TRENDS HEAVY DUTY DIESEL ENGINE OILS KEY DRIVERS AND CONSEQUENCES FOR THE ENGINE OIL
Frank Machatschek
Key Drivers For Engine Oil Development
 
New requirements for the engine oil
 
Key Drivers For Engine Oil Development
 
Significant reduction has been achieved
> EU 3: Exhaust Gas Aftertreatment Systems needed
 
Modern Trucks Are Not Big Polluters Anymore
1 truck 100 trucks49 trucks
2008 Euro V
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Reduction of NOx And PM
EURO III (2000)
NOx, g/kWh; ESC test
Development mainly in USA, Japan and EU
EPA 10, Post New Long Term, Euro 6
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NOx g/kW.Hr 
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Series1
Copyright of Shell Global Solutions
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
Europe
Route
Europe
Euro IV Euro V Euro VI
Brazil Euro II Proconve P-5 (Euro III) Proconve P-7 (Euro V)
China China II (Euro II) China III (Euro III) China IV (Euro IV)
India Bharat II (Euro II) Bharat III (Euro III)
Russia Euro I Euro II Euro III Euro IV Euro V
South
Thailand Euro III Euro IV
Non
Europe
Mexico US 1998 / Euro III US 2004 / Euro IV TBD
Major cities in China and India have adopted
accelerated time schemes
Different timelines due to fuel quality
 Worldwide Introduction Of Emission Standards
 
Reduction of NOx & PM BUT new fundamental changes:
1) New test cycles: WHTC (60% colder than 300°C) and WHSC
2) Emission in-use compliance up to 700.000 km
3) Number limit for particulates (6-8 1011/kWh)
Euro 6 Is More Revolution Than Evolution
 
Black Smoke Is A Thing Of The Past
Keep this engine running!
between the DPF and the Engine Oil?
 
DPF Working Principle
Residues from engine oil („ash“) also being trapped in DPF 
Cannot be removed through regeneration
 Ash accumulation in DPF
 Active and passive regeneration
Engine Oil Related Ash Accumulations In The DPF
Increased back pressure, filter cleaning and maintenance cost
 
Euro 6 Aftertreatment System: Complex And Sensitive
 
Sulphated Ash Phosphorous Sulphur
DOC Low Medium High
SCR Low High Medium
DPF High Medium High
 
Low SA-P-S Engine Oil Is Required
Engine oils that are low in SA-P-S are needed to protect EATS
Sulphated A sh (DPF blocking, poisons NOx sensor esp Mg)
Phosphorus (poisons catalysts, NOx sensor)
Sulfur (poisons catalysts and DPF blocking)
 
Base oil Gp I, II, III PAO E ster
Dispersants Hig h MW, mono, mono-bis and bis  Succinimides
 Antioxidant  Aminic Hindered phenol
Pour point depressant Polymethacrylate
VI improver  S tyrene-is oprene Olefin co-polymer  polymethacrylate
 Anti wear Pr imary, s econdary and aryl ZDTPs
Detergents  Salicy lates  Sulphonates Phenates
 Sulfur
 Sulfur
 Sulfur
 Sulfur
 Ash
 Ash
Phosphorus
Phosphorus
1) Low SA-P-S  Limitation of key performance chemistry
Consequences/Challenges
Low SA-P-S with significant effect on DPF ash loading
 
 Achieved through: highly efficient oil mist separator and optimised
piston-piston ring-liner system
Reduction Of Oil Consumption
1) Low SA-P-S  Limitation of key performance chemistry
2) Reduced oil consumption  Less re-freshment
Consequences/Challenges
Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz Quiz
Question:
 
Key Drivers For Engine Oil Development
 
Engine protection: OEMs increased service life of engines
Capability for extended oil drain interval
 
