Development High Duty Performance Engine Oil

Development of High
Performance Heavy Duty

Engine Oils
Frank Lauterwasser
Chevron Oronite LLC
August 6, 2009
2009 Chevron Oronite Companies. All rights reserved.

Pressures on the OEMs
Main Drivers for New HD Diesel Engine Technology
Globalization Performance
Fuel
Performance Economy
Emissions
Compliance
New
Reliability Reliability Hardware,
Fuel, Oils
Operating Operating
Costs Costs
The Old Days Today
2
Challenge of Emission Compliance
ULSD
3
Drivers For Increased Biodiesel Use In U.S.
Growth will no longer be based solely on relative economics
700
600
Renewable Fuel State
Standard (RFS) Biodiesel
500 Mandates
400
300
Light Duty B20 Low Carbon Fuel
200 CAF Credits Standard (LCFS)
100
0
2000 2001 2002 2003 2004 2005 2006 2007 2008
4
Biodiesel Use Can Challenge Conventional
Diesel Engine Oils
Engine deposits and

lead corrosion
5
Fuels, Lubricants, Additives and After-treatment
Changes to Achieve Heavy Duty Emissions Targets
Low Ash
Engine Engine Oil
Engine
Oil Additives
Heat Tolerance Low SAPs
EGR
Advanced Injection System Volatility Oxidation Inhibitors
Base Oil Change

Diesel Particulate
Filters Low Emissions
Low Sulfur
Fuel
Base Oil
Ultra-Low Additive
Sulfur NOx abs
Diesel Fuel Low Phosphorous

Additive
DeNOx cat
Urea
Additive
Lubricity and SCR
Cold Flow Additive Emissions Catalysts
6
API CJ-4: Most Robust Heavy Duty Engine Oil*
CJ-4 oils allow the use of EGR, DPF to reach the low emission
compliance for 2007
Low SAPs level to enable the use of after treatment system
Low ash level 1.0 for DPF protection
Higher stress on the oil due to EGR
Copyright Johnson Matthey Pic 2005
2010 Emission Regulation (no new category)

Lower NOx (SCR and EGR, or higher EGR rate)
Particulates matters stay at the 2007 limit
ULSD 15 ppm on and off highway
Oil for 2010 emission regulation: CJ-4 oil low SAPs (1.0 ash limit)
15W40 and 10W30 (fuel economy) available
James A. McGeehan, Chairman of ASTM Heavy Duty Engine Oil Classification Panel
James A. McGeehan et al, SAE 2009-01-1781 (DPF)
Wim van Dam et al, SAE 2009, submitted (fuel economy) 7
CO2 Emissions Regulations in U.S. Future?
Greenhouse Gas by
U.S. Economic Sector
2,500
2,000
Million Metric Tons
1,500
1,000
500
0
1990 1995 2000 2005
Electricity Generation Agriculture

Transportation Commercial
Source: Transport Topics
Industry Residential
Source: Environmental Protection Agency
8 8
Active and Pending HD Fuel Economy Regulations
Japan
First Truck Fuel Economy Standards in the World
Fully Implemented in 2015

Based on engine dynamometer test
Fuel economy assessed at various operating conditions and parameters
United States
Truck Fuel Economy Standards included Energy Independence and Security
Act of 2007
Study in progress to establish regulations and criteria not likely
simple mpg, probably ton-miles/gallon or some other measure
Likely to me implemented in 2016/2017
CO2 emissions regulations may be implemented earlier
Europe
No current Truck Fuel Economy Standard, but CO2 emissions
considered when establishing NOx and Particulate Emissions limits in
EURO 6
9
The Impact of Biodiesel Use on the
Lubrication of Diesel Engines
Presented by
Frank Lauterwasser
Chevron Oronite Technology
Authors
Maarten Boons
Walter Hartgers
Frank Lauterwasser
Michelle Morcos
Gary Parsons
The Role of Renewables
Chevron Views
The world needs all kinds of energy
sources Oil, gas, unconventionals
and renewables To meet growing
demand in an environmentally sound
manner
Developing infrastructure to produce
and distribute new forms of energy
such as biofuels on a large scale will
be a significant challenge
Our goal is energy solutions that are
practical, innovative and enduring
11
Non-Food Biofuels Technology Pathways
Biotechnology
Routes
Catalytic Transportation
Biomass
Routes Fuels
Thermochemical
Routes
12
Biodiesel is a Global Phenomena
Norway
Canada Fish Oil
Fish Oil
Tallow
Asia
Jatropha
Europe Cooking Oil
Rape Seed
United States India

