Advances in Environmental Technology

Advances in Environmental Technology

Sustainable reclamation of transformer oils via tailored mesoporous γ-alumina: Oil regeneration and durability performance of adsorbents

Document Type : Research Paper

Authors
1 Department of Chemical Engineering, Faculty of Engineering, University of Sistan and Baluchestan, Zahedan, Iran.
2 Department of Materials and Metallurgical Engineering, Ferdowsi University of Mashhad, Mashhad, Iran.
Abstract
The large volumes of waste oils produced by electric power generation systems have heightened concerns about their disposal. As an alternative, the regeneration and reclamation of these oils are environmentally preferred. This study investigates the regeneration of contaminated transformer oil using mesoporous γ-alumina adsorbents synthesized from cost-effective boehmite. Two synthesis routes, thermal–chemical (TC) and chemical–thermal (CT), were evaluated using Taguchi’s L16 orthogonal array to optimize the preparation conditions. The performance of the synthesized adsorbents in oil regeneration was then assessed through a one-step batch adsorption process and multiple saturation cycles. Textural characterization by BET analysis identified the optimal TC-derived γ-alumina with a specific surface area of 226.76 m² g⁻¹, a pore volume of 0.25 cm³ g⁻¹, and an average pore diameter of 5.95 nm. The optimized adsorbent demonstrated superior physicochemical performance in treated oil, significantly improving the total acid number (TAN), dielectric dissipation factor (DDF), and electrical resistivity. In addition, it exhibited low mechanical erosion (3.35% within a particle size range of 0.710–0.850 mm), outperforming comparable commercial products (~7.04% erosion). FTIR and GC–MS analyses confirmed the effective removal of key contaminants, including 1,2-benzenedicarboxylic acid derivatives (diisooctyl ester and mono-(2-ethylhexyl) ester). Based on the latest literature, the comparison of thermal–chemical and chemical–thermal synthesis routes, along with their effects on pore-size distribution and the attrition strength of γ-Al₂O₃ adsorbents, represents a novel aspect of this study and warrants further investigation to maximize adsorption performance.

Graphical Abstract

Sustainable reclamation of transformer oils via tailored mesoporous γ-alumina: Oil regeneration and durability performance of adsorbents
Keywords
Subjects