Significant increase of ODI over 5 decades (Mercedes-Benz)
 ACEA E2 ACEA E7/E9 ACEA E4/E6 
RLD-2 RLD-3
Emission Stage Sulphur Limit in Fuel
Euro 1, 1993 max. 0,200 %
Euro 2, 1996 max. 0,050 %
Euro 3, 2001 max. 0,035 %
Euro 4, 2006 max. 0,005 %
Euro 5, 2009 max. 0,001 %
Euro 6, 2014 max. 0,001 %
Oil Drain
EU Oil Drain Intervals 100.000 - 150.000 km
 
0 20 40 60 80 100 120 140 160 Drain interval ( ×1000 km)
1) With extended drain package (extra filters) 2) On board computer calculates actual drain interval.
 ACEA E6/E9 ACEA E6 1)
 ACEA E2 ACEA E7/E9 ACEA E4/E6 
M 3275 M 3677 M 3477 M 3377 2)
228.3/31 228.5/51 228.51 2)
1) Low SA-P-S  Limitation of key performance chemistry
2) Reduced oil consumption  Less re-freshment
3) Longer ODIs  oil has to last longer
Consequences/Challenges
Euro 6 Pistons: Steel Replaces Aluminium
OM 501 Euro 5  Aluminium
OM 471 Euro 6 Steel
PFP, bar: max 200 > 200
Heat Conductivity, W/mK: ~200 ~50
Race for high Peak Fire Pressure (PFP)
More power and higher efficiency
Higher mechanical load needs to be withstood longer: 1,5 Mio km
  Steel more durable
Steel pistons for better Fuel Economy
Lower compression height:  21 mm for MD engine (PC: 9 mm)
Longer conrod  smaller pivoting angle  closer to ideal vertical movement
lower friction losses on the cylinder wall
 
 
1) Low SA-P-S  Limitation of key performance chemistry
2) Reduced oil consumption  Less re-freshment
3) Longer ODIs  has to last longer
4) Lower steel heat conductivity  higher oil peak temperatures
5) Longer service life  long term protection/cleanliness cabapilities
Consequences/Challenges
Performance Proof Point: Total Cost Of Ownership
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Engine Milage [km]
500.000 km field trial with Euro 6 prototype engines at Mercedes-Benz´s accelerated test
circuit in South Africa
 
Key Drivers For Engine Oil Development
 
Lower operating costs  fuel 2nd largest cost block (25-30%)
 
More power, Higher speed, Higher payload – Less consumption
~ 40% reduction of fuel consumption
Significant Progress Over Last 5 Decades
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1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2014
Power Fuel
Output Consumption
[HP] [L/100km]
Key Areas To Improve Fuel Economy
 
Downsizing, restricting oil flow rate, thermal management, hybrids,...
Combustion: PFP, adv. injection system, temp  less soot but more NOx
Friction: coatings (DLC), ultra-fine honing pattern, low vis oils  durability
 Aerodynamics
Front active shutters, aerodynamic underbody
 Auxilliaries
On/off air compressor, steering pump
Control Systems and Training
Driver training and monitoring
1) Low SA-P-S  Limitation of key performance chemistry
2) Reduced oil consumption  Less re-freshment
3) Longer ODIs  oil has to last longer
4) Lower steel heat conductivity  higher oil peak temperatures
5) Longer service life  long term protection/cleanliness cabapilities
6) Highly efficient combustion  more nitration/oxidation
Consequences/Challenges
Clear link between oil viscosity and fuel economy
Consistant phenomenon in all engine makes/model and cycles
 
   [   %    ] ,    B   a   s   i  s  :
   1    5    W   -   4
 
MAN Euro 4
Performance Proof Point: Fuel Economy
Consistant FE performance of Shell Rimula R6 LME 5W-30 in different models/brands and emission stages
 Volvo Euro 5
Low friction engine oils for Euro 6 First Fill
OEMs increasingly use 10W-30 and 5W-30 instead of 10W-40, 15W-40
Mercedes-Benz and MAN only allow 5W-30 as First Fill in all Euro 6 engines
Increased Use Of Low Viscosity Engine Oils
 