Soy Jatropha
Tallow
Cooking Oil
Philippines
Thailand & Coconut
Brazil Malaysia
Soy Palm Indonesia
Mamouna (plant) Palm
Ecuador Babsoo (nut)
Palm
Latin
America
Jatropha Argentina Australia/New Zealand
Soy Sheep Marrow
Tallow
13
Biodiesel Feedstock Properties Impact
Performance
100%
90%
80% Higher Cetane
70%
60%
50% Better Cold Flow
40%
30%
20% Better Oxidation Stability
10%
0%
e
er
t
m
t
rd
an
w
n
er
ha
ed
fa
u
nu
li v
or
ee
l lo
al
on
w
ow
La
be
op
se
er
O
ea
P
es
lo
Ta
oc
tt
n
y
tr
fl
nf
ap
to
So
u
f
Ja
C
Sa
f
Su
ee
ot
R
C
B
Saturated Fat Monounsaturated Fat Polyunsaturated Fat
Source: NREL
14
OEM Biodiesel Issues & Concerns
Fuel System Emissions Systems
Injector deposits Impact on after-treatment

devices and sensors
Fuel filter plugging
Impact on NOx emissions
Injection pump durability
Lower BTU content
Materials incompatibility and fuel economy
Fuel Instability
Lubricant Performance
Low temperature handling
Fuel dilution
May reduce detergency
and anti-foam properties Corrosion
of fuel additive
Viscosity change
packages
Oxidation
Piston Deposits
Crankcase Deposits
15
Crankcase Fuel Dilution With Biodiesel
Surface Tension
Diesel normal
droplet size
Specific Gravity
Viscosity, cSt @ 100C Larger fuel spray

droplet size
Properties of biodiesel lead to

higher levels of fuel dilution
16
Late Post-Injection Leads to Higher Levels of
Fuel Dilution
Conventional Late Post
Injection Timing Injection
Increased
Wall Wetting
Fuel Enters
Crankcase
Some OEMs have reported 15-20% fuel dilution (FAME) at

oil drain
OEMs often reduce drain intervals when biodiesel is used
17
Crankcase Fuel Dilution With Biodiesel
Higher and Narrower boiling range of biodiesel makes it more

persistent once it enters the crankcase 100
80
Mass %
60
40
20
0
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Carbon Number
Soy Methyl Ester
12
10
Mass %
6
0
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
Carbon number
There is a need for a robust analytical method to
measure biodiesel content in used engine oils Mineral Diesel
18
Oil Dilution During Particulate Trap
Regeneration
Biodiesel
Fuel Dilution
Mineral Diesel
Mileage
19
Biodiesel Fuel Dilution Measurement By GC-
FID
Accurate fuel dilution measurement is important for R&D
Oil
Typical
Petro
Used Oil
Sample
B100
GC-FID Measurement is Confounded in Used Oil
Michelle Morcos et al., SAE 2009 submitted 20

Fuel Dilution
Results From OEM Field Test Samples

Oxidation
Soot
21
Cummins High Temperature Corrosion Bench
Test
API / ACEA / Cummins Require HTCBT ASTM D6594 for Heavy Duty Diesel Oils
High Temperature Corrosion Bench Test

Air bubbling at 10 l/h through 150 ml sample
No Catalyst
Temperature 135C
4 metal strips are submerged
Copper
Lead
Tin
Phosphor Bronze
Duration 168h
EOT oil samples checked for
Cu,Pb and Sn Increase
Copper Strip Rating at EOT
22
Lubrication Aspects Corrosion
B100 Fuel Dilution Rapeseed Used Oil Pb
Impact on Lead and Copper Corrosion Rapeseed Used Oil Cu

