5w-xx heavy duty diesel formulations-delivering improved fuel economy and durability_npra 2010

8/9/2019 5W-XX Heavy Duty Diesel Formulations-Delivering Improved Fuel Economy and Durability_NPRA 2010

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Jeff Thompson

Crankcase Technologist

Infineum USA LP

Linden, NJ

5W-XX Heavy Duty DieselFormulations

Delivering Improved

Fuel Economy andDurability


2/31

Table of Contents

HDEO Market Status and Needs

Durability Testing

Fuel Economy Testing Program

GM 6.5L Engine Fuel Economy Testing

FTP Dynamometer Fuel Economy Testing

SAE J1321 Testing

Base Oil impacts

Industry challenges

Summary


3/31

Market Status and Needs

There are many drivers attracting increased attention to HDD

vehicle fuel economy

Increasing attention to reduce CO2emissions & potential

regulation

Fleet fuel economy standards reaching into Class 8 trucks

Increasing crude and diesel prices focus attention to diesel truck

fuel economy.

New purchases

Existing fleet management

Can the engine oil help improve fuel economy and meet this

growing need?


4/31

What drives fuel economy?

Engine oil lubricants systems consume energy while pumping andengine oil films play a role determining frictional losses in engineoperation

Efficiency could be increased with a engine oil lubricant tailored tominimize friction and pumping losses

Durabilityremains a paramount concern and should not be sacrificedfor fuel economy benefits

This requires a carefully balanced lubricant formulation with anoptimized combination of additive components, viscosity modifiersand base oils.


5/31

Data suggests that SAE 5W-40 & lighter viscosity gradesdirectionally provide improvements in fuel economy

Although difficult to quantify in limited field testing, fleet operators reporthaving seen fuel economy improvements on the order of 1% to 3% in theirmonthly fuel bill over an entire fleet when using lighter viscosity grades

For a large fleet this savings can be quite substantial. A fleet of 50 truckscould save ~ $30,000 in diesel fuel during the year

Europe has had significant experience with

SAE 5W-30 oils and confirms this benefit

Fuel Economy Background Information


6/31

Durability of Fuel Economy Formulations

A common misconception that fuel economy is a durabilitycompromise!

If no formulation changes were made lower HTHS formulations

reduce engine operating film thicknesses and could lead to an

increased the risk of engine wear

Careful design of the additive package can alleviate these

concerns with formulation changes for:

Optimized anti-wear componentry addressing boundary

interactions Optimized soot dispersancy avoiding soot agglomeration and

subsequent soot induced wear


7/31


Formulation modifications were developed and confirmed usingAPI CJ-4 engine wear tests

Performance proven: API CJ-4 and OEM performance levels achieved

Candidate SAE 5W-30 Field Trial involving the same additive chemistry used in

the fuel economy tests

API Testing Successes with Candidate SAE 5W-30 & 5W-40 formulations Greater than13001300merits in Mack T-12 : Mack EO-O /VDS-4 performance

Greater than16001600merits in the Cummins ISM with the SAE 5W-30

Greater than18001800merits in the Cummins ISM with the SAE 5W-40

Exceeding Cummins ISB limitsExceeding Cummins ISB limitsfor API and OEMs with SAE 5W-XX oils Meeting or surpassing API and OEM limits in all other necessary tests

FE Formulations can exceed durability requirements in industryaccepted engine tests!!


8/31


2007 Emission Configuration Cummins Engine Testing at CookeTrucking, Mt. Airy, NC

Eleven 2008 Peterbilt model 387, Class 8, long-haul trucksequipped with 2007 Cummins ISX 450-hp EGR engines 5 Vehicles on an SAE5W-30demonstration oil

3 Vehicles on an SAE 15W-40 CJ-4/SM reference oil

Same additive chemistry proven in API and OEM testing used inCandidate SAE 5W-40 and SAE 5W-30 formulations

Engine Teardown and inspection completed between 500,000and 600,000 miles

Inspection and ratings completed with Cummins participation


9/31


Engine inspection shows

excellent performance of all

oils

Candidate SAE 5W-30

demonstrates outstandingprotection and comparable

to both the Candidate SAE

5W-40 and Reference

SAE 15W-40 oils.

Vehicle X136 X130 X127

Oil Grade 5W-30 5W-40 15W-40

Test mileage 532K 580K 577K

Average Sludge

Rating 9.41 9.28 8.84

Avg Cylinder Liner

Varnish Rating 8.82 9.02 8.78

Avg Top Compression

Ring Gap, in. 0.02 0.02 0.02

Avg 2nd Compression

Ring Gap, in. 0.048 0.048 0.049

Average Hone

Retention, %

93 94 95

Average Max.

