                                                                                                  v

Acknowledgements                                                                                                    v

Table of content                                                                                                          vi

List of tables                                                                                                               x   

Abstract                                                                                                                      xi

1.0       CHAPTER ONE                                                                                                       1

1.1       Introduction                                                                                                                1

1.2       History of the usage and of biobased product for hydraulic system                                     3

1.3       Types of biobased Fluids                                                                                            3

1.4       Biobased Fluids that transmit pressure                                                                       4

1.5       Factors that affect biobiased fluid.                                                                             5

1.6       Advantage and disadvantages of biobased fluid                                                        8

1.7       How to produce biobased hydraulic fluid using castor seed                                      10

1.7       Castor oil extraction                                                                                                   10

1.7.2    Commercial continuous screw press assembly                                                          11

1.7.3    Castor oil filtration and purification                                                                           12

1.7.4    Castor oil refining                                                                                                       12

1.8       Aim and Objectives                                                                                                    13

CHAPTER TWO                                                                                                                  14

2.0       Literature Review                                                                                                       14

2.1       Microorganism found in biobased Fluid                                                                    14

2.2       Different types of biobased hydraulic fluid                                                                14

2.2.1    Vegetable oil as a source of biobased hydraulic fluid                                                14

2.2.2    Industrial used of biobised hydraulic fluid produced from vegetable                     15

2.2.3    Synthetic esters as a biobased fluid product                                                               17

2.2.4    Advantages and disadvantage of synthetic ester-based eals                                     18

2.3       Microbial survival in biobased hydraulic fluid                                                          19

2.3.1     PH and acidity                                                                                                           19

2.3.2.    Nutrient content of the fluid                                                                                      20

2.3.3    Moisture                                                                                                                      21

2.3.4    Temperature                                                                                                               21

2.3.5    Elements Present                                                                                                        21                                                                   

3.0       CHAPTER THREE                                                                                                  23

3.1       Materials and Methods                                                                                               23

3.1       Study Area                                                                                                                  23

3.2       Collection of Sample                                                                                                  23

3.3       Media Used                                                                                                                 23

3.4       Sterilization                                                                                                                24

3.5       Isolation of Bacterial Strains                                                                                      24

3.6       Identification of Bacterial Isolates                                                                             24

3.6.1    Gram’s staining                                                                                                          24

3.6.2    Motility Test                                                                                                               25

3.6.3   Catalase Test                                                                                                                25

3.6.4    Oxidase Test                                                                                                               25

3.6.5    Methyl Red Test                                                                                                         26

3.6.6    Indole Test                                                                                                                  26

3.6.8    Citrate Utilization                                                                                                       27

3.6.9    Sugar Fermentation                                                                                                    27

3.7       Characterization and Identification of the Fungal Isolates                                         27

3.7.1    Lactophenol Cotton Blue Staining                                                                             28

3.8       Physiochemical Parameters                                                                                        28

3.8.1    Determination of Pour point                                                                                       28

3.8.2    Determination of viscosity                                                                                         29

3.8.3    Determination of density                                                                                            30

3.8.4    Determination of flash point                                                                                      31

4.0       CHAPTER FOUR                                                                                                    32

4.1       Results                                                                                                                        32

5.0       CHAPTER FIVE                                                                                                      46

5.1       Discussion, Conclusion and Recommendation                                                          46

5.1       Conclusion                                                                                                                  48

5.2       Recommendations                                                                                                      48

Reference

LIST OF TABLES

                                                          CHAPTER ONE

1.1  INTRODUCTION

Biobased hydraulic fluid products are commercial or industrial products (other than food or feed) that are composed in whole or in significant part of biological products or renewable domestic agricultural materials (including plant, animal, and marine materials) or forestry materials. In the past, The United States Department of Agriculture (USDA) generally described biobased in reference to products, including lubricants and greases that were made of at least 51% biological materials.The use of fats and oils by man dates back to antiquity. Their chemical composition and specific properties have allowed them to find use as foods, fuels and lubricants. Their sources are numerous, encompassing vegetable, animal, and marine sources. As it is with all matter, their usefulness to man is determined by their chemical nature; and all fats and oils have certain characteristics in common. Fats and oils are naturally occurring substances which consist predominantly of mixtures of fatty acid esters of the trihydroxy alcohol or glycerol (Nwobi et al., 2006). Different fats and oils come about due to the fact that there are numerous fatty acids of various kinds and these can be combined in an infinite number of ways on the hydroxyl centers of glycerol.