[1]     Zheng, K., Li, W., Wang, W., Chen, H., Huang, C., Ren, Q., & Qin, C. (2019). Preparation and characterisation of carboxymethyl-chitosan/sodium phytate composite membranes for adsorption in transformer oil. International Journal of Biological Macromolecules, 132, 658–665.
[2]    Kim, T.-H., An, S. Y., & Gim, G. H. (2026). Electrical properties of liquid insulation oil under varying electrode shapes and temperatures. Korean Journal of Materials Research, 36(1).
[3]    Jia, Y., Luo, X., Ji, S., Zhao, D., Qiu, Z., & Li, S. (2025). Pressure and stress characteristics of transformer tank with power-frequency arc fault in oil. Thin-Walled Structures, 210, Article 112986.
[4]    Guerbas, F., Adjaout, L., & Abada, A. (2023). Accelerated thermal aging effect on the new and reclamation transformer oil behavior. In 2023 IEEE Electrical Insulation Conference (EIC) (pp. 1–4). IEEE.
[5]    Wang, Y., Ma, G., Gao, D., Wang, Y., Xie, Y., Gao, X., Du, H., & Ji, J. (2024). Transformer oil-dissolved methane detection based on non-adiabatic tapered fiber using polyacrylate and cryptophane-A overlay deposition. Sensors and Actuators B: Chemical, 400, Article 134869.
[6]   Yang, F., Zhou, L., Gui, Y., Tao, J., Zhang, J., Zhang, Q., & Xu, L. (2026). Adsorption performance of transition metal (Ag, Pb, and Ni)-modified ZrSe₂ monolayers toward dissolved gases (CO, CO₂, CH₄, and C₂H₄) in oil-immersed power transformers: A DFT study. Surfaces and Interfaces, Article 108471.
[7]    Chen, X., Chen, S., Yang, D., Luo, H., Yang, P., & Cui, W. (2021). Quantitative prediction of aging state of oil-paper insulation based on Raman spectroscopy. AIP Advances, 11.
[8]   Atanasova-Höhlein, I. (2021). IEC 60296 (Ed. 5)–A standard for classification of mineral insulating oil on performance and not on the origin. Transformers Magazine, 8, 86–91.
[9]   Zhu, H., Zong, C., Fang, L., Zhang, H., Sun, Y., Tian, Y., Zhang, S., & Wang, X. (2026). Intelligent machine learning-based spectroscopy for condition monitoring of energy infrastructure: A review focused on transformer oils and hydrogen systems. Processes, 14(2), Article 255.
[10] Mahankali, S., Velpula, R., & Rao, D. (2026). Experimental investigation of transformer fault diagnosis using integrated DGA and physical inspection. Electric Power Systems Research, 254, Article 112669.
[11]  Gherdaoui, C. E., Fontaine, H., Delbarre, J.-P., Debiak, R., Sansano, R., Hutin, O., & Roussey, A. (2025). Enhancing fumes catalytic treatment in transformer oil regeneration: A study on catalyst performances and process conditions. Journal of Environmental Chemical Engineering, Article 117181.
[12] Safiddine, L., Hadj‐Ziane Zafour, A., Fofana, I., Skender, A., Guerbas, F., & Boucherit, A. (2017). Transformer oil reclamation by combining several strategies enhanced by the use of four adsorbents. IET Generation, Transmission & Distribution, 11(11), 2912–2920.
[13] Fofana, I., Wasserberg, V., Borsi, H., & Gockenbach, E. (2004). Drying of transformer insulation using zeolite. IEEE Electrical Insulation Magazine, 20(1), 20–30.
[14] Hafez, A., Gerges, N., El-nagar, K., Mohamed, S., & Hashem, A. (2015). Reclamation of old transformer oil using kaolin clay. International Journal of Advanced Scientific and Technical Research, 4, 752–769.
[15] Laurentino, A., Parize, A., Laranjeira, M., Martins, A., Mayer, N., & De Favere, V. (2007). Regeneration of insulating mineral oil by carbonated amorphous calcium phosphate–chitosan adsorbent. Process Safety and Environmental Protection, 85(4), 327–331.
[16] Al-Zuhair, S., Noura, H., & Fardoun, A. (2011). Using activated carbon from waste date-pits as an adsorbent for transformer oil regeneration. In 2011 World Congress on Sustainable Technologies (WCST) (pp. 69–72). IEEE.
[17] Vu, T. T., La, T. V., Vu, M. K., Huynh, D. C., & Tran, N. K. (2020). Highly efficient adsorbent for the transformer oil purification by ZnO/graphene composite. Arabian Journal of Chemistry, 13(11), 7798–7808.