 
Less focus on viscosity grades (eg 15W-40, 5W-30)
More focus on High Temperature High Shear (HTHS) viscosity
HTHS better reflects real conditon in an engine, esp in plain bearings
High shear rate: nrotor : 3.200 min-1 , high temperature: 150°C
HTHS used to be “frozen” at min 3,5 mPa*s due to durability concerns
Now: 2,9 and even 2,6 are considered in industry ( 0W-20, 0W-10)
Rotor
Lubricant
Cylinder
 
1) Low SA-P-S  Limitation of key performance chemistry
2) Reduced oil consumption  Less re-freshment
3) Longer ODIs  oil has to last longer
4) Lower heat conductivity  higher oil peak temperatures
5) Longer service life  long term protection/cleanliness cabapilities
6) Highly efficient combustion  more nitration/oxidation
7) Thinner oils  no compromise on durability
Consequences/Challenges
2 x 120k km (75k ml) ODI
Engine inspection
 
Performance Proof Point: FE & Durability
 
Copyright of Shell Global Solutions
Performance Proof Point: FE & Durability
TATA and Shell first to launch 10W-30 API CI-4 Plus in India
3% FE vs 15W-40
Copyright of Shell Global Solutions
TATA and Shell first to launch 10W-30 API CI-4 Plus in India
3% FE vs 15W-40 1.600 hrs Full load full speed
Performance Proof Point: FE & Durability
 
1) Low SA-P-S  Limitation of key performance chemistry
2) Reduced oil consumption  Less oil has to last longer
3) Longer ODIs  oil has to last longer
4) Lower heat conductivity  higher oil peak temperatures
5) Longer service life  long term protection/cleanliness cabapilities
6) Highly efficient combustion  more nitration/oxidation
7) Thinner oils  no compromise on durability
Consequences/Challenges
Improved nitration and oxidation resistance
Improved wear protection
Fuel Economy  lubricant viscosity as low as possible
NOx, more renewable/bio fuels under discussion
Greenhouse Gas (CO2 , N2O) under discussion
EU GHG target: 60% reduction for transport sector (1990-2050)
 
Driverless Truck
Front/rear/side sensors & cameras
 
First fully approved low SA-P-S engine oil for extended ODI
First to prove extended engine lifetime and ODI targets for Euro 6
First to develop next generation low viscositiy prototype lubricants for leading OEMs
Shell will continue R&D efforts for world-class products and services
 You Can Be Sure Of Shell
 
Carlos Torres
Market Influence: Technology
output
 
Technology developed for on-highway emissions control will be used in off-highway
equipment
EGR= Exhaust Gas Recirculation, VGT=Variable Geometry Turbo charging, SCR=Selective Catalytic Reduction
•Cooled EGR • VGT Turbo Charging •Diesel Oxidation Catalysts
•Cooled EGR •Diesel Particulate Filters •Diesel Oxidation Catalysts •Enhanced VGT
•Cooled EGR •Diesel Particulate Filters •Diesel Oxidation Catalysts •Enhanced VGT •SCR •Enhanced Fuel Injection •CNG/LNG •Hybridization
Off-Highway Tier 3
Off-Highway Tier 4 Final
Future Fuels for the Mining Sector
Current Technology • Ultra Low
Next Generation • LNG • Higher
 
Oil Film Thickness
   F  r   i  c   t   i  o   n
  c  o   e    f    f   i  c   i  e  n   t 
 valve train
 
Key challenges to HDDEO in the field
Demonstration of real world performance of Shell HDDEO in the key areas of:
Protection
Durability
North American Test Site Komatsu WA 500 (Tier 3) Switch from API CI-4+ to
 API CJ-4 Rimula R4 MV 15W-40
Long Engine Life = Lower Maintenance Costs
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API CI-4+ 15W-40
 
Copyright of Shell Global Solutions
North American Quarry  Volvo and Caterpillar Tier 2 & Tier 3 engines
Extended Oil Drain From 250 to 350 hours
Engine Oil(s): Rimula R5 LE 10W-30
Long Oil Drain Interval
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Rimula RT4 L 10W-30
Rimula R5 LE 10W-30