Engine Lubricants: Trends And Challenges

Engine Lubricants :Trends and ChallengesJai G. Bansal,Chief Scientist – Engine LubricantsInfineum USA LPDEER 2012 – DetroitOctober 19, 2012

Global Concerns leading to Global RegulationsEnvironmentalConcernsGHG : GlobalWarmingEmissions andFuel EfficiencyregulationsDepletion of NaturalResourcesSecurity of EnergySupply Copyright INFINEUM INTERNATIONAL LIMITED 20092Performance you can rely on.

Rapid evolution of engine technologies Challenges and opportunities for lubricant izationInjectionOn-board oilVariable gEGRAdvancedmaterials/surfacetreatments Copyright INFINEUM INTERNATIONAL LIMITED 2009DieselcommonrailCooled EGRACERTTMDPFSCR3Challenge :Continuallyadaptinginvestmentstrategies tomaintain leadershipin fast changingenvironmentOpportunities fortechnologyleaders to delivervaluepropositionstargeted tospecific needsPerformance you can rely on.

Today’s PresentationEmissionsFuelEconomy Copyright INFINEUM INTERNATIONAL LIMITED 2009 Light Duty Vehicles Heavy Duty Vehicles Light Duty Vehicles Heavy Duty Vehicles4Performance you can rely on.

Emissions :Heavy DutyVehicles Copyright INFINEUM INTERNATIONAL LIMITED 20095Performancerely on.Performance youyoucancanrely on.

Evolution of Emission Legislations Copyright INFINEUM INTERNATIONAL LIMITED 20096Performance you can rely on.

Emission Control Strategies Approaches vary with OEMs but involvesome combination of Exhaust Gas Recirculation (EGR)– without or with external cooling Diesel Particulate Filter (DPF) Selective Catalyst Reduction (SCR) Other proprietary systems Different approaches lead to differentlubricant needs Copyright INFINEUM INTERNATIONAL LIMITED 20097Performance you can rely on.

Lubricant Soot LoadingRetardedTiming Copyright INFINEUM INTERNATIONAL LIMITED 2009CooledEGREGR8SCR / ReducedEGRPerformance you can rely on.

Increasing soot loading required significantadvances in additive technologyConventional TechnologyExcessivewearLowwearCummins ISM Copyright INFINEUM INTERNATIONAL LIMITED 20099Performance you can rely on.

After-Treatment Compatibility SCR/DPF systems are used in modernengines to reduce PM and NOx in the exhaust Efficiency and life of these systems can becompromised by presence of certainlubricant additive emissions in exhaustgases Leads to restrictions on permissible amountsof phosphorus, sulfur and metal containingadditives in the oil Choice of detergent chemistry becomescritical Copyright INFINEUM INTERNATIONAL LIMITED 200910Performance you can rely on.

Role of Detergent TypeSulphonatesPiston CleanlinessTopBottomTBN DurabilityRust ControlAntioxidancySulphur - esYesYesYesYesYesYesWell-roundedperformance and zerosulfur Copyright INFINEUM INTERNATIONAL LIMITED 200911Performance you can rely on.

Role of Detergent MetalLower atomic weightmeans 36% less SASH atequal acid neutralizationpowerNext FrontierNon-metallic technologiesfor piston cleanliness andacid neutralization Copyright INFINEUM INTERNATIONAL LIMITED 200912Performance you can rely on.

Fuel Economy Copyright INFINEUM INTERNATIONALCopyright INFINEUMLIMITEDINTERNATIONAL2009LIMITED 201213Performanceyourely on.Performance youcancanrely on.

Tough GHG regulations are coming intoeffect in all major marketsCO2 emissions, g/km270California250230210190170Solid lines: EnactedDotted line: Proposed or contestedUnited StatesAustraliaChina150130110European UnionJapan902002 2004 2006 2008 2010 2012 2014 2016 2018 2020 2022Source:Passenger Vehicle Greenhouse Gas and Fuel Economy Standards: A Global Update, ICCT. May 2009 update.Source: Passenger Vehicle Greenhouse Gas and Fuel Economy Standards: A Global UpdateCCI May 2009 Update Copyright INFINEUM INTERNATIONAL LIMITED 2009Performance you can rely on.

Lubricants have important role to play OEMs are looking at all aspects of hardware designand operation for energy efficiencies Majority of fuel efficiency improvements willundoubtedly come from hardware changes Nevertheless lubricants also have an important roleto play North American experience illustrates theimportance of lubricant contribution to fuelefficiency15 Copyright INFINEUM INTERNATIONAL LIMITED 2009Performance you can rely on.

Lubricants have important role to playWeighted Average FEI(Relative to 1980 Baseline)2.5FEI, %2.01.51.00.5NA Passenger Car Lubricants0.01980198519901995200020042009Steady increase in FE performance over last3 decades! Copyright INFINEUM INTERNATIONAL LIMITED 200916Performance you can rely on.

