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© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.

DELIVERING FUEL ECONOMY THROUGH ADVANCED LUBRICANTS

Dean B. Clarke

Infineum USA L.P.

May 5, 2015

Performance you can rely on. © INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved. 2

• Introduction

• Lubricant Additive Chemistry

• PCMO Fuel Economy

• HDD Fuel Economy

• Lubricants Challenges in the Future

Outline

http://resources/sites/CorpImages/Test/Abstract oil spill.jpg

© INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved. Performance you can rely on. 3

INTRODUCTION


Three Cogs of Fuel Economy

Tribology

• Wear

Rheology

• Fuel Economy

Retention

• FE and engine durability


New SAE J300 Engine Oil Viscosity Grades To Enable FE (Issued Jan 2015)

• Viscosity grades as low as 0W-8 are now defined by SAE J300


ADDITIVE CHEMISTRY


Additives Used in Engine Oils

Anti-Oxidant

Detergent

Dispersant Antiwear

Friction Modifier

Demulsifer Antifoam

Emulsifer Rust

Inhibitor

Corrosion Inhibitor

Tackifier Viscosity Modifier

Anti-Mist Biocide

Dye


Viscosity Modifier Chemistry

Ethylene-Propylene: (Olefin Co-Polymer)

(OCP)

Polymethacrylate: (PMA)

Styrene-Isoprene: Linear Polymer

Loose physical association due

to polarity differences

Chemically bonded together

Styrene-Isoprene: Star Polymer

O O O O O O

R R R


Shear-Thinning: Temporary and Permanent Viscosity Loss

Permanent Viscosity Loss: Shear Stability Index (SSI) measures loss of polymer added

viscosity after 30 cycle KO test.

Reversible Non-reversible

Rupture of coil under shear forces

Quiescent polymer coil in oil solution

Orientation of coil under shear forces

Smaller cross- section gives less thickening which equals lower viscosity

Lower molecular weight gives less thickening which equals lower viscosity

Temporary Viscosity Loss


What Are Friction Modifiers?

• Long chain hydrocarbons with polar end groups

• Surfactants

• They work by adsorbing to metal surfaces

• ‘Plush carpet’

• Molecules designed to:

• Adhere to metal surfaces

• Rather than soot, for example

• ‘Stand’ upright into bulk oil

• Friction coefficient is affected by:

• Type, Concentration, Temperature, Speed, Load

Performance you can rely on. 11 © INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.

ASPERITY RIDING ON FRICTION MODIFIER LAYER

Metal surface

Oxide layer

Friction Modifier film

Moving asperity


Typical Organic Friction Modifiers (OFMs)

OH

O

P

O

O

OH

O

O OHC

C

O

O

Oleic acid Dioleyl phosphite Glycerol dioleate


Surface Adsorption Models Simulation of Film Formation

OH

O OHO

R

• Computer model of a Mono Oleate molecule in the vicinity of a metal surface

• Molecular Dynamics shows that the molecule naturally attaches to the surface

• Hydrogen-bonds from the OH groups are key to this process

Simulating OFM Metal Surface Interaction


Advanced Organic Friction Modifiers

• Linking OFMs together into poly OFM architecture • Factors to consider:

• H-bonding and conformation (in solution) • Solubility • Chain length • Distribution of functionality (homo-polymer vs. co-polymer)


© Copyright INFINEUM INTERNATIONAL LIMITED 2004

OFM vs “poly-OFM”

1-D

OFM

2-D

Chain OFM

3-D

Carpet OFM

Increased surface activity

Decreased friction


Inorganic Friction Modifiers

• Molybdenum Sulfide dimer

• Molybdenum Sulfide trimer

• Delivers friction coefficients of 0.04 to 0.07

• Also performs as a powerful antioxidant and antiwear additive

Tribochemical

Reaction MoS2 – Graphitic structure

– low friction

Performance you can rely on. 17 © INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved.