The generally accepted definition of biobased lubricants is that they’re formulated with renewable and biodegradable basestocks. It’s worth noting that some definitions only consider biodegradability. To be biobased, lubricants don’t have to be composed entirely of unaltered vegetable oil; rather, the base materials just need to be renewable. This means fatty acids qualify, as do natural vegetable oils that are treated to produce a modified product (Abramovi, 2005).

1.2 HISTORY OF THE USAGE OF BIO BASED PRODUCT FOR HYDRAULIC SYSTEM

Prior to the industrial revolution in mid-19th century, mankind has relied mainly on renewable resources for fulfilling the needs for food as well as non-food products. Subsequently, fossil resources, first coal and then mineral oil and gas, became the base material for the production of energy, chemicals and materials. The rapid growth of the petrochemical refineries has transformed the world completely by providing us with innumerable number of products for all aspects of our lives. As a result, the use of renewable raw materials decreased substantially, accounting for only 10% of the current chemicals production. The recurring oil crisis in 1973, 1979 and 2008, however led to the concern about the finite nature of the fossil resources that would not suffice for the increasing demands of the growing population. Added to this, is the increasing awareness of the negative environmental impact of the fossil-based production seen as global warming, acid rain, smog, and recalcitrant wastes. Increasing public pressure and policy regulations are driving for the search for alternative resources for providing clean energy, green chemicals and materials that can be biodegraded when released into the environment after their useful lifespan (Kapilian, 2009). These resources, besides being renewable, should be cheap, readily available, and not interfere with the food chain. The increased awareness and demand for sustainability in the modern society has made terms such as eco-friendly, environment-friendly, nature-friendly, green, bio-based and renewable quite popular for marketing of many products and increasing the profit of industries.

According to a Frost and Sullivan study in 2007, European Bio-lubricants Market, the estimated usage in 2006 of bio-lubricants was 127,000 tons, or about 40 million gallons. Growth was estimated at 3.7%/yr between 2000 and 2006. Volume growth is still small although revenue growth is larger because of the higher price of the bio-lubes. The overall use of bio-lubes in the European Union was estimated at 1% of the total lubricant use according to Rolf Luther of Fuchs Oil, Europe. This would be 16 million gallons if the overall lubricant use suggested above is 1.6 billion gallons. This number is lower than the Frost and Sullivan estimate. INFRA, France estimates the total bio-lubricant market in Europe at 3.2% of the total lubricant usage, which is closer to the Frost and Sullivan estimate. In the EU, some countries are more bio-oriented than others. It is estimated that biolubricants in Germany are about 15% of the total. The Scandinavians are not far behind at about 11% (Arnot, 2010). Other countries, such as, France, Spain and the UK are below 1%. The major vegetable oil in use in Europe for industrial products is rapeseed. However, not all the bio-lubricants are completely vegetable oil-based. In some countries, to get a label only requires that 50% of the oil is renewable. Thus, synthetic esters or even petroleum oils can be used in the formulation.

1.3 TYPES OF BIO-BASED HYDRAULIC FLUIDS

·       Vegetable oils which comprises of rapeseed, sun flower, corn, soybean, canola, coconut, etc.)

·       Synthetic ester, such as polyol ester, and additive packages which are:.

FUNCTIONAL HF-546 is an additive package for producing ISO 46 hydraulic fluids. It is formulated to provide excellent antiwear and corrosion resistance, oxidative stability, foam resistance, cold flow properties and resistance to water. HF- 546 and HF-580 are compatible with TMP trioleate diluents for increased thermal and oxidative stability.

FUNCTIONAL HF-580 is a non-hazardous light color, low odor additive package which is compatible in a wide variety of base oils including vegetable oils, high oleic algal oils, modified castor oils and synthetic esters including TMP and pentaerythritol esters. It also has outstanding solubility in Groups III and IV oils (PAOs) as well as OSP fluids. HF-580 can be formulated in high oleic canola oil to ISO 46 grade using approximately 2.5%

FUNCTIONAL PD-551 as a highly shear stable thickener. The ISO 46 grade passes the V104C Vane Pump Test (ASTM D7043) and exhibits excellent demulsibility, rust and copper inhibition 4-ball wear performance and hydrolytic and thermal stability.

FUNCTIONAL HF-580 shows exceptional RPVOT oxidative stability, especially when used in base fluids with high oleic, high saturate and low polyunsaturate content such as very high oleic algal oils, modified castor oils and OSPs.

