Process gas lubricants for improved reliability and profitability.
Navigating the complexities of gas compressor lubrication: Why expertise matters in selecting the right solution for your application.
Industry Insight
Process gas compressors impose unique lubrication challenges. Process gases often thin and contaminate oils; for example, fresh compressor oil at 150 cSt may dilute to only 18 cSt after exposure. Dissolved hydrocarbons and entrained contaminants (like H2S, moisture, particulates) create sludge and corrosion, while oil carryover can foul downstream equipment and violate emissions rules. In reciprocating cylinders, conventional oils can simply be washed off cylinder walls or form deposits that plug injectors and foul valves. These effects diminish film strength, accelerate wear and drive unscheduled shutdowns. With volatile energy prices and regulatory pressures, reliability is paramount; even a single compressor outage risks costly flaring penalties and lost production.
High performance synthetics are now best practice. Modern compressor oils use tailored bases and additives to resist gas absorption and extreme conditions. For instance, PAG-based compressor oils remain extremely resistant to hydrocarbon dilution compared to mineral lubricants. Such oils have a very high viscosity index, giving stable film strength over wide temperature swings. Compatibility is also key: oils are selected to avoid adverse reactions and to match seal materials. In short, the right oil choice – guided by gas analysis and OEM specs – is critical for reliability.
By combining high performance oils with proactive condition monitoring and proper housekeeping, plant managers can maximise uptime while cutting maintenance costs and environmental impact.
There are various issues that could occur if the right lubricant is not used. They are:
- Viscosity Dilution
- Foaming
- Gas Entrainment
- Oil Carryover
- Acid Gas
- Sour Gas
- Chemical Reactivity
- Water Contamination
- Corrosion
- Increased Wear Rates
- Cold Weather Flow
- Non-flammable products
- Non-toxic substances
- No VOC materials or chlorine
- Chemically intert and silicone-free
- Compatability with a wide range of elastomers
- Compatability with many chemicals
Klüber’s Perspective
Klüber Lubrication offers a proven range of lubricants and services designed around these challenges – engineered for the most demanding gas compositions and conditions.
Precision Lubrication for Every Gas Stream
From refineries and chemical plants to biogas facilities and vapor recovery units, no two gas streams are the same. Each stream presents its own set of challenges – and demands a tailored lubrication solution.
Klüber understands this complexity. That’s why we’ve developed and analysed the solubility tendencies of individual gases in our lubricating oils. This allows us to recommend the ideal gas compressor lubricant for your specific application – no matter the industry.
Our lubricants deliver measurable benefits. In field use, they have significantly reduced downtime and maintenance costs. Customers report extended oil drain intervals, reduced waste oil disposal, and reduced TCO (total cost of ownership). Klüber’s oil analysis service also helps catch problems before they escalate, supporting predictive maintenance.
At Klüber, we partner with OEMs and plants to optimise compressor lubrication. The outcome of our work is clearer compressor performance data, reduced unplanned outages, and quantifiable sustainability gains.
Optimise performance. Minimise downtime. Together Beyond Lubrication.
For more details click here.
CONTACT
Bilal Al-Khanchi
Area Sales Manager – North East & Scotland
Klüber Lubrication GB Ltd
Mobile: +44 7542 027583
Email: bilal.alkhanchi@klueber.com
LinkedIn: Bilal Al Khanchi
or visit klueber.com/de/en/industry-solutions/components/compressors/gas-compressor-oil/