Cylinder Liner Wear, in. 0.0015 0.0018 0.0011

Cooke Engine Teardown Results


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Engine Performance SAE 5W-30 Teardown

Roller follower wear: Trace wear

Oil pan sludge Rating:9.2 Merit

Camshaft wear:

Trace Wear


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Engine Performance SAE 5W-30 Teardown

Excellent Wrist PinBushing

Protection Hone Retention

Rating

93% average

Copper exposed:Zero


12/31


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SAE 5W-XX formulations can also provide more wear protection than

conventional oils in cold starting conditions

Candidate SAE 5W-XX formulations help lubricate critical engine parts

much faster than seen with an SAE 15W-40 conventional oil. This is a

function of base stock selection, pour point depressant and viscosity

modifier selection.

Cold Box Testing with used oils in diesel engines clearly showed this

benefit in pressure readings on startup after the cold soak

0

10

20

30

40

50

60

70

80

0 60 120

180

240

300

360

420

480

540

Time (s)

Pressu

re(psi)

5W40

15W40


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Field Testing, API and OEM engine tests all show superb engine

protection

This confirms that with proper formulation, a fuel economy

formulation does not sacrifice durability and can provide the some of

the highest levels of durability available in the marketplace

Lets now examine fuel economy.



15/31

Fuel Economy Testing

Infineum sought to explore the fuel economy benefits of SAE 5W-XX

formulations for diesel engines in a methodical fashion

GM 6.5 L

US ARMY FE Test

(slight modification)

ENGINE RIG

Modified

GM 6.5 L


17 Stages

ENGINE RIG

Light Duty Diesel

Dynamometer Testing


Dynamometer Car Test

SAE J1321


Class 8 Truck Testing


16/31

GM 6.5L Fuel Economy Results

There are little to no industry established and accepted engine tests formeasuring fuel economy in diesel engines

Infineum noticed that a US Army FE test based on the GM 6.5L diesel

engine provided a reasonably consistent measurement of fuelconsumption and was practical from a cost and time standpoint

Early testing focused on three oils:

SAE 15W-40 API CJ-4/SM Reference, HTHS Viscosity of4.2cP

Candidate SAE 5W-40 Oil, HTHS Viscosity of3.8cP (run x2)

Candidate SAE 5W-30 Oil, HTHS Viscosity of3.0cP

5W-XX Oils were formulated with Grp III and Grp IV (PAO) base stocks


17/31

GM 6.5L Fuel Economy Results

Test protocol:

GM 6.5 Liter, indirect-injected 160

hp diesel engine mounted on dyno

Fuel consumption rate was

measured over the length of the

test

Independent laboratory conducted

testing (Southwest Research

Institute)


18/31

Fuel Economy Relationship to HTHS

FE improvement shown as a function of HTHS relative to SAE 15W-40 grade

SAE 5W-40 run twice with similar results showing very good repeatability

SAE 5W-30 demonstrates best fuel economy relative to SAE 15W-40

Test has good repeatability and can discriminate between oils

HTHS Effect Relative to SAE 15W-40

0.0

0.2

0.40.6

0.8

1.0

1.2

1.4

1.6

1.8

2.0

3.0 3.3 3.5 3.8 4.0 4.3 4.5

HTHS@150C, cP

%

FuelEco

nomyImprovement

SAE 5W-30

SAE 15W-40

SAE 5W-40 Run 2SAE 5W-40 Run 1


19/31

Refining the GM 6.5L Test

GM 6.5L test was useful but was the drive cycle representativeof real world operation?

Modified engine speeds and load conditions specifically tosimulate different driving conditions throughout 18 cycles

Translated results to project fuel economy at High Idle, LineHaul, and Off Road services

Three test oils:

SAE 15W-40 API CJ-4/SM Reference, HTHS Viscosity of4.2cP

Candidate SAE 5W-30, HTHS Viscosity of3.5cP Candidate SAE 5W-30, HTHS Viscosity of2.9cP


20/31

Modified GM 6.5L Fuel Economy Results

Overall, the lower the HTHS viscosity, the better the fuel economy compared to an

SAE 15W-40 with 4.2 cP HTHS viscosity

Over-the-road or highway hauling shows more advantage for lower viscosity oils than other

operating conditions

Up to a 1.5% FE improvement was demonstrated in the GM 6.5L test

Can we continue to confirm a fuel economy benefit as we scale up fuel economy testing?