Their lubrication properties are very similar to mineral oils and readily biodegradable and low toxic fluids, some of fluids have a limited operational capability such as a poor low temperature characteristics and oxidation stability. Many oil companies have developed bio-based fluids to eliminate the hazardous pollution caused by accidental oil spillage, which is especially important in environmentally sensitive applications such as construction. Another good reason to use bio-based hydraulic fluids is to develop a market for US grown agricultural feedstock and to reduce reliance on overseas petroleum crude oil.

1.4. BIO-BASED FLUID THAT TRANSMIT PRESSURE

Bio-based Hydraulic fluids transmit power/pressure to the moving parts of many machines, including cars, bulldozers, tractors, and most heavy equipment used to build roads and structures. A good hydraulic fluid should have the following characteristics: power transmission with minimum loss, lubrication of surfaces moving against each other and corrosion protection of metal surfaces (San lazaro,2005). They are an important group of industrial oils with a market share of 15% in Europe and 22% in The United States. The trend towards the rapidly growing use of bio-based oils is most noticeable in this area because of their biodegradability, recyclability, reasonable level of fire-resistance, good thermal stability and good wear performance in a broad range of temperatures. Vegetable oils have most of the required properties as potential candidates for hydraulic applications except that they have poor low temperature flow behavior and poor oxidation and hydrolytic stability. However, this can be overcome with the use of additives and by modifying the fatty acid composition of the basestock (Rudnick, 2006). Structural limitations of naturally occurring basestocks restrict the application of vegetable oil hydraulic fluids to moderate temperatures. Vegetable oils used in hydraulic fluids are triglycerides of fatty acids, mostly C18 unsaturated, and their oxidation stability depends on the degree of unsaturation of their fatty acids.

1.5. FACTORS THAT AFFECTS BIO-BASED FLUIDS

 (a) Viscosity - Maximum and minimum operating temperatures, along with the system's load, determine the fluid's viscosity requirements. The fluid must maintain a minimum viscosity at the highest operating temperature. However, the hydraulic fluid must not be so viscous at low temperature that it cannot be pumped (Eichenberger, 2001).

(b) Wear - Of all hydraulic system problems, wear is most frequently misunderstood because wear and friction usually are considered together. Friction should be considered apart from wear.

Wear is the unavoidable result of metal-to-metal contact. The designer's goal is to minimize metal breakdown through an additive that protects the metal. By comparison, friction is reduced by preventing metal-tometal contact through the use of fluids that create a thin protective oil or additive film between moving metal parts. Note that excessive wear may not be the fault of the fluid. It may be caused by poor system design, such as excessive pressure or inadequate cooling.

(c) Anti-wear - The compound most frequently added to hydraulic fluid to reduce wear is zinc dithiophosphate (ZDP), but today, ashless anti-wear hydraulic fluids have become popular with some companies and in certain states to reduce loads on waste treatment plants. No ZDP or other type heavy metals have been used in the formulation of ashless anti-wear fluids. The pump is the critical dynamic element in any hydraulic system, and each pump type (vane, gear, piston) has different requirements for wear protection. Vane and gear pumps need anti-wear protection. With piston pumps, rust and oxidation (R & O) protection is more important. This is because gear and vane pumps operate with inherent metal-tometal contact, while pistons ride on an oil film. When two or more types of pumps are used in the same system, it is impractical to have a separate fluid for each, even though their operating requirements differ. The common fluid selected, therefore, must bridge the operating requirements of all pump types.

(d) Foaming - When foam is carried by a fluid, it degrades system performance and therefore should be eliminated. Foam usually can be prevented by eliminating air leaks within the system. However, two general types of foam still occur frequently: surface foam, which usually collects on the fluid surface in a reservoir, and • entrained air. Surface foam is the easiest to eliminate, with defoaming additives or by proper sump design so that foam enters the sump and has time to dissipate. Entrained air can cause more serious problems because this foam is drawn into the system. In worst cases, it causes cavitation, a hammering action that can destroy parts. Entrained air is usually prevented by properly selecting the additive and base oils. Caution: certain anti-foam agents, when used at a high concentration to reduce surface foam, will increase entrained air. Also linked to the foam problem, is fluid viscosity, which determines how easily air bubbles can migrate through the fluid and escape (Anderson, 2007).

 (e) Temperature - System operating temperature varies with job requirements. Here are a few general rules: the maximum recommended operating temperature usually is 150° F. Operating temperatures of 180° to 200° F are practical, but the fluid will have to be changed two to three times as often. Systems can operate at temperatures as high as 250° F, but the penalty is fairly rapid decomposition of the fluid and especially rapid decomposition of the additives - sometimes within 24 hours!

