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Lubricants Russia 2005, Moscow, 23. 25.11.2005

Additive Solutions for Industrial Lubricants

by

Detlef Pazdzior&Achim Fessenbecker

Rhein Chemie / Germany - Division Lubricant Oil Additives (LOA)


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Content

1. Introduction of Rhein Chemie

2. Additive solutions for industrial lubricants

Anti-hydrolysis additive for esters

Polyurea Powder Technology a new ready for use thickener

New Industrial Oil Additive Package optimized for new,low Sulfur / high VI Base Oils

3. Summary


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Chapter 1

Introduction of Rhein Chemie


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Rhein Chemie Rheinau GmbH

RC is a medium sized chemical company developing and producing additives

for the Rubber, Plastic and Lubricant Industry

Part of the new Lanxess Chemical Company (formerly Bayer AG)

RC turnover > 300 Mio in 2004

RCs Lubricant Oil Additive Division (LOA)

focussed on the industrial side of the lube oil business

Addit ins for Metalworking Fluids

Addit ins for Greases

Addit ins for Industrial Machine Lubrication

European based global supplier

Reliable partner since more than 100 years


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LOA Division

- Product Portfolio -

Extreme Pressure Additives

Light Colored Low Odor

Sulfur Carriers

Anti-Wear Additives

Ash and Ashless AW Additives(Phosphorus based)

Corrosion Inhibitors

Sulfonates/Carboxylates

Succinic Halfesters,

Amine Phosphates

Metal Deactivators

Anti-Oxidants

Phenolic/Aminic

Specialty Products

Synthetic Esters

Anti-hydrolysis Agents

Additive-Packages

Ash/Ashless R&O/Hydraulic

Multi-Functional MWFs

EP Grease Package


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Chapter 2

3 Examples ofAdditin Solutionsfor Industrial Lubricants


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2.1. Anti-Hydrolysis Additive for Esters

- General Aspects -

Problems with Esters

Degradation in the presence of water

Ester based lubricants attack and dissolve bearing metals (Pb, Zn, Sn) as acidity increases

Reasons for Hydrolysis of esters

Kinetically slow process in absence of catalysts

Very typical autocatalytic process because acids are formed which themselves stronglycatalyse the degradation

Simple solution:Addition of a special carbodiimide which works as acid scavenger removesthe catalyst and stabilizes the ester and protects the bearing metals.

Why does it work?

It reacts only with acids even in the presence of excess water(not just neutralizing)


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2.1. Anti-Hydrolysis Additive

- Hydrolytic Stabil ity Test (ASTM-D 2619) -

192 h

Modified ASTM-D 2619

Base Oil: TMP-Oleate (TAN = 0.2 mg KOH/g)Additive: Carbodiimide

Modification: Time extended to 192 h

No Additive

+ 0.5% Carbodiimide

+ 1% Carbodiimide

0 24 48 72 96 120 144 168

0

0.5

1

1.5

2

2.5

3

TAN

[mgKOH/g]


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- Oxidation and Hydrolytic Stability Test (ASTM-D 943) -

TAN[mgKOH/g]

500 h 1.000 h 1.500 h 2.000 h0

1

2

3

4

5

6

7

8

No Additive

1.3% AO

1% Carbodiimide

1% Carbodiimide

1.3% AO

ASTM-D 943

Base Fluid: Saturated C8/C10-TMP-Ester(V40 = 32 mm/s; TAN = 0.1 mg KOH/g)


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- Metal Compatibility Pb/Zn/Sn -

Time [h]

Weightloss[mg]

0 48 96 144 192 240 288 336

00

-50

-100

-150

-200

-250

-300

-350

Zinc (Zn)

Lead (Pb)

Tin (Sn)

1% Carbodiimide

(Pb + Zn + Sn)

Condition: Static Immersion

Base Fluid: TMP-Oleate (V40 = 46 mm/s; TAN = 0.97 mg KOH/g)

Specimen: Zinc sheets; Tin-coated Iron sheets; Lead sheets;Sample Size: 500 ml

Temperature: 60 C


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2.1. Anti-Hydrolysis Additive High Lights

Stabilizes all kinds of esters against hydrolysis

Can be used widely as oil soluble acid scavenger

including acidity reduction e.g. coming from oxidative degradation

Also applicable in Phosphate Esters and mineral oils and other baseoils

Potential applicationsHigh performance ester lubricants used for hydraulics, gears, aircrafts

Fire resistant inorganic Phosphate esters in fire restistant hydraulics,aircraft etc.

