You are worried about the issue of water sneaking into hydraulic oil? All of us know it’s a huge problem. Because it drags down efficiency, cuts the hydraulic system’s lifespan, and messes with performance. So, getting that water out becomes super important. To learn the types of handy additives that keep that water far, far away, this article is for you!
Why Does Water End Up in Hydraulic Systems?
It gets in through high humidity, condensation, or even direct exposure in watery operating environments. Sometimes, seals, fittings or hoses leak and water slides in during operation. It’s not always easy to spot.
Because if you’ve got equipment working in damp environments, or the hydraulic fluid is being stored improperly, it will be hard to know. Even just a poorly sealed cap can lead to contamination. Another common entry point for water is through system breaches. Breaches like cracked seals, worn-out gaskets, or loose reservoir caps provide the perfect gateway for water to get inside.
What are the Consequences of the Presence of Water in Hydraulic Oil?
When water stays in hydraulic oil, the oil loses its protective thickness. It means components get worn down faster. Plus, water means rust, and rust means metal pitting and precision parts going to wear. If it gets worse, microbes find water delightful, turning oil into sludge, acids, and more problems.
With all this happening in the hydraulic system, you end up with corroded parts and less efficient systems. The hydraulic systems will consume more energy which will further shorten the life of your equipment.
Water will cause cavitation in the system under high pressure which will also damage the system. Furthermore, water speeds up the oxidation process that turns the hydraulic oil into a mess of acids and varnish deposits.
Additives for Water Removal from Hydraulic Oil
All hydraulic problems have solutions. Luckily, there are specially-made additives that kick water out of your hydraulic oil. Below you can learn about some of these champions.
Zinc Additives – ZDDP (Zinc Dialkyl-Dithiophosphate)
Zinc-based additives play double duty: they fight against wear and help split water out of oil. ZDDP helps break emulsions and even adds a protective layer to metal, keeping rust at bay. But you need to check for compatibility first. Because ZDDP sometimes reacts with other system materials.
These ZDDP additives also have a thermal stability factor, which means they remain effective even under high temperatures, reducing the risk of deposit build-up. But keep in mind, that some oil filters struggle to handle it, and sensitive components might react poorly.
Demulsifiers – Polysiloxanes, Polyethylene Glycols
If you found that the system got an emulsion? Demulsifiers break it up. When water is finely mixed in oil, chemicals like polysiloxanes change how the oil and water interact, making water drop out and settle at the bottom. Simple enough to then drain the water, right?
Demulsifiers such as Polysiloxanes and Polyethylene Glycols are perfect for big, obvious water issues and work smoothly with typical filtration systems. They’re most effective in systems where water exists as free or emulsified droplets rather than dissolved.
Water Absorbing Additives – Calcium Sulfonate, Silica Gel
These additives are like sponges. They pull water in and keep it trapped. So, you do not need downtime as these additives will keep working continuously. Calcium Sulfonate and Silica Gel are ideal for keeping water levels down and prolonging system and oil lifespan.
Calcium sulfonate additives, for example, contain hydrophilic components that attract water molecules and bind them into a gel-like consistency. This process is particularly helpful for getting rid of dissolved water that standard filters can’t easily handle.
One of the big pluses is that these additives don’t need the system to be stopped to work. You can add them, and they get busy, making sure even trace amounts of water are held in place until it’s time for an oil change. This is especially useful in systems with minor but persistent water issues.
Anti-Emulsifiers – Alkyl Phenol-Formaldehyde Resins
Worried about emulsions forming in the first place? Use anti-emulsifiers. They make water droplets tough to mix in, perfect for systems dealing with humid conditions. Keeps everything running smooth and clean.
Anti-emulsifiers such as Alkyl Phenol-Formaldehyde Resins essentially alter the surface properties of water droplets. It reduces their ability to stick around and fewer opportunities for water to emulsify with oil. If your machinery operates in particularly wet or humid areas, these agents are game-changers.
Coalescing Agents – Polyoxyalkylene Glycols, Amine Salts
These (Polyoxyalkylene Glycols and amine Salts) help tiny water drops merge into bigger ones, making them easier to remove. They’re awesome when water is finely mixed in and traditional methods fall short.
These additives behave as magnets pulling small droplets together until they’re big enough to separate. Once the droplets coalesce into larger ones, they naturally settle out of the oil, making removal far simpler. This is especially beneficial in systems where filtration is used as part of routine maintenance.
Hydrophobic Agents – Organosilicon Compounds, Fluoropolymers
You can use hydrophobic agents when you want the oil to outright reject water. These agents do that. They make oil and water like repelling magnets so that they simply won’t stay mixed. These additives are great for systems that are exposed to frequent moisture.
These agents work by forming a protective coating around oil molecules, almost like wrapping them in a raincoat. This reduces the overall affinity of the oil for water, preventing new contamination from becoming an issue.
These additives are particularly effective in outdoor environments with heavy exposure to moisture.
How to Use These Additives Right
Assess Water Contamination Levels
Firstly, know how much water is in your hydraulic system. You can do tests like Karl Fischer titration or on-site water sensors to assess water contamination levels.
Select the Right Additive
Use lab testing data to help you decide to pick the additive. If there’s a lot of free water? Try a demulsifier. For small water issues, a water absorber is fine. The key is choosing the right additive here.
Apply the Additive
Mix in the additive based on the manufacturer’s guide. Make sure it’s well-distributed. This is essential because you don’t want pockets of untreated oil. Use system agitation or oil circulation to make sure everything’s mixed in thoroughly. If you can, keep the system running for a while to help blend the additive completely.
Monitor and Drain
Then, keep an eye on it and drain any separated water. Also, change filters to maintain oil quality. If you’re using demulsifiers, regularly check for water accumulation at the bottom of the reservoir. Remove it promptly to prevent any chances of recontamination.
Filter and Replace
For continuous absorbers, regularly monitor the water content and check if the additive capacity is maxed out. Filters may also need to be changed more often, especially if the water contamination was significant initially. This extra step ensures that the oil remains pure and effective for longer.
Conclusion – A Water free Hydraulic System
Water in hydraulic oil can be catastrophic if ignored. But with the right additive, whether it’s demulsifiers, coalescers, or absorbers, you can keep everything running smoothly. It’s all about matching the right solution to your specific problem. Keep your equipment safe, and efficient, and extend its service life with these proactive measures.
If you have any questions or need more details on a particular additive, reach out to Hydraflu.