(f) Fluid makeup - Most fluids are evaluated based on their ratings for rust and oxidation (R & O), thermal stability, and wear protection, plus other characteristics that must be considered for efficient operation:

(i) Seal compatibility - In most systems, seals are selected so that when they encounter the fluid they will not change size or they will expand only slightly, thus ensuring tight fits. The fluid selected should be checked to be sure that the fluid and seal materials are compatible, so the fluid will not interfere with proper seal operation.

(j) Fluid life, disposability - There are two other important considerations that do not directly relate to fluid performance in the hydraulic system, but have a great influence on total cost. They are fluid life and disposability. Fluids that have long operating lives bring added savings through reduced maintenance and replacement-fluid costs. The cost of changing a fluid can be substantial in a large system. Part life should also be longer with the higher-quality, longer-lived fluid.

Longer fluid life also reduces disposal problems. With greater demands to keep the environment clean, and ever-changing definitions of what is toxic, the problem of fluid disposability increases. Fluids and local anti-pollution laws should both be evaluated to determine any potential problems. Synthesized hydrocarbon (synthetic) hydraulic fluids contain no waxes that congeal at low temperatures nor compounds that readily oxidize at high temperatures which are inevitable in natural mineral oils. Synthetic hydraulic fluids are being used for applications with very low, very high, or a very wide range of temperatures (Eichenberger, 2001).

1.6 ADVANTAGES AND DISADVANTAGE OF BIO-BASED FLUID

The following are the advantages of bio-based hydraulic fluid

1.     Reduce hazardous waste by natural recycling

2.     Reduce petroleum hydrocarbon contamination in landfill

3.     Preserve ground water and soil

4.     Reduce disposal costs of hazardous wastes

5.     Reduce cleanup costs of soil and ground water

6.     Reduce petroleum consumption

7.     Alternative lubrication resource

The disadvantage include

1.     High oxidative stability: One of the most important properties of lubricating oils and hydraulic fluids is oxidation stability. Oils with low oxidative stability oxidize rapidly at elevated temperatures in the presence of water. When oil oxidizes it undergoes a complex chemical reaction, producing acid and sludge that polymerizes to a plastic consistency. Sludge may settle in critical areas of the equipment and interfere with the lubrication and cooling functions of the fluid. The oxidized oil also corrodes equipment. There are several fatty acids present in vegetable oil, but only oleic, linoleic and linolenic have the potential for positive or negative impact (Howell, 2007).

2.     High pour point. Pour point is the lowest temperature at which a fluid will flow, while cloud point is the temperature at which dissolved solids are no longer completely soluble, precipitating as a second phase that gives the fluid a cloudy appearance. In the petroleum industry, cloud point refers to the temperature below which wax in diesel (or biowax in biodiesels) looks cloudy. The presence of solidified waxes thickens the oil and clogs fuel filters and injectors in engines. The wax also accumulates on cold surfaces (e.g., tubings or heat exchanger fouling) and forms an emulsion with water. The low-temperature fluidity of unmodified biobased lubricants is inferior to mineral-based and synthetic lubricants. The pour point of mineral-based lubricants ranges from -18⁰C to -30⁰C: canola and rapeseed oil are around -9⁰C while unmodified soybean lubricant is about -2⁰C and modified vegetable-based lubricants have pour points as low as -40⁰C. The soybean pour point problem can be solved with chemical additives or blending with other fluids such as synthetic oils with lower pour points. The key to success is retaining as much of the lubricant’s biodegradability as possible while keeping the cost down.

3.     Price: Bio-based hydraulic fluid are more expensive than other mineral oil. Many biobased products are priced to compete with mid- to high-performance mineral oil products. But higher-priced products still can be justified for use in many applications where biodegradability, lubricity, viscosity and fire safety are especially important (see sidebar: Price comparison between bio- and mineral-based lubricants). (Honary, 2004) “We can synthesize a vegetable oil-based lubricant that is price competitive with synthetic lubricants,” Sharma says. “Our current research target is to make lubricants for various applications by modifying the vegetable oil structure so that we can improve some of its disadvantages and still compete with synthetic-based oils.”

4.     Difficult to recycle. There’s disagreement as to just how recyclable biobased lubricants are. Some, like Sharma, say that once the oil is used it’s hard to restore to its original state—and recycling is even more challenging if it’s mixed

5.     They have poor low temperature flow behavior and poor oxidation and hydrolytic stability. However, this can be overcome with the use of additives and by modifying the fatty acid composition of the basestock (Rudnick, 2006).