1000
20 wt% B100 dilution
gives 9000 mg Pb
900
800
HT-CBT Pb & Cu numbers (ppm)
Used oil Pb
700
600
500
400
300
Reference with Used oil Cu
200 6 wt% diesel fuel
100
API CJ-4 pass limit on HT-CBT
0
0 5 10 15 20 25
Wt % B100 in Lubricant
23
Mack T-12 Standard Engine Test
Mack T-12 is a 300-hr test run in Mack E-7E-tech 460-HP

engine with high EGR
Test is part of API CJ-4, as well as Mack EO-O specification
First 100 hr are at rated speed

and power
Last 200 hr are over-fueled at

peak torque to maximize wear rates
Primary purpose is evaluation of

Mack T-12
oxidation, Pb corrosion, and liner
High EGR - 100 Hr
and ring wear resistance High EGR - 200 Hr
15 ppm
Fuel Sulfur
24
Oil Oxidation and Lead Corrosion Mineral Diesel (15 ppm)
B20 = Soy
Identified With Biodiesel Blend Use
Pb2
35.0
Pb
BETTER
30.0
25.0
Lead (ppm)
20.0
Rapid rise in lead corrosion with SME B20
15.0
10.0
5.0
0.0
0 25 50 75 100 125 150 175 200 225 250 275 300
Hours
Reference Impact Of Biodiesel Use on the Lubrication of Diesel Engines,
Gary Parsons, 13th Annual Fuels & Lubes Asia Conference 2007
25
Mack T-12 Parameter Comparison
API CJ-4 Heavy Duty Engine Oil
ULSD
BETTER
B20 = Soy
Oil Ring Cylinder Lead Lead 2

Consumption Weight Loss Liner Wear
26
Biodiesel Blend Engine Oil Formulation
Performance
600 Total Mack Merits

Core Lubricant (CH-4) 1439
A P I C I-4 P lu s M a c k M e rits
500
BETTER
Biodiesel Formulation 1394
400
300
200
100
0
Lead 1 Lead 2 Ring Weight Cylinder Liner Oil
Loss Wear Consumption
Core Lubricant (CH-4) Biodiesel Formulation
Mineral Diesel B20 = Palm
Excellent Mack T12 Pass on B20 Palm Methyl Ester
27
Summary
FAME biodiesel will likely remain a part of the global diesel
pool for the coming years
Mandates, energy independence, supports local agriculture
Low capital investment, low complexity plants
New FAME technology being developed
Use of biodiesel can lead to lubrication issues

High and persistent fuel dilution
Oil oxidation and bearing corrosion
Piston deposits
Specific methods were developed for biodiesel fuel dilution

method
Specially formulated lubricants can enable safe biodiesel use

An Oronite additive booster is available
28

Development High Duty Performance Engine Oil

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Development High Duty Performance Engine Oil

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Copyright:

Formati disponibili

Development of High

Performance Heavy Duty

2009 Chevron Oronite Companies. All rights reserved.

The Old Days Today

Engine deposits and

Base Oil Change

Diesel Fuel Low Phosphorous

Cold Flow Additive Emissions Catalysts

Copyright Johnson Matthey Pic 2005

2010 Emission Regulation (no new category)

Electricity Generation Agriculture

Fully Implemented in 2015

United States India

Injector deposits Impact on after-treatment

Viscosity, cSt @ 100C Larger fuel spray

Properties of biodiesel lead to

Some OEMs have reported 15-20% fuel dilution (FAME) at

Higher and Narrower boiling range of biodiesel makes it more

Soy Methyl Ester

Accurate fuel dilution measurement is important for R&D

GC-FID Measurement is Confounded in Used Oil

Michelle Morcos et al., SAE 2009 submitted 20

Results From OEM Field Test Samples

High Temperature Corrosion Bench Test

B100 Fuel Dilution Rapeseed Used Oil Pb

Impact on Lead and Copper Corrosion Rapeseed Used Oil Cu

Mack T-12 is a 300-hr test run in Mack E-7E-tech 460-HP

Test is part of API CJ-4, as well as Mack EO-O specification

First 100 hr are at rated speed

Last 200 hr are over-fueled at

Primary purpose is evaluation of

Oil Ring Cylinder Lead Lead 2

600 Total Mack Merits

Excellent Mack T12 Pass on B20 Palm Methyl Ester

Use of biodiesel can lead to lubrication issues

Specific methods were developed for biodiesel fuel dilution

Specially formulated lubricants can enable safe biodiesel use

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