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BLENDING HEAVY DUTY DIESEL ENGINE OILS- TBN/SULPHATED ASH CORRELATION

DISKUSI ILMIAH MASPI VI - JAKARTA

22 JAN 2008

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Dispersant capability keep the finer particles suspended

Cleaning capability Detergents have to keep the engineparts clean (eg the piston)

Wear protection Additives that can withstand high

loads for longer times

Temperature stability maintain performance under highthermal stress

Acid absorption protect the engine from corrosion

Viscosity stability prevent the lubricant from excessivethickening

Requirements of Heavy Duty DEO

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Heavy Duty DEOs: Sources of TBN and S.Ash

• HDDEOs additives include metal detergents, soot dispersants, anti-wear and antioxidant components to provide wear and corrosion protection, engine cleanliness and oxidation control

• Metal detergents neutralize acids in HDDEO and are small particles of inorganic base (calcium or magnesium carbonate and hydroxide) and stabilised in hydrocarbon baseoils by inorganic ‘soap’ molecules such as phenates, sulphonates and salicylates.

• They also provide surfactant behaviour to help prevent deposit formation on metal surfaces within engines, and in some cases contribute to antioxidancy.

• Metal detergents are the main contributor to lubricant sulphated ash. ZDTP, anti-wear additives and organic components such as dispersants and some antioxidants provide additional limited TBN.

• Metal detergents and other additives are optimised to meet the engine test performance requirements in key performance areas for various Industry specifications (API, ACEA, JASO) and OEM specifications (eg, US: Cummins, Mack, Caterpillar, Europe: Mercedes Benz, MAN, Volvo, Japan: Mitsubishi, Nissan, Hino, Isuzu)

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Base5-15 nm

Soap

Inorganic core:

•Calcium carbonate / hydroxide

•Magnesium hydroxide

Polar head group:

Calcium/Magnesium:

•Phenate

•Sulphonate

•Salicylate

Alkyl chain:

C12-24

Metal detergents provide:

• alkalinity: to neutralise acids from combustion process, preventing deposit formation

• surfactancy: inhibit deposit formation

• antioxidancy (phenate, salicylate): high temperature protection in piston ring belt region

• fuel economy: friction reduction under boundary lubrication conditions

Metal DetergentsMetal Detergents

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Detergents

Base oil

Dispersants

Anti wear

Antioxidant

Pour pointdepressant

Anti foam

VI improver

SalicylatesSulphonates

Phenates

Succinimides

Esters

ZDTP’s

Hindered phenol Aminic

Polymethacrylate

Siliconefluid

Styrenecopolymer

OCPPMA

HVI

XHVI PAOEster

high m.w

mono mono-bis

bis

primary

secondary aryl

TBN range

Formulation Components of a Heavy Duty DEO

Ash

Ash

Phosphorus

Sulphur

Sulphur

Star

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HDDEOs: TBN and S.Ash levels required at various performance specifications

• HDDEOs meeting API CH-4/CI-4 + ACEA + other OEMs specs. typically have >10 TBN and S.Ash of 1.2 – 1.5 % wt.

• Increased detergent levels in this TBN/S.Ash range provide stronger performance for Industry and OEM specifications.

• The less stringent performance requirements for API CG-4 and CF-4 relative to above means that these specifications can be achieved at lower TBN levels, ie in 7-10 TBN range.

• The API CF oil specification can be met using oil compositions with TBN levels as low as 6-7 units. More robust product performance is achieved at higher TBN levels. At above 10 TBN, oils ash levels are greater than 1.0%wt.

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Manufacturers of On-Highway Vehicles in Indonesia

Mitsubishi (Fuso)

71%

Mercedes Benz

3%Other

3%

Nissan

2%

Daihatsu

8%

Toyota

10%

Isuzu

1%

Hino

2%

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Impact of TBN/S.Ash changes on OEM Requirements in Indonesia

Indonesian Heavy Duty engine “On Highway” market is dominated by Japanese OEMs

– Japanese OEM’s have a preference for oils meeting JASO DH-1

– JASO DH-1 requires minimum TBN by ASTM D4739 >10

– To meet JASO DH-1 requires high S.Ash oil

– Many Japanese OEM’s also have their own preference for high S. Ash oils

– Placing Limits on TBN/Sulphated Ash restricts the ability to meet the requirements of JASO DH-1 and specific OEM requirements