0.00

0.250.50

0.75

1.00

1.25

1.50

1.75

Overall High Idle Line Haul Off Road

3.5 cP HTHS 2.9 cP HTHS

%

FuelEconom

%

FuelEconom

Imp

rovement

Imp

rovement

Simulated Engine Operating ConditionsSimulated Engine Operating Conditions

SAE 5W-30 Fuel Economy


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Fuel Economy FTP Cycles

Moving away from engine rigs, fuel economy needed to bedemonstrated on an FTP dynamometer with a production vehicle

To achieve this a 2007 light duty diesel pickup truck running through

various FTP Fuel Economy Cycles

The candidate SAE 5W-30 was evaluated in FTP tests relative to areference SAE 15W-40


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SAE 5W-30 Fuel Economy Results - FTP Cycle

Results are in agreement with the improvement seen in the SwRI test utilizing GM 6.5L

engine

Proven FE improvement on engine dyno, in a pick-up truck, next was to demonstrate in

actual on-highway Class 8 diesel truck

0.0

1.0

2.0

3.0

4.0

5.0

City Highway 55/45

Combined

Cold Start Stabilized Hot Start

F

uelEconomy

F

uelEconomy

Im

provement(%)

Im

provement(%)

Driving CycleDriving Cycle

FTP cycle FE data SAE 5W-30


23/31

SAE J1321 Fuel Economy Testing

Joint TMC/SAE Fuel Consumption Test Procedure Type II

This provides a standardized test procedure for comparing in-service fuel

consumption of a vehicle operated under two conditions (lube oil

differences)

Two test oils:

Reference SAE 15W-40 API CJ-4/SM

HTHS Viscosity of4.2cP

Candidate SAE 5W-30 API CJ-4/SM

HTHS Viscosity of2.9cP


24/31

SAE J1321 Fuel Economy Testing

Design of experiment Four trucks, 1 Control Truck, 3 Test Trucks

All trucks completed base-line, on-highway segment with SAE 15W-40

Then all trucks had their oil changed

Control truck was drained of SAE 15W-40 and refilled with fresh SAE 15W-40

Test trucks were drained of SAE 15W-40 and filled with fresh SAE 5W-30

Finally, all trucks completed a test on-highway segment

The percent difference in fuel consumption was calculated for each test

truck relative to the control truck


25/31

SAE J1321 Fuel Economy Results

As in the GM 6.5L testing up to a 1.6 % improvement in fuel economy is possiblewith the candidate SAE 5W-30 oil compared to the SAE 15W-40 control oil inactual on-highway testing

Repeatability was demonstrated with Truck 85 at a 1.5% improvement

Statistical analysis from Truck 81 showed it to be an outlier and notrepresentative of the true performance of the SAE 5W-30 oil

1.61.5

0.00

0.25

0.50

0.75

1.00

1.25

1.50

1.75

2.00

FuelEconomy

Im

provement(%)

Truck 84 Truck 85


26/31

SAE J1321 Fuel Economy Results

Overall, results were excellent and aligned with the GM 6.5L dynotesting.

Premium additive technology can enable fuel economy improvementthrough the use of light viscosity grades by providing outstanding wear

performance

The SAE 5W-30 oil demonstrated fuel economy credits in a class 8vehicle in real world operating conditions.

Fuel Economy improvement of 1.5 - 1.6% over theuse of an SAE 15W-40 oil!


27/31

Base Stock Impacts

Fuel Economy formulations for HDD are likely to require a higherproportion of lower viscosity stocks to meet lower HTHS. Tocontinue to meet volatility requirements, higher quality basestocks are needed

HDD Fuel Economy formulations are expected to use Grp IIIand/or PAO to meet viscosity and volatility requirements

Demand is expected to increase steadily along with the demandsfor base oils needed to enable their sale

These oils also become advantaged in low temperature, used oilpumpability. This makes them additionally well suited for colderclimates


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Formulation Considerations

Formulation variables other than HTHS can be quite importantfor fuel economy and should be considered in development offuel economy formulations

Current API CJ-4 specification mandates an HTHS150 minimum of

3.5 cP, limiting potential fuel economy gains

Selection of these component types have also been found toeffect observed fuel economy:

Viscosity Modifier

Detergent Components

Friction Modifiers


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Striking a balance

Oil drain intervals and fuel economy are understandably linked As the engine oil ages, viscosity increases and soot accumulation

reduce fuel economy from its initial highs

The magnitude of this effect is additive chemistry dependant and may

be able to be mitigated with a tailored formulation

Economic balance

Oil drain change interval balance with improved fuel economy

Environmental balance

Oil drain waste generation balanced with improved fuel economy


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Summary

Lower viscosity engine oils can provide improved fuel economyperformance compared to traditional SAE 15W-40. SAE 5W-30 grade

may be a unique value-added offering in the marketplace

Lower viscosity grade HDD engine oils provide significant improvements

in protection for cold temperature start ups where most engine wear

takes place

SAE 5W-40 is currently an excellent choice, providing improved fuel

economy, improved low temperature wear protection and excellent

overall engine protection.

All OEMs allow SAE 5W-40 engine oils, many allowing SAE 5W-30

Provides outstanding value for end customers

Lower viscosity does not mean a compromise in wear performance if the

overall balance of additive technology, viscosity modifier and base oil

blends are robust


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5w-xx heavy duty diesel formulations-delivering improved fuel economy and durability_npra 2010

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