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TRANSCRIPT
III. Viscosity and Engine Oils – and why it matters to all base oil demand sectors
Amy Claxton, CEOMy Energy Consulting and Training
Agenda
18 February 2020 Viscosity Measurements and Engine Oils 2
• The technical details of viscosity – what is it, and what do those numbers mean for base oils?
• Putting it all together: SAE J300 engine oils
• Why engine oil specs matter to ALL base oils
Viscosity refresher
• Viscosity = resistance to flow
• Higher viscosity = greater resistance to flow
Group IS150N
Group IS325N
Group IS650N
Group ISolvent150BS
• Thicker, higher viscosity fluids flow more slowly
• Higher viscosity = thicker film boundary for protecting metal parts from scoring or being damaged
18 February 2020 Viscosity Measurements and Engine Oils 3
Viscosity – but at what temperature?
• Viscosity of a fluid changes with temperature (…the definition of VI…!)
• Fluids become “runny” or decrease in viscosity at hotter temperatures
• Fluids become “thicker” or increase in temperature at colder temperatures
• You must specify a temperature when you quote a viscosity … otherwise it is meaningless
18 February 2020 Viscosity Measurements and Engine Oils 4
You were already specifying a temperature but didn’t know it …
DistillateName
Paraffinic base oil name Corresponds to base oil viscosity (SSU @ 100F or cSt @ 100C)
light 100 solvent neutral “100SN” (~ 100 SSU, 4 cSt)
mid 150 solvent neutral “150SN” (~ 150 SSU, 5 cSt)
heavy 500 (or 600) solvent neutral “500SN” (~ 500 SSU,10 cSt)
resid Bright Stock, BS150, or SEBS (~ 2500 SSU, ~ 30 cSt)
Base oil fractions
De-asphaltin
g
“DAO”
Deasphalted Oil
Light
Mid
Heavy
Vacuum residuum
18 February 2020 Viscosity Measurements and Engine Oils 5
• Temperature is built into the ATSM test method for viscosity in SSU or cSt
Viscosity – but at what pressure?
• Viscosity of a fluid will change with pressure (shear stress) – the thicker the fluid, the less it will deform or change with pressure
• You must include a pressure when you quote a viscosity; otherwise it is meaningless
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• Viscosity can be described as a “dynamic” viscosity (stand alone, relative to itself) or as a “kinematic” viscosity (relative to a standard density scale defined by water)
Water at 20 °C has a dynamic viscosity of 1.00 cP
Water at 20 °C has a kinematic viscosity of 1.00 cSt.
You were already accounting for pressure too …
DistillateName
Paraffinic base oil name Corresponds to base oil viscosity (SSU @ 100F or cSt @ 100C)
... Because SSU and cSt are kinematic viscosity measurements with pressure relative to water built into the scale
Light
Mid
Heavy
Vacuum residuum
18 February 2020 Viscosity Measurements and Engine Oils 7
• Pressure is built into the ATSM test method for viscosity in SSU or cSt
Base oils must perform over a wide range of conditions
• Base oils must flow and protect machinery at extreme high and low temperatures
• … and at high and low pressures within the environment as well as between sliding parts
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Base oil viscosity testing is performed via ASTM laboratory tests
• The ASTM test will specify exact temperatures, pressures, length of time, and type of equipment
• Viscometers come in all shapes and sizes
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Four primary viscosity tests used to predict fluid behavior in varying conditions
10
Low T / High P
Cold Cranking Simulator Viscosity (CCS)
High T / High P
High Temperature/High Shear Viscosity (HTHS)
Mini-Rotary Viscometer Viscosity (MRV)
Low T / Low P
Kinematic Viscometer Viscosity (KV)
High T / Low P
Temperature
Pre
ssu
re (
Sh
ea
r)
Not measured in refineries except kinematic vis; measured in finished oil after additives are incorporated
18 February 2020 Viscosity Measurements and Engine Oils
CCS Viscosity: Low temp viscosity at high pressure
11
• Cold cranking simulator test (CCS): low temp, high pressure (shear)
- Oil resistance to flow is responsible for the majority of drag put on an engine starter during cranking – think “engine startability”
• CCS (ASTM D5293) correlates with engine speed during low temperature cranking – dynamic viscosity quoted in centipoise (cP)
18 February 2020 Viscosity Measurements and Engine Oils
MRV Viscosity: Low temp viscosity at low pressure
12
• Mini-rotary viscometer test (MRV): low temp, low pressure (shear)
• Low temperature pumpability used to address air-binding and flow problems during initial cold engine start
• ASTM D4684 used to replicate low pressure, low temperature conditions; measured in cP
18 February 2020 Viscosity Measurements and Engine Oils
HTHS Viscosity: High temp viscosity at high pressure
13
• HTHS – high temperature and high pressure (shear) test – ensures adequate viscosity on piston ring surfaces and cylinder walls seal combustion chamber – tracks oil film thickness
• Correlates with engine wear developed during high temperature cranking and measured in centipoise (cP) at 150°C (ASTM D4683)
18 February 2020 Viscosity Measurements and Engine Oils
Kinematic Viscosity: High temp viscosity at low pressure
14
• Kinematic viscosity (KV) - high temp, low pressure (shear)
• Used to ensure full film or hydrodynamic viscosity to minimize engine wear
- Measured in centistokes (cSt) at 100°C (ASTM D445)
18 February 2020 Viscosity Measurements and Engine Oils
Refiners and marketers quote base oils in kinematic viscosityMetric System - cSt
Kinematic viscositiesImperial System - SSUKinematic viscosities
• SSU in the Imperial system
• cSt in the metric system
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Agenda
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• The technical details of viscosity – what is it, and what do those numbers mean for base oils?