[18] Vu, T. T., La, T. V., & Vu, T. G. (2022). The highly efficient purification capacity of rGO-zeolite composites for aged oil in transformer machines. Arabian Journal of Chemistry, 15(3), Article 103683.
[19] He, F., Li, W., Pang, T., Zhou, L., Wang, C., Liu, H., Li, M., & He, X. (2022). Hydrothermal synthesis of boehmite nanorods from alumina sols. Ceramics International, 48(12), 18035–18047.
[20]           Huang, H., Wang, L., Cai, Y., Zhou, C., Yuan, Y., Zhang, X., Wan, H., & Guan, G. (2015). Facile fabrication of urchin-like hollow boehmite and alumina microspheres with a hierarchical structure via Triton X-100 assisted hydrothermal synthesis. CrystEngComm, 17(6), 1318–1325.
[21] Dinarvandi, K., Samimi, A., Mohebbi-Kalhori, D., Zakeri, M., & Zakeralhosseini, R. (2024). Synthesis of mesoporous γ-alumina from a low-grade boehmite ore: Effect of thermal/chemical processing order on physico-chemical characteristics of adsorbent and regeneration of used transformer oils. Chemical Engineering Research and Design, 209, 72–80.
[22]Li, M., Si, Z., Wu, X., Weng, D., & Kang, F. (2014). Facile synthesis of hierarchical porous γ-Al₂O₃ hollow microspheres for water treatment. Journal of Colloid and Interface Science, 417, 369–378.
[23]Spiridon, I., Apostol, I., Dinu, M. V., Anghel, N., & Doroftei, F. (2024). New porous adsorbents based on natural polymers for treatment of motor oil contaminated wastewaters. Journal of Polymer Science, 62(22), 5411–5423.
[24]Jankovic, J., Lukic, J., Planojevic, J., Kolarski, D., & Janackovic, D. (2022). Application of highly selective adsorbent in the removal of elemental sulfur and other corrosive sulfur compounds from mineral insulating oils. IEEE Transactions on Dielectrics and Electrical Insulation, 29(1), 54–61.
[25]Fei, K., Dong, Z. Y., Shi, L., Meng, X., & Liu, N. (2024). K₂CO₃-loaded γ-Al₂O₃ for acid removal in waste transformer oil. Asia-Pacific Journal of Chemical Engineering, 19(2), Article e3016.
[26]           Bekele, E. A., Korsa, H. A., & Desalegn, Y. M. (2024). Electrolytic synthesis of γ-Al₂O₃ nanoparticle from aluminum scrap for enhanced methylene blue adsorption: Experimental and RSM modeling. Scientific Reports, 14, Article 16957.
[27]Abdollahi, M., Atashi, H., & Tabrizi, F. F. (2017). Parametric investigation of γ-alumina granule preparation via the oil-drop route. Advanced Powder Technology, 28(5), 1356–1371.
[28]           Kermani, M., Samimi, A., Mohebbi-Kalhori, D., Beigmoradi, R., Shokrollahzadeh, S., Xia, A., Sun, C., Sun, F., Ashori, A., & Madadi, M. (2024). Pulsed electric field treatment for efficient oil extraction from Nannochloropsis salina microalgae: A green and sustainable approach. Journal of Polymers and the Environment, 32, 5888–5901.
[29]           Walkowicz, J., Staśkiewicz, J., Szafirowicz, K., Jakrzewski, D., Grzesiak, G., & Stępniak, M. (2013). Optimization of the ASPN process to bright nitriding of woodworking tools using the Taguchi approach. Journal of Materials Engineering and Performance, 22, 410–420.
[30]           Koppenol, W. H., Stanbury, D. M., & Bounds, P. L. (2010). Electrode potentials of partially reduced oxygen species, from dioxygen to water. Free Radical Biology and Medicine, 49(3), 317–322.
[31] Armstrong, D. A., Huie, R. E., Koppenol, W. H., Lymar, S. V., Merényi, G., Neta, P., Ruscic, B., Stanbury, D. M., Steenken, S., & Wardman, P. (2015). Standard electrode potentials involving radicals in aqueous solution: Inorganic radicals (IUPAC Technical Report). Pure and Applied Chemistry, 87(11–12), 1139–1150.
[32]Schull, C. (1948). The determination of pore size distribution from gas adsorption data. Journal of the American Chemical Society, 70(4), 1405–1410.
[33]Wen, J., Yuan, R., Jiang, T., Yu, T., & Zhang, Y. (2024). Solvothermal synthesis and adsorption performance of layered boehmite using aluminum chloride and high-alumina fly ash. Chinese Journal of Chemical Engineering, 70, 280–290.
