Reducing Lubricant Ash Impact on Exhaust

Aftertreatment with a Oil Conditioning Filter

Simon A.G. Watson and Victor W. Wong, MIT
Darrell Brownawell and Scott P. Lockledge, Lutek LLC.
Scott Harold, Ciba Specialty Chemicals

2009 Directions in Engine-Efficiency and Emissions Research (DEER) Conference

August 6th, 2009

Sloan Automotive Laboratory

 Lubricant Derived Ash
• Ash negatively effects
aftertreatment systems:
– Increases fuel consumption
and exhaust back pressure
– Phosphorus may chemically
deactivate catalysts
– Periodic cleaning requirements
and possible engine damage
(Sappok, 2009)

Diesel Particulate Filter Ash Deposits:

Inlet Outlet

(Aravelli, DEER 2006)

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 Reducing Ash Accumulation in DPF’s
Typical DPF Ash Composition:

• Lubricant additives are the

source of most DPF ash:
– Detergents
– Zinc Dialkyldithiophosphate
(ZDDP)
• Detergents contribute about
75% of ash found in DPF’s
(CaSO4)
• Lower detergent levels
significantly reduces DPF ash

(Sappok, 2009)

XRD analysis of DPF ash from a CJ-4 lubricant

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 Are there any alternatives for additives that
do not contribute to DPF ash?

• Strong Base Oil Filter

– Strong base is anchored in the filter
– Strong base in filter immobilizes acids
– Releases nothing
– Selectively sequesters acids only

• Ashless Antiwear
– Provides protection from wear without contributing to sulfated
ash (ASTM D874)

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 Test Program
• Long-duration steady-state testing to investigate the potential
benefits of filter conditioning with reduced ash oils
• Three long-duration tests:
– Test 2 – Zero Detergent oil, Strong base filter - 300 hrs
– Test 3 – Zero Detergent oil, Standard oil filter - 82 hrs
– Test 1 – CI-4 PLUS oil, Standard oil filter - 318 hrs (Reference)
Test Parameters
Load 100%FP
Speed 1800 rpm
Fuel 15 ppm Sulfur Diesel
1. Experimental Zero Detergent
Lubricants Formulation
2. Fully Formulated (CI-4 PLUS)

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Experimental Zero-Detergent Oil Formulation
Description of the Components in the Zero Detergent Oil:
Component Description
Base Oil Blend of Americas Core Group I
Detergent None
Dispersant PIBSA/PAM (~10% of formulation)
Ashless phosphorus and sulfur
Antiwear
containing additives
Additional Corrosion
None
Inhibitors

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 Lubricant Properties
Lubricant Properties:
Property Zero Detergent CI-4 PLUS
SAE Grade 15W40 40W
API Gravity 29.1 28.9
Viscosity @ 40°C [cSt] ~ 146
Viscosity @100°C [cSt] 15.2 14.9
Sulfated Ash [%] (D874) 0.057 1.35
TBN [mg KOH/g] (D2986) 5.5 10.2

Elemental Analysis (ASTM D4951):

Element Zero Detergent CI-4 PLUS
Ca 0 3130
Mg 0 10
Zn 0 1350
P 480 1490

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 Test Engine

Lister Petter TR1 Generator Set

• Specifications:
– Single Cylinder
– Naturally Aspirated
– Air Cooled
– No EGR
– Maximum Power 5.5 kW
– Direct Fuel Injection
– Displacement 0.773 L
– Compression Ratio 15.5:1
– Sump Capacity 2.4 L

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 Test Procedure
• Lubrication system cleaned with triple flush between tests
• Routine maintenance performed every 24 hours
• Parameters measured every 24 hours:
• Oil Consumption (oil mass measurement)
• Fuel Consumption
• Oil Temperature
• Crankcase oil samples
extracted every 48 hours:
• For Tests 1 - ~17 g
• For Tests 2 and 3 - ~38 g
• Samples are extracted
through the dipstick opening

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 Oil Consumption and Soot Contamination
Oil Consumption Soot Content
2000 1.6
T o ta l O il C o n su m p tio n

1.4
1600 5.93 g/hr 1.2

S o o t (% w
1200 1
0.8
800 5.49 g/hr
3.61 g/hr 0.6
0.4
400 Test 1 - CI-4+, Standard Filter Test 1 - CI-4+, Standard Filter
Test 2 - Zero Detergent, Strong Base Filter 0.2 Test 2 - Zero Detergent, Strong Base Filter
Test 3 - Zero Detergent, Standard Filter Test 3 - Zero Detergent, Standard Filter
0 0
0 100 200 300 400 0 100 200 300 400
Elapsed Operating Time (hours) Elapsed Operating Time (hours)

• Mean oil temperatures of tests are equal

• Mean fuel consumption of tests are equal

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 Total Acid Number
2.5

y = 0.0088x + 1.1427
R2 = 0.8841 Zero-Detergent, y = 0.0028x + 0.9475
2.0 Zero-Detergent, 2
R = 0.9791
Standard Filter
Strong Base Filter
TA N (m g K O H /

1.5

y = 0.0028x + 0.5572
2
R = 0.983
1.0
Fully Formulated, Standard Filter

Test 1 - CI-4+, Standard Filter, Colorimetric Titration

0.5
Test 2 - Zero Detergent, Strong Base Filter, Colorimeteric Titration

Test 3 - Zero Detergent, Standard Filter, Colorimetric Titration

0.0
0 50 100 150 200 250 300 350
Elapsed Operating Time (hours)
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 Lubricant Acidity
9.00

