Grease & Lubricant Industry – Move towards Sustainability using Circular Economy & Tribology Principles

The Oil and Gas industry plays a pivotal role in the global energy systems, with lubricants and greases serving as critical elements in the efficient operation of machinery in all sectors. Each year, over 40 million metric tons (MMTs) of lubricating oil are produced. A portion of this oil is either burned, consumed during use, or spilled, leaving roughly 22 MMT available annually as feedstock for recycling. Globally, about 68% of this oil is collected, although collection rates vary significantly depending on regional legislation. From this collected oil, approximately 40% can be re-refined into new products, yielding around 4 MMT of re-refined base oils each year.

The UN's definition of sustainable development is “a development that meets the needs of the present without compromising the ability of future generations to meet their own needs.” This concept prioritizes sustainability. In the case of lubricant/grease manufacturing & marketing organizations, technology and product management teams across the board need to keep sustainability in mind as it comes under scrutiny from governments, original equipment manufacturers, consumers and stakeholders.

To measure sustainability profiles, lubricant/grease formulators must perform life cycle assessments ensuring that products are being sourced, produced and handled responsibly and efficiently, minimizing the carbon footprint while preserving and protecting natural resources.

To help define direct and indirect emission sources, improve transparency, and provide utility for different types of organizations, climate policies and business goals, three “scopes” (scope 1, scope 2, and scope 3) are defined for GHG (Green House Gases) accounting and reporting purposes. Organizations shall, at a minimum, separately account for, and report on, Scopes 1 and 2.

• Scope 1Direct GHG emissions that occur from sources owned or controlled by the organizations.
  For example, emissions from combustion in owned or controlled boilers, furnaces, vehicles, etc.; emissions from chemical production in owned or controlled process equipment.
• Scope 2Accounts for GHG emissions from the generation of purchased electricity consumed by an organization. Purchased electricity is defined as electricity that is purchased or otherwise brought into the organizational boundary. Scope 2 emissions physically occur at the facility where electricity is consumed.
• Scope 3 This is an optional reporting category that allows for the treatment of all other indirect emissions. Scope 3 emissions are a consequence of the activities of the organization but occur from sources not owned or controlled by the organization. The use of products and services by end consumers is a largely accepted example of scope 3 activities of carbon emission.

The lubricant/grease manufacturing & marketing organizations aim to achieve net zero on emissions generated by all by 2050 in alignment with India's sustainability goals. To achieve net-zero Scope 1 and 2 GHG emissions, organizations must set targets to reduce absolute emissions from a 2016 baseline and develop a roadmap that incorporates various reduction measures. Strong emphasis on circular economy and tribology principles are essential components for this success.

The adoption of a circular economy within the lubricants and greases sector is revolutionizing the way we approach sustainability in the oil and gas industry. Central to this transformation is tribology—the science of friction, lubrication, and wear. Tribology provides crucial insights into optimizing lubricant performance, extending the lifespan of machinery, and reducing environmental impact. Through a tribological perspective, we recognize the immense potential for improving the sustainability of lubricants and greases, not only from an efficiency standpoint but also through substantial ecological benefits.

Circular Economy and Sustainability: Re-defining Lubricant and Grease Production

Re-refining waste oil into new base oils presents numerous sustainability advantages, particularly when viewed through a tribological lens. This process supports the efficient use of resources, reduces energy consumption, and mitigates the environmental impact associated with lubricant and grease production.

3. Conservation of Fossil Petroleum: Re-refining waste oil helps preserve finite fossil petroleum resources. By utilizing regenerated oils, we reduce the need for crude oil extraction, ensuring a more sustainable future for lubricant and grease production. This aligns with the principles of sustainability in tribology, where the aim is to minimize resource consumption and wear, optimizing efficiency across industrial processes.

4. Reduced Carbon Footprint:Re-refined base oils have a significantly lower carbon footprint compared to crude-derived oils, with reductions ranging from 50-90%. This is particularly crucial for industries with high friction and wear, where sustainable lubricants significantly reduce the environmental impact of machinery and operations.

The Groupement Européen de l'Industrie de la Régénération (GEIR)'s Life Cycle Assessment Report (2022) on re-refining waste oil highlights the environmental benefits of the circular economy approach:
● 64% reduction in CO2 emissions
● 86% reduction in resource usage
● 88% reduction in fine particulate emissions (PM 2.5)

These figures reflect the profound environmental impact of transitioning to a circular economy model, underpinned by efficient tribological practices.