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P e r f o r m a n c e

C h a r a c t e r i s t ic s

E n g in e o r

B e n c h T e s t s

T e s t L im i t s &

R e q u ir e m e n t s P is to n D e p o s i t

C o n t r o l J A S O D e te r g e n c y Te s t

J A S O M 3 3 6 -9 8 T G F ≤≤≤≤ 6 0 .0

R in g S t ic k in g : A l l F r e e V a lv e T r a in W e a r J A S O V T W Te s t

J A S O M 3 5 4 -2 0 0 5 ≤≤≤≤ 9 5 .0 µµµµ m

S o o t C o n t r o l M a c k T - 8 A S o o t D is p e r s a n c y

A S T M D 5 9 6 7 ≤≤≤≤ 0 .2

O x id a t io n S t a b i l i t y S e q . I I I F （（（（ A S T M D 5 5 3 3 ））））

o r I I I G （（（（ A S T M 6 9 8 4 ））））

= A P I C H - 4

H o t S u r fa c e D e p o s i t C o n t r o l

J P I H o t Tu b e T e s t J P I - 5 S -5 5 -9 9

≥≥≥≥ 7 .0 a t 2 8 0 °°°° C

F o a m in g J I S K 2 5 1 8 : 2 0 0 3

( A S T M D 8 9 2 - 9 7 )

S e q . I & I I I : 1 0 /0

S e q . I I : 5 0 /0

V o la t i l i t y J P I -5 S - 4 1 - 2 0 0 4

( A S T M D 5 8 0 0 -9 5 ) ≤≤≤≤ 1 8 .0

C o r r o s iv e n e s s C o r r o s io n B e n c h T e s t

A S T M D 6 5 9 4 & D 1 3 0 -9 4

= A P I C H - 4

S h e a r S t a b i l i t y( 1 )

A S T M D 6 2 7 8 S t a y in G r a d e

B N J I S K 2 5 0 1 o r

A S T M D 4 7 3 9 ≥≥≥≥ 1 0 .0

S e a l C o m p a t ib i l i t y C E C - L - 3 9 - T - 9 6 = A C E A E

( 1 ) f o r m u l t i - g r a d e o i ls ( N o r e q u ir e m e n t s f o r m o n o - g r a d e s )

JASO DH-1Performance Requirements

Source:JASO

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87

DH-1JASO M355

DH-1 Recommendations by Japanese Heavy

Duty OEMs ( Owner’s Manual )

MitsubishiMitsubishi

Nissan DieselNissan Diesel

Source:JASO

Sulphated Ash >1.0%

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Indonesian Off Highway/Mining market is dominated by two major OEM’s:

• Komatsu

– Preference for oils meeting JASO DH-1(high S.Ash)

– Can also use API CF-4, CH-4 or CI-4

• Caterpillar

– Caterpillar place no minimum limit on TBN but limit S.Ash to 1.5%wt

– Suitable oils are determined by passing either Caterpillar 1P SCOTE test(ECF-1a) or Caterpillar C13 500 hour test(ECF-2)

Performance is determined by passes in the above tests and not by limiting TBN

Impact of TBN/S.Ash changes on OEM Requirements in Indonesia

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Heavy Duty Diesel Engine Oils – S.Ash restrictions

• There are no restrictions on S.Ash content for finished heavy-duty engine oils in the API CF, CF-4 CG-4, CH-4 and CI-4 categories.

• ACEA specifications E2, E3, E5, and E7 have a maximum S.Ash limit of 2.0%wt

• API CJ-4, ACEA E-6, JASO DH-2 specifications and some OEM specifications eg MB 228.51 and 228.3 have S.Ash restrictions. Introduced for oils used in latest heavy-duty diesel engine hardware equipped with exhaust after-treatment devices such as diesel particulate filters, and also using ULSD diesel fuel. This measure is to help prevent filter blocking by lubricant derived ash.

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• Requires significant formulation change using non-ash forming organic TBN components.

• These components are less effective than metal additives in corrosion protection and piston cleanliness.

• Oil quality is reduced and particularly for high sulphur (>500 ppm) diesel applications.

• They are less cost effective and therefore higher consumer spending.

Consequence of reducing S.Ash level to1.0% S.Ash coupled with a minimum TBN requirement of 9-10

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Thank You for Your Attention!

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