8.50
Fully Formulated, Standard Filter y = -0.0037x + 8.4521
8.00 2
R = 0.7123

7.50

7.00
p H U n it

6.50 y = -0.0076x + 8.1965

Zero-Detergent, 2
R = 0.9371
Strong Base Filter
6.00
Zero-Detergent,
5.50 Standard Filter
y = -0.0236x + 7.6
2 Test 1 - CI-4+, Strong Base Filter
5.00 R =1
Test 2 - Zero Detergent, Strong Base Filter
4.50 Test 3 - Zero Detergent, Standard Filter

4.00
0 50 100 150 200 250 300 350
Elapsed Operating Time (hours)

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 Total Base Number

10 Fully Formulated, Standard Filter

8
T B N (m g K O H /

Test 1 - CI-4+, Standard Filter, ASTM D-5984

6 Test 2 - Zero Detergent, Strong Base Filter, ASTM D-5984
Test 2 - Zero Detergent, Strong Base Filter, ASTM D-2896
Zero-Detergent, Test 3 - Zero Detergent, Standard Filter, ASTM D-5984
4 Strong Base Filter Test 3 - Zero Detergent, Standard Filter, ASTM D-2896

2
Zero-Detergent, Standard Filter

0
0 50 100 150 200 250 300 350
Elapsed Operating Time (hours)
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 Magnesium Concentration
16
Test 1 - CI-4 PLUS, Standard Filter
14 Test 2 - Zero Detergent, Strong Base Filter
Test 3 - Zero Detergent, Standard Filter Zero-Detergent,
M g C o n c e n tra tio n (p

12 Strong Base Filter

10

8
Fully Formulated,
Zero-Detergent,
Standard Filter
6 Standard Filter

0
0 50 100 150 200 250 300 350
Elapsed Operating Time (hours)
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 Oxidation
47 Test 1 - CI-4 PLUS, Standard Filter
Test 2 - Zero Detergent, Strong Base Filter
42
O x id a tion N um b e r (A b s

Zero-Detergent, Test 3 - Zero Detergent, Standard Filter

Standard Filter
37
Zero-Detergent,
32 Strong Base Filter
y = 0.2134x + 15.428
2
R = 0.8306 y = 0.0241x + 18.064
27 2
R = 0.3299

22

17
y = 0.0268x + 12.171
2
12 Fully Formulated, Standard Filter R = 0.9721

7
0 50 100 150 200 250 300 350
Elapsed Operating Time (hours)
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 Viscosity
45
y = 0.278x + 13.795
40 2
R = 0.9409
Zero-Detergent,
35 Zero-Detergent,
Strong Base Filter
Viscosity at 100C (cSt)

Standard Filter
y = 0.0688x + 15.808
30 2
R = 0.9807
25
Fully Formulated, Standard Filter
20

15
Test 1 - CI-4 PLUS, Standard Filter, ASTM D-445
Test 2 - Zero Detergent, Strong Base Filter, ASTM D-445
10 Test 3 - Zero Detergent, Standard Filter, ASTM D-445
Linear (Test 3 - Zero Detergent, Standard Filter, ASTM D-445)
5 Linear (Test 2 - Zero Detergent, Strong Base Filter, ASTM D-445)
Linear (Test 1 - CI-4 PLUS, Standard Filter, ASTM D-445)
0
0 50 100 150 200 250 300 350
Elapsed Operating Time (hours)
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 Engine Wear
160
Test 1 - CI-4+, Standard Filter
C orre c te d F e C on c e n tra tio n (

140 Test 2 - Zero Detergent, Strong Base Filter

Test 3 - Zero Detergent, Standard Filter
120
Fully Formulated,
Standard Filter
100

80

60

40 Zero-Detergent, Zero-Detergent,
Standard Filter Strong Base Filter
20

0
0 50 100 150 200 250 300 350
Elapsed Operating Time (hours)
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 Bearing Wear Metals
90
C orre c te d M e ta l C on c e n tra tio n

80 T2, Pb

70

60

50
Test 1 - CI-4+, Standard Filter, Pb
40
Test 2 - Zero Detergent, Strong Base Filter, Pb
30 Test 3 - Zero Detergent, Standard Filter, Pb

T3, Pb Test 4 - CI-4+, Strong Base Filter, Pb

20

10 T1, Pb
T3, Pb

0
0 50 100 150 200 250 300 350
Elapsed Operating Time (hours)

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 Four Ball Wear Tests

1.00
Average Wear Scar Depth (mm)

0.80

0.60

0.40

0.20

0.00
Zero Detergent, CI-4+, Fresh Oil Test 1 - CI-4+, Test 2 - Zero Test 3 - Zero
Fresh Oil Standard Filter - Detergent, Detergent,
318 hours Strong Base Standard Filter -
Filter - 300 82 hours
hours

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 Conclusions
• Under the test conditions used in this study, the strong base
filter had a significant and beneficial effect on the rate of oil
degradation
• The strong base filter reduced lubricant acidity by absorbing
acidic contaminants in the lubricant
• The filter performs an acid control function similar to that
provided by over-based detergents, when used with a zero-
detergent oil
• The zero-detergent oil (formulated with ashless antiwear
additives) and the CI-4 PLUS oil provide similar levels of wear
protection after aging with the strong base filter.
• With more development, it may be possible use a zero
detergent oil in combination with a strong base filter; providing
adequate engine protection while minimizing lubricant ash
effects on aftertreatment systems
Sloan Automotive Laboratory
 Acknowledgements
This research is supported by the MIT Consortium to
Optimize Lubricants and Diesel Engines for Robust
Emission Aftertreatment Systems

We thank for the following organizations/companies for

their support:
• Department of Energy – Vehicle Technologies Program
• Caterpillar • Komatsu
• Chevron • Lutek LLC.
• Ciba Specialty Chemicals • Sud-Chemie
• Cummins • Valvoline
• Detroit Diesel • Ford
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