1.7. HOW TO PRODUCE BIOBASED HYDRAULIC FLUID USING CASTOR SEED

1.7.1 Castor Oil Extraction

Castor oil seed contains about 30%–50% oil (m/m) (Abitogun, 2009). Castor oil can be extracted from castor beans by either mechanical pressing, solvent extraction, or a combination of pressing and extraction (Mudhffar, 2010). After harvesting, the seeds are allowed to dry so that the seed hull will split open, releasing the seed inside. The extraction process begins with the removal of the hull from the seeds. This can be accomplished mechanically with the aid of a castor bean dehuller or manually with the hands. When economically feasible, the use of a machine to aid in the dehulling process is more preferable.

After the hull is removed from the seed, the seeds are then cleaned to remove any foreign materials such as sticks, stems, leaves, sand, or dirt (Abitogun, 2009). These materials can usually be removed using a series of revolving screens or reels. Magnets used above the conveyer belts can remove iron. The seeds can then be heated to harden the interior of the seeds for extraction. In this process, the seeds are warmed in a steam-jacketed press to remove moisture, and this hardening process will aid in extraction. The cooked seeds are then dried before the extraction process begins. A continuous screw or hydraulic press is used to crush the castor oil seeds to facilitate removal of the oil. The first part of this extraction phase is called prepressing. Prepressing usually involves using a screw press called an oil expeller. The oil expeller is a high-pressure continuous screw press to extract the oil.

1.7.2 Commercial continuous screw press assembly.

Although this process can be done at a low temperature, mechanical pressing leads to only about 45% recovery of oil from the castor beans (Muzenda, 2012).  Higher temperatures can increase the efficiency of the extraction. Yields of up to 80% of the available oil can be obtained by using high-temperature hydraulic pressing in the extraction process (Mudhaffar, 2010). The extraction temperature can be controlled by circulating cold water through a pressing machine responsible for cold pressing of the seeds. Cold-pressed castor oil has lower acid and iodine content and is lighter in color than solvent-extracted castor oil (Abitogun, 2009).  Following extraction, the oil is collected and filtered and the filtered material is combined back with new, fresh seeds for repeat extraction. In this way, the bulk filtered material keeps getting collected and runs through several extraction cycles combining with new bulk material as the process gets repeated. This material is finally ejected from the press and is known as castor cake. The castor cake from the press contains up to approximately 10% castor oil content (Abitogun, 2009). After crushing and extracting oil from the bulk of the castor oil seeds, further extraction of oil from the leftover castor cake material can be accomplished by crushing the castor cake and by using solvent extraction methods. A Soxhlet or commercial solvent extractor is used for extracting oil from the castor cake. Use of organic solvents such as hexane, heptane, or a petroleum ether as a solvent in the extraction process then results in removal of most of the residual oil still inaccessible in the remaining seed bulk.

1.7.3 Castor oil filtration/purification

Following extraction of the oil through the use of a press, there still remain impurities in the extracted oil. To aid in the removal of the remaining impurities, filtration systems are usually employed. The filtration systems are able to remove large and small size particulates, any dissolved gases, acids, and even water from the oil (Abitogun, 2009). The filtration system equipment normally used for this task is the filter press. Crude castor seed oil is pale yellow or straw colored but can be made colorless or near colorless following refining and bleaching. The crude oil also has a distinct odor but can also be deodorized during the refining process.

1.7.4 Castor oil refining

After filtration, the crude or unrefined oil is sent to a refinery for processing. During the refining process, impurities such as colloidal matter, phospholipids, excess free fatty acids (FFAs), and coloring agents are removed from the oil. Removal of these impurities facilitates the oil not to deteriorate during extended storage. The refining process steps include degumming, neutralization, bleaching, and deodorization (Muzenda, 2012; Mudhaffar, 2010). The oil is degummed by adding hot water to the oil, allowing the mixture to sit, and finally the aqueous layer is removed. This process can be repeated. Following the degumming step, a strong base such as sodium hydroxide is added for neutralization. The base is then removed using hot water and separation between the aqueous layer and oil allows for removal of the water layer. Neutralization is followed by bleaching to remove color, remaining phospholipids, and any leftover oxidation products. The castor oil is then deodorized to remove any odor from the oil (Akpan, 2006). The refined castor oil typically has a long shelf life about 12 months as long as it is not subjected to excessive heat. The steps involved in crude castor oil refining are further discussed in the next section.

1.8  AIMS AND OBJECTIVES

The aim of the present study is to determine the microbial implication on bio-based hydraulic fluid

The objectives are

·       To screen for the highest occurring microorganism.

·       To monitor the sample by checking for TVC, p^H and OD

·       To carry out some physiochemical tests on the sample.

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