[34]           Edwards, M., Russell, R., Shimskey, R., & Peterson, R. (2010). Bench-scale testing of the continuous sludge leaching process. Separation Science and Technology, 45(12–13), 1807–1813.
[35]Han, X., Wang, Y., Zhang, N., Meng, J., Li, Y., & Liang, J. (2021). Facile synthesis of mesoporous silica derived from iron ore tailings for efficient adsorption of methylene blue. Colloids and Surfaces A: Physicochemical and Engineering Aspects, 617, Article 126391.
[36]           Hao, J., Wang, X., Wang, Y., Guo, F., & Wu, Y. (2022). Optimization, kinetic studies of tin leaching from waste printed circuit boards and selective tin recovery from its pregnant solution. Metals, 12(6), Article 954.
[37]Behmadi, R., Mokhtarian, M., Ghadrian, K., Davoodi, A., & Hosseinpour, S. (2022). Development of a low-cost activated mesoporous bauxite for the reclamation of used transformer oil. Separation and Purification Technology, 280, Article 119826.
[38]           Soni, P., Sur, A., Gaba, V. K., & Sah, R. P. (2025). Review on improvement of adsorption refrigeration systems performance using composite adsorbent: Current state of art. Energy Sources, Part A: Recovery, Utilization, and Environmental Effects, 47(1), 8031–8055.
[39]           Elele, U., Nekahi, A., Arshad, A., & Fofana, I. (2022). Towards online ageing detection in transformer oil: A review. Sensors, 22(20), Article 7923.
[40]           Soni, R., & Mehta, B. (2021). Review on asset management of power transformer by diagnosing incipient faults and faults identification using various testing methodologies. Engineering Failure Analysis, 128, Article 105634.
[41] Zhang, J., Guo, Y., Pau, D., Li, K., Xie, K., & Zou, Y. (2021). Pyrolysis kinetics and determination of organic components and N-alkanes yields of Karamay transformer oil using TG, FTIR and Py-GC/MS analyses. Fuel, 306, Article 121691.
[42]Wan, F., Du, L., Chen, W., Wang, P., Wang, J., & Shi, H. (2017). A novel method to directly analyze dissolved acetic acid in transformer oil without extraction using Raman spectroscopy. Energies, 10(7), Article 967.
[43]           Kalathiripi, H., & Karmakar, S. (2017). Analysis of transformer oil degradation due to thermal stress using optical spectroscopic techniques. International Transactions on Electrical Energy Systems, 27(9), Article e2346.
[44]           Meena, R. R., Chaki, S., Khimani, A. J., & Deshpande, M. (2018). Transformer oil degradation study by chromatography, spectroscopy and dissolved gas analysis. Petroleum & Coal, 60.
[45]           Abi Munajad, C. S. (2018). Fourier transform infrared (FTIR) spectroscopy analysis of transformer paper in mineral oil-paper composite insulation under accelerated thermal aging. Energies, 11(2), Article 364.
[46]           Darwish, M. M., Hassan, M. H., Abdel‐Gawad, N. M., Lehtonen, M., & Mansour, D. E. A. (2024). A new technique for fault diagnosis in transformer insulating oil based on infrared spectroscopy measurements. High Voltage, 9(2), 319–335.
[47]Pillai, S. S., Aarathy, A., Gopinath, D., Aryanandiny, B., & Sankar, B. (2020). Effects of magnetite and titania nanoparticles on properties of transformer insulating oil. Nano Express, 1(2), Article 020040.
[48]           Oparanti, S. O., Salaudeen, I. K., Adekunle, A. A., Oteikwu, V. E., Galadima, A. I., & Abdelmalik, A. A. (2023). Physicochemical and dielectric study on Nigerian Thevetia peruviana as a potential green alternative fluid for transformer cooling/insulation. Waste and Biomass Valorization, 14, 1693–1703.
[49]           Wang, Y., Dou, P., You, X., Liu, Q., Fei, Z., Chen, X., Zhang, Z., Tang, J., Cui, M., & Qiao, X. (2023). Naphthenic acids removal from model transformer oil by diethylamine modified resins. Molecules, 28(6), Article 2444.
Volume 12, Issue 4
Issue in Progress
Autumn 2026
Pages 491-511

  • Receive Date 20 February 2026
  • Revise Date 13 August 2026
  • Accept Date 18 July 2026