Relative Size of Things

Oil Filters

Atom

Soap Molecule

Friction Modifier

Detergent Colloid

Virus

Dispersant

Viscosity Modifier

Surface Roughness

Soot Particles

Oil Film Thickness

Bacteria

Human Hair

micrometer

= micron

= µm

Log (Meters)

-10 -9 -8 -7 -6 -5 -4 -3

millimeter = mm

thousandth

inch millionth inch

Ångstrom = Å

nanometer = nm


PCMO FUEL ECONOMY


N. America PCMO Fuel Economy

• Fuel Economy is the key driver for change in PCMO lubricants in N. America

• 3.5 million hybrid-electric vehicles sold in US since 1990 (2nd largest fleet)

• Since ILSAC GF-2 in 1996, each new category has increased FE standards

19

Fuel Economy Testing

• The Sequence VID was developed for GF-5 Fuel Economy

– 2009 model year Chevy Malibu engine

• A new category GF-6 is now under development

– 2012 model year Chevy Malibu engine

– New Fuel Economy test will be called the Sequence VIE once limits are established

– For now we call it the Development VIE or VIEDEV

• Industry data indicated that the response of the new engine might be

significantly different than the 2009 MY engine

• Infineum decided to get an early start in understanding the response of the 2012

engine

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Sequence VIE – Test Stages

BLB1 : BaseLine calibration Before Test Oil 1st (20W-30)

BLB2 : BaseLine calibration Before Test Oil 2nd

BLA : BaseLine calibration After Test Oil

Tentative Phase 1 baseline weight : 0.8 BLB2 + 0.2 BLA

Tentative Phase 2 baseline weight : 0.1 BLB2 + 0.9 BLA

Phase I

Phase II

VIE Aging

16 hrs

Stage

1 Stage

2 Stage

3 Stage

4 Stage

5 Stage

6

VIE Aging

109 hrs

Stage

1 Stage

2 Stage

3 Stage

4 Stage

5 Stage

6

Test A

BLB1 BLB2 Test Oil A BLA BLB1 BLB2 Test Oil B BLA

Test B


Sequence VIE – Test Stages

Speed rpm

Torque Nm

Power kW

Oil Temp

oC

Coolant Temp

oC

Stage 1

2000

105

22

115

109

Stage 2

2000

105

22

65

65

Stage 3

1500

105

16.5

115

109

Stage 4

695

20

1.5

115

109

Stage 5

695

20

1.5

35

35

Stage 6

695

40

2.9

115

109


Sequence VIE - Stribeck Curve

𝐒𝐨𝐦𝐦𝐞𝐫𝐟𝐞𝐥𝐝 𝐍𝐮𝐦𝐛𝐞𝐫 = 𝐜𝐨𝐧𝐬𝐭𝐚𝐧𝐭 𝐱 𝐋𝐨𝐠 Viscosity x Speed

Load

EHD

• Sommerfeld Number is proportional to the film thickness and can be used to identify the lubrication regime

• An estimation of the Sommerfeld Number can be obtained by using manifold pressure to estimate the load


• Test stages shown in order of increasing Sommerfeld Number • Stages 6 and 4 are the most Boundary • Stages 5 and 2 are the most Hydrodynamic

• Viscosity grade differences are small in comparison to the impact of stage conditions

Sequence VIE – Sommerfeld Number

10

100

1000

10000

Spe

ed

* V

is/M

anif

old

Ab

s P

ress

ure

VIE Sommerfeld Parameter by Stage

Manifold Pressure Used for Load

0w16 0w20 5w20 5w30 10w30

Stage Stage Stage Stage Stage Stage 6 4 3 1 2 5

Boundary Hydrodynamic

Performance you can rely on. © INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved. Proprietary to Infineum. 24

Sequence VIE – Fuel Consumption by Stage

• We have analyzed the fuel

consumption data from each

stage before and after

weighting.

– Hydrodynamic - BLUE

– Mixed - ORANGE

– Boundary - RED

• "Mixed" stages are dominant

(>80%) - key is to reduce

friction in "mixed" stages

• >90% of the test is at 115

deg. C

− Lower viscosity grades

(0W-16) will be better in the

low temperature stages

• Stage weighting is currently

being debated in the test dev

committee


Sequence VIE – Changes from VID

• Procedure differences:

– Stabilization time before BSFC measurement will be 90 minutes versus 60 minutes in

the VID

– Additional flushing - six BL oil flushes versus three in the VID

– Coolant: 50/50 mixture of Dexcool and demineralized or distilled water instead of

100% Dexcool

– Aging step lengthened from 100 hr in the VID to 125 hr in the VIE (16 + 109 hrs vs.

16 + 84 hrs).

• Longer aging to achieve similar oxidation and nitration DIR as the VID (intended to match the

FTP FE cycle).