Pioneering Sustainable Lubricant and Grease Manufacturing

It is time the companies start manufacturing sustainable lubricant and grease by embracing sustainability through a comprehensive series of forward-thinking initiatives at the ground zero. These initiatives will demonstrate environmental stewardship and its proactive approach to reducing its ecological footprint. Some key sustainability initiatives may include:

3. Carbon Footprint Measurement and Reduction:Companies should start establishing a rigorous framework for measuring and tracking their carbon footprint, ensuring that all aspects of operations are optimized for minimal environmental impact. Include continuous improvements in energy efficiency, process optimization, and the integration of green technologies—all of which contribute to the sustainability of lubricants and greases.

4. Extended Producer Responsibility (EPR): ): To comply with EPR regulations, it's important to prioritize environmentally sound management of used oil by utilizing re-refining processes or obtaining energy recovery certificates from registered recyclers. This practice ensures responsible disposal and recycling of spent lubricants, aligning with circular economy principles.

Sustainable Lubricants: Reducing Environmental Impact through Tribological Innovation

Focus on key R&D initiatives dedicated to advancing Innovation and sustainable lubrication solutions by reducing greenhouse gas emissions and the carbon footprint of lubricants. Formulate premium products that balance high performance with environmental considerations:

1. Reduction in CO2 Emissions: Developing a new line of lubricants that incorporate 30-50% regenerated base oils, resulting in a 20-30% reduction in CO2 emissions, is essential. These lubricants should also demonstrate improved tribological performance, offering superior friction reduction and reduced wear, which prolongs equipment lifespan and minimizes resource consumption.

2. Optimized Resource Utilization: By utilizing regenerated base oils, achieve a 25-40% reduction in resource consumption compared to traditional lubricants. This reduction is pivotal in decreasing the overall demand for virgin base oils and minimizing the energy required for their production, thereby supporting sustainability efforts across industries.

3. Minimized Particle Generation:The use of regenerated base oils results in a 25-40% reduction in particle generation, which is critical for industries where precision and low wear are essential. Fewer particles mean less wear on machinery, leading to better operational efficiency and reduced maintenance costs.

Sustainable Greases: Cutting-Edge Solutions for Tribological Efficiency

Develop greases that not only excel in performance but also contribute to a reduction in greenhouse gas (GHG) emissions and environmental harm. Some range of advanced greases incorporate innovative tribological technologies designed to enhance performance and sustainability:

1. Special Energy Efficient Greases: The Special Energy Efficient Grease technology has demonstrated impressive tribological benefits, including:
o Reduction in bearing temperature
o Reduction in the coefficient of friction
o Reduction in power consumption
These improvements contribute to better energy efficiency, reduced wear, and a lower environmental impact on industrial operations.

2. Biodegradable Greases:Biodegradable greases, based on vegetable-origin esters, offer a minimum of 60% biodegradability for various applications. These greases reduce water and soil contamination, ensuring that sustainability is not sacrificed for performance.

3. Non-Lithium Greases:These greases provide excellent performance across various applications, ensuring long service life and reduced reliance on critical resources like lithium.

4. Long-Life Lithium Complex Greases: introducing a high-performance solution with an extended service life of over 300,000 km for on-road vehicles, while also being suitable for off-highway equipment. This helps achieve sustainability goals by reducing replacement frequency and overall consumption.

Conclusion: Forging a Sustainable Future in Lubricants and Greases

Companies must take the lead in transitioning to more sustainable lubricant and grease solutions, setting new benchmarks for environmental responsibility and performance. By embracing circular economy principles, they can not only reduce their environmental footprint but also enhance the efficiency and longevity of their products. Moreover, by embracing innovations in renewable energy, regenerated oils and advanced tribological technologies, companies can create a sustainable future for the oil and gas industry—one where eco-friendly solutions become the norm rather than the exception.

The transition to bio-lubricants and re-refined base oils represents a critical shift toward more sustainable industrial practices. Only through unwavering focus on sustainability, all players across the globe can continue to demonstrate how the oil and gas industry can thrive while reducing its environmental impact, ensuring that future generations can benefit from a healthier, more sustainable planet. Adopting these methodologies will enable lubricant and grease manufacturers to achieve a sustainable future and achieve NET ZERO status in the next 20-30 years.