• Putting it all together: SAE J300 engine oils
• Why engine oil specs matter to ALL base oils
J-300 engine oil classification system
• Most engine oils are blends of different viscosity base oils with VI improver and pour point depressant to meet viscometric properties at low and high temperatures
- The term “multi-grade” refers to the oil’s ability to meet low & high temp / pressure specs
- The “W” refers to low temperature “winter” characteristics (not “weight”!)
- Monograde engine oils are a single number and do not contain VI improvers
• The Society of Automotive Engineers (SAE) developed a viscosity-basedlabeling system for engine oils in 1911 called “J-300”
- used globally, many revisions over the years
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J300 specs are met with unique base oil and additive formulations
• Additive companies develop additive packages, formulate sample oils, and run massive test programs
• Additive companies along with oil companies and finished lubricant formulators have R&D programs to develop engine oils
Infineum
Oronite
Afton
dozens of others
Chemtura Lubrizol
Evonik Rohmax
18 February 2020 Viscosity Measurements and Engine Oils 18
Current SAE J-300 engine oil viscosity grades
Viscosity Grade
Cold Cranking Simulator (cP)
MRV TP-1 (cP) Cold Temp Pump
Kin Vis @ 100°C,
(cSt)
High Temp Shear Vis @ 150°C (cP)
0W < 6200 @-35°C < 60,000 @ -40°C > 3.8 --
5W < 6600 @-30°C < 60,000 @ -35°C > 3.8 --
10W < 7000 @-25°C < 60,000 @ -30°C > 4.1 --
15W < 7000 @-20°C < 60,000 @ -25°C > 5.6 --
20W < 9500 @-15°C < 60,000 @ -20°C > 5.6 --
25W <13000 @ -10°C < 60,000 @ -15°C > 9.3 --
20 -- -- 5.6 - 9.3 > 2.6
30 -- -- 9.3 - 12.5 > 2.9
40 -- -- 12.5 - 16.3 > 2.9*
40 -- -- 12.5 - 16.3 > 3.7**
50 -- -- 16.3 - 21.9 > 3.7
60 -- -- 21.9 - 26.1 > 3.7
18 February 2020 Viscosity Measurements and Engine Oils 19
• Values measured with additives and base oil except kinematic viscosity – base oil only
Example: viscosities of a 5W-30 engine oil
Viscosity Grade
Cold Cranking Simulator (cP)
MRV TP-1 (cP) Cold Temp Pump
Kin Vis @ 100°C,
(cSt)
High Temp Shear Vis @ 150°C (cP)
0W < 6200 @-35°C < 60,000 @ -40°C > 3.8 --
5W < 6600 @-30°C < 60,000 @ -35°C > 3.8 --
10W < 7000 @-25°C < 60,000 @ -30°C > 4.1 --
15W < 7000 @-20°C < 60,000 @ -25°C > 5.6 --
20W < 9500 @-15°C < 60,000 @ -20°C > 5.6 --
25W <13000 @ -10°C < 60,000 @ -15°C > 9.3 --
20 -- -- 5.6 - 9.3 > 2.6
30 -- -- 9.3 - 12.5 > 2.9
40 -- -- 12.5 - 16.3 > 2.9*
40 -- -- 12.5 - 16.3 > 3.7**
• Must meet all “5W” and “ 30” viscosities – or it’s not a 5W-30 … !