– Additized fuel introduced in 2013 to protect hardware, especially to prevent exhaust

valve deposits


Sequence VIE - Proposed Limits

ILSAC GF-6 FE Limit

Viscosity Grade FEI2 FEI SUM

XW-20 1.7% 3.6%

XW-30 1.4% 2.9%

10W-30 1.1% 2.5%

Seq. VID GF-5 Limit

Viscosity Grade FEI2 FEI SUM

XW-20 1.2% 2.6%

XW-30 0.9% 1.9%

10W-30 0.6% 1.5%

• Based on 2009 engine plus proposed improvements

• FEI2 increase is intended to correlate to a drain extension from 6.5K miles to

10K miles

• Changes are possible based on results from precision matrix set to run soon

• Advanced lubricants will deliver VIE and the rest of GF-6

VIE Proposed limits


HDD FUEL ECONOMY

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HDD Fuel Economy

• Non-Rheological Effects

– FM can help at least below 2.3 HTHS

– Credit of salicylate over sulfonate detergent

• Viscometrics dominate fuel economy

– Lower HTHS is better up to a point

– Viscosity Modifier type can matter

• New Developments for HDD

– 2.6 HTHS N. American HDD FE Demo oil

• Passes full CJ-4 tests except HTHS limit of 3.5 min

• Passes ACEA E9-08, Volvo D12D, OM501LA

p228.51, and OM646LA

– Single Common Powertrain Lubricant Arctic to Desert for US Military

• 0W-20 oil replacing former 15W-40 in HDD ground vehicles; extensive field testing

• Together with low viscosity ATF, US Army TACOM division measured 7% FEI over ref oils

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Performance you can rely on. © INFINEUM INTERNATIONAL LIMITED 2015. All rights reserved. 29 29

VM Type can make a difference!

• At constant HTHSV @150C, oil with

higher VI should deliver higher FE

• Infineum SV600 designed to shrink its polymer coil as temperature reduces

• VI Increases

• FEI Increases

VI Effect on Temp-Viscosity Relationship

0

5

10

15

20

25

30

50 75 100 125 150

Temp, oC

HT

HS

V @

10

6 S

hear

189 VI (SV260)

223 VI

(Experimental VM)

FE Performance in GM6.5

0.0

0.5

1.0

1.5

Oil 1

(SV260)

Oil 2

(Expt VM)

FE

IM

pro

vem

en

t, %

(Infineum

SV260)

(Infineum

SV600)

223 VI

189 VI

(Infineum SV260)

(Infineum SV600)

Low High Temperature


LUBRICANT CHALLENGES IN THE FUTURE


NA overview: PCMO lubricant market

• Lighter viscosity grades improve FE,

reduce emissions, and complement

engine advances with same aim

• SAE 5W-XX grades dominate

• SAE 0W-20 has grown to 4% of market

• API SN/ ILSAC GF-5 quality level

represents two-thirds of the market

Source: Infineum data


NA overview: PCMO viscosity grade trends

• Trend toward lighter vis grades will continue in N. America

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

2000 today 2016 forecast 2020 forecast

Other Monograde SAE 20W-50 SAE 10W-40

SAE 10W-30 SAE 5W-30 SAE 5W-20 SAE 0W-XX

5W-30

10W-30

10W-40


0W-XX

5W-20


Global Vehicle Market


• Vehicle population continues to grow

• China accounts for 40% of the increase

• Significant growth in developing markets

‒ Brazil, India, Indonesia, Mexico

• Emissions limits tightening

in many countries

• Tough fuel economy and CO2

emissions limits

• OEMs must respond with

hardware innovations

1.7 Billion light-duty

vehicles by 2040


Changing Vehicle Global Market


33% hybrids in global

fleet by 2040.

Given the current

price of crude this

forecast is likely

optimistic.

Fuel economy drives the development of new hardware

0

50

100

150

2010 2020 2030 2040

New Vehicle Sales by Type, Millions

Gasoline Diesel Gas/LPG

Full hybrid Electric/fuel cell

Data

so

urc

e: E

xxo

n M

ob

il


Changing Vehicle Global Market


Data

so

urc

e: E

xxo

n M

ob

il

• China, Brazil, India and Russia

• Large vehicle population

• Increase in use of modern cars

• Pollution concerns growing

• Potential for lube volume growth

• Potential for lubricant quality upgrade

>37% world new vehicle

sales in BRIC


Future Lubricants

Data

so

urc

e: E

xxo

n M

ob

il

• Fuel Economy will be the main

driver shaping new lubricants

• In PCMO, higher performing FMs,

dispersants, and detergents will be

required to meet performance

targets

– New surface active lubricant additives

designed to reduce friction on new

materials and coatings will increase

• In HDD, as engine design advances

and tighter tolerances are used

between moving parts, HTHS can

be reduced

– Low HTHS will open door for FMs to

play more of a role


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