Fuel SavingsNA PCMO Lubricants3Billiongallonsper year210198019851990199520002004200917 Copyright INFINEUM INTERNATIONAL LIMITED 2009Performance you can rely on.

Typical energy distribution in a vehicleIndicated HPFuel EnergyInput100%To WheelsBHP22%38%DriveTrain(10%)Mechanical Losses(16%)Exhaust, Coolantand Air (62%)Air y a fraction of theselosses can be saved withFE engine lubricantMajority of the data taken from “Pinkus and Wilcox, The Role of Tribology in Energy Conservation, Lubrication Engineering, 34 (11),pp 599-610” Copyright INFINEUM INTERNATIONAL LIMITED 200918Performance you can rely on.

Energy Distribution varies with Drive Cycle19 Copyright INFINEUM INTERNATIONAL LIMITED 2009Performance you can rely on.

On-Road FE Results - Drive Cycle Effect14FE Improvement, %12Avg. 12%10864Avg. 3.3%Avg. 1.8%20Line Haul Copyright INFINEUM INTERNATIONAL LIMITED 200920Stop & GoIdlePerformance you can rely on.

Fuel Economy triangle ogicalLosses LubricantViscosityIn-ServiceLosses Copyright INFINEUM INTERNATIONAL LIMITED 200921 Volatility Durable FrictionModifiersPerformance you can rely on.

Boundary friction losses Friction modifier is the main additive lever to reducingboundary friction losses However, increasing use of low friction engines has reducedthe effectiveness of conventional friction modifiers In addition, the ILSAC quality lubricants are required todemonstrate FE performance not only in the fresh state butupon ageing as well Today’s friction modifiers must be effective in reducing friction in boundary as well as mixed lubricationregimes retain their effectiveness even after ageing Copyright INFINEUM INTERNATIONAL LIMITED 200922Performance you can rely on.

Advances in FM technology offer clearadvantage in ILSAC FE ProtocolSequence VI-D : New vs.Conventional FM Copyright INFINEUM INTERNATIONAL LIMITED 200923Performance you can rely on.

Rheological Losses Lubricant viscosity is the key factor in controlling energylosses in hydrodynamic and mixed lubrication regimes Bearings, oil pump, piston assembly Combined energy losses in these components are estimatesto be 3-4% NA and Japan have been at the forefront in capturing theseenergy credits by transitioning to low viscosity lubricants Copyright INFINEUM INTERNATIONAL LIMITED 200924Performance you can rely on.

Sustained march to lighter viscosity gradesEvolution of PCMO Grades in NorthAmerica(NPRA 2009)% of PCMO Volume1005W-205W-30755010W-3010W-4025Others01980 Copyright INFINEUM INTERNATIONAL LIMITED 200919851990199525200020042009Performance you can rely on.

Which viscosity is relevant to FE? HTHS viscosity is widely seen as the most critical lubricantproperty for fuel economyLower HTHS Higher FE Copyright INFINEUM INTERNATIONAL LIMITED 200926Performance you can rely on.

However, HTHS may not be serving us wellMuch higher FE for oils with VMDifferent FE performance for different VMs Copyright INFINEUM INTERNATIONAL LIMITED 200927Performance you can rely on.

Viscosity at ultra high shear rates maybe more Important than HTHSIncreasing FEShear RateOpportunity to design “FE Optimized” VM bymaximizing shear thinning at very high shear rates ! Copyright INFINEUM INTERNATIONAL LIMITED 200928Performance you can rely on.

VM Optimized for “Cold Start” European NEDC and Japan JC-08 test procedures involvesignificant “Cold Start” segments Recent advances in VM technology have made it possible tominimize lubricant viscosity under the cold start conditions Copyright INFINEUM INTERNATIONAL LIMITED 200929Performance you can rely on.

FE-Optimized VM offers significantadvantage in NEDC testing Copyright INFINEUM INTERNATIONAL LIMITED 200930Performance you can rely on.

Summary Copyright INFINEUM INTERNATIONALCopyright INFINEUMLIMITEDINTERNATIONAL2009LIMITED 201231Performanceyourely on.Performance youcancanrely on.

Summary and Conclusions Environmental and energy supply concerns are majordrivers of change for the transportation industry Engine manufacturers respond to these concerns with newhardware technologies, resulting in rapidly evolvingperformance challenges for the lubricant industry Performance challenges provide opportunities to createvalue for lubricant developers, lubricant marketers andOEMs High technology solutions require high investments Early collaboration is essential for optimum deployment ofthese investments Copyright INFINEUM INTERNATIONAL LIMITED 2009Performance you can rely on.

Oct 19, 2012 · Engine manufacturers respond to these concerns with new hardware technologies, resulting in rapidly evolving performance challenges for the lubricant industry Performance challenges provide opportunities to create value for lubricant developers, lubricant marketers and OEMs High