18 February 2020 Viscosity Measurements and Engine Oils 20
Qualifications for API SAE certified engine oils
• In addition to meeting viscosity requirements on SAE J300 chart, oils are rigorously tested in certified laboratories worldwide
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• “Bench tests” are run by chemists to certify oils meet all required physical and chemical properties
• “Engine tests” are run by engineers to certify oils meet all engine test procedure limits
- engine tests are run for a specified length of time
- engines are torn down and evaluated for wear
Example: GF-5 bench tests – GF-6 coming
Bench Tests GF-4 vs. GF-5 Test ProcedureFRESH OIL VISCOMETRICS (J300)
0W-40, 5W-40 & 10W-40 changed from 2.9 to 3.5 cp minimum at 150 C
HTHS
CATALYST COMPATIBILITYPhosphorus, mass % max
Mass % maximum set at 0.08% wt D4951
Sulfur Content, mass % max
0.5% wt maximum for all vis grades except 10W-30 which is 0.6% wt maximum
D4951 OR D2622
Phosphorus Volatility New to GF-5 ILSAC/OIL approved test method, test length and calculation; specification has yet to be determined
SEQUENCE IIIGB
WEARPhosphorus, mass % min
Same as GF-4 0.06% wt
D4951
OIL CONSUMPTIONNoack Volatility Same as GF-4 D5800GCD Distillation Same as GF-4 D6417
18 February 2020 Viscosity Measurements and Engine Oils 22
Example: N. American engine tests; ACEA has similar tests
Engine Test GF-4 vs. GF-5 Test Procedure
High Temperature Deposits
TBD Limit for Weighted Piston Deposit (WPD) under discussion
SEQUENCE IIIG
Oil Thickening Same as GF-4 SEQUENCE IIIG
Sludge and Varnish TBD Limits for Average Engine Sludge increased from 7.8 in GF-4 to 8.0 in GF-5. Limits for Rocker Arm Cover Sludge are under discussion
SEQUENCE VG
Oil Screen Clogging Oil Screen Clogging limit set at 15% SEQUENCE VG
Valve train Wear Same as GF-4 SEQUENCE IVA
Bearing Corrosion Same as GF-4 SEQUENCE VIII
Used Oil Aeration New to GF-5 GM indicated need; if adopted, limit must be determined
EOAT (ASTM D6894)
Fuel Economy New to GF-5 Proposed specifications issued by ILSAC
SEQUENCE VID
18 February 2020 Viscosity Measurements and Engine Oils 23
What’s Next? You put too many engineers in a room
• SAE EOVC (Engine Oil Viscosity Classification) Task Force
- developing a new SAE J300 category
- includes new, lighter viscosity engine oil grades with HTHS properties below current minimums
18 February 2020 Viscosity Measurements and Engine Oils 24
• New low viscosity engine oils must be formulated with Group III, Group III+, Group IV (PAO) and Group V (POE, PIO)
• New grade is 0W-16 (not 0W-15) due to concerns over mix-ups with 15W-xx grades
• New naming convention reduces the 2nd number number by 4 (future will be 0W-12, 8,4); the numbers have no inherent meaning
WE LOVE ACRONYMS: SAE EOVC TF
• API Engine Oil Licensing and Certification System API 1509 seventeenth edition (138 pages)
Recommended Reading
• American Chemistry Council Petroleum Additives Product Approval Code of Practice (137 pages)
• Lubricant Test Monitoring System ASTM Test Monitoring Center Requirements for Engine Test Stand Laboratory Calibration (219 pages)
18 February 2020 Viscosity Measurements and Engine Oils 25
… War and Peace … Complete Works of Shakespeare …
Agenda
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• The technical details of viscosity – what is it, and what do those numbers mean for base oils?
• Putting it all together: SAE J300 engine oils
• Why engine oil specs matter to ALL base oils
Remember: half of base oils go into some type of engine oil
Sources: My Energy Databases, Fuchs Lubricants, Kline & Company
Demand by Sector
17 February 2020 Base Oil Demand 27
• Refiners make base oils with properties historically set to meet engine oil specifications (most stringent; largest sector)
What if I don’t care about making base oils for engine oils?
• Global base oil refinery viscosity grades and quality standards were developed by large base oil manufacturers and licensed worldwide
• All other market sectors conform to the exact same base oil qualities
• Refiners make 3-4 base grades
• Intermediate grades blended
• Same grades for all customers
• Refiners must meet the most stringent properties of the largest market segment … which is the engine oil market
18 February 2020 Viscosity Measurements and Engine Oils 28
Base oil quality: set by engine oil requirements
• Do you mean that refinery base oil properties like VI, viscosity, volatility, and pour point are actually set to meet engine oil requirements?
• Yes
• Do you mean that tires, cosmetics, metalworking fluids and everybody else conforms to engine fluid qualities?
• Yes
• What if my application doesn’t need that same VI, saturates, color, etc?
• Too bad
18 February 2020 Viscosity Measurements and Engine Oils 29
Objectives / Agenda
• Did we learn anything?
18 February 2020 Viscosity Measurements and Engine Oils 30
Viscosity refresher
• Viscosity = resistance to flow
• Higher viscosity = greater resistance to flow
Group IS150N
Group IS325N
Group IS650N
Group ISolvent150BS
• Thicker, higher viscosity fluids flow more slowly
• Higher viscosity = thicker film boundary for protecting metal parts from scoring or being damaged
18 February 2020 Viscosity Measurements and Engine Oils 31
Four primary viscosity tests used to predict fluid behavior in varying conditions
32
Low T / High P
Cold Cranking Simulator Viscosity (CCS)
High T / High P
High Temperature/High Shear Viscosity (HTHS)
Mini-Rotary Viscometer Viscosity (MRV)
Low T / Low P
Kinematic Viscometer Viscosity (KV)
High T / Low P
Temperature
Pre
ssu
re (
Sh
ea
r)
Not measured in refineries except kinematic vis; measured in finished oil after additives are incorporated
18 February 2020 Viscosity Measurements and Engine Oils
SAE J-300 engine oil specs set today’s base oil quality specs
• Engine oil specifications will continue to be the focus of most base oil refining investments
Finished Lubricant Demand by Sector
18 February 2020 Viscosity Measurements and Engine Oils 33