Refrigerant compressor oilAfter treatment / Tank side additive to control acidity

Acidity control in greases


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2.2. Polyurea Powder Technology

- a new ready for use thickener -

Polyurea GreaseHeat

Mechanical Energy

Base Oil

Polyurea Powder

+

Additin M 10411


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- The Simple Solution -

No restrictions anymore regarding

Toxicity and workers safetyNo special storage facilities

Easy handling in the factory

No special approvals of the authorities

Environment

Readily biodegradable thickener

Your supply chain

Free choice location of where you wish to produce PU greases

Standard grease manufacturing equipment sufficient

Use your existing highly sophisticated PU grease plant for high value added productsand have the standard grades made on powder technology in cheaper plants or viceversa depending on your companys strategy

Increase your product portfolio without additional investments


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- Minimum Manufacturing Requirements -

Vessel for stirring and heating up to 200C

Good homogenisation equipment

M 10411 like other powdered grease additives such as Graphite

requires thorough milling to ensure that the particles are very effectively

broken down (the smaller the better)

Roller Mill, High Pressure Homogenisers (200 400 bars) and others

Handling of powders in bags

The powder technology works in standard grease manufacturing

equipment


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- Performance Data -

240245Dropping Point [C]

0,380,70Four Ball Wear Scar

1200 rpm/400N/75C/1h

1a

1a

1a

1a

Cu Strip Test3h/100C

24h/100C

226

230

296

194

207

278

Penetration [1/10mm]

(ASTM-D 217) PuPw60

Pw60.000

0,53 / 1,980,20 / 1,09Oil Bleeding

18h/168h@40C

+ 2800 / - 3000


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2.3. Optimized Turbine and Compressor Additive

for new low Sulfur Base Oils

Observation: Base Oil Trend goes towards Group II, III and III+

These base stocks are quite different in composition compared toGroup I (Solvent Neutrals)

Most additive packages today have been developed and optimized forSolvent Neutral type base stock

Existing standard packages do not give the maximum benefits due todifferent additive response

SN based products are not good enough to pass the newest OEM gasturbine specs (GEK 107395, DIN 51515 p.2 L-TG)

How to make the most out of these excellent base oilsfor industrial applications?


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0

200

400

600

800

1000

1200

Group I Group II Group III Group III+ Group IV

LifeTime[min]

RC I RC New RC Old

C1 C2 C3

2.3. Optimized Additive for new Base Oils

- RBOT Test (ASTM-D 2272) @ 0,4% Additive -


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- RBOT Test (ASTM-D 2272) -

0

200

400

600

800

1000

1200

1400

1600

RC New

0,3%

RC New

0,4%

RC New

0,6%

RC Old

0,6%

RC New

0,3%

RC New

0,4%

RC New

0,6%

RC Old

0,6%

LifeTi

me[min]

Limit MAN Turbo

Limit DIN 51515 T.2 (L-TG))

Limit GEK 107395

in Group I

Base Oil

in Group III+

Base Oil


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- TOST Test Data (ASTM-D 943) -

45004800

5300

4700

8500

12000

5800

7500

0

2000

4000

6000

8000

10000

12000

14000

RC New

0,3%

RC New

0,4%

RC New

0,6%

RC Old

0,6%

RC New

0,3%

RC New

0,4%

RC New

0,6%

RC Old

0,6%

TimetoTAN2

mgKOH/g[h]

in Group I Base Oil in Group III+ Base Oill

Limit DIN 51515 P.2 (L-TG)

Limit GEK 107395


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2.3. Optimized Additive fo new Base Oils

- Conlusions -

Applications for new additive technology / Group III Base Oils

in industrial lubrication

Single shaft gas trubine oils (new standard GEK107395)

Gas turbines (DIN 51515 L-TG part 2, new since 2003)

Heavy Duty Turbo Compressors (MAN)

Multigrade / HVI Circulating Oils with extended oil drain

If you are considering to use the higher quality type base

fluids such as Group III, III+ or PAOs

dont give performance advantages away by using old

additive technology


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Summary


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3. Summary

Address some current trends and technical needs on the industriallubricant market

Present latest solutions from an RC additive point of view

Growing use of esters as base fluids

Anti-Hydrolysis Additive Carbodiimide

Growing demand for high temperature stable greases

Ready for use Polyurea Thickener Technology

Upcoming base oils Group III and new specs on gas turbine oils

Specifically optimized additives to get the maximum performance

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