next generation gasoline developmentsource: api/martec, 2010 confidential and proprietary. this...

Next Generation Gasoline Development

Fuel Additives for Future Fuel and Vehicle Technologies

PEMEX/IMP Technical Seminar

July 11, 2012

Company Confidential

Presentation Overview

The Gasoline Market

Industry Trends & Issues

Performance Parameters

Direct Injection Gasoline (DIG) Overview

Defining DIG

The DIG market and growth expectations

DIG test development and capabilities

Additive Direction

Confidential and Proprietary. This document should not be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation

Fuel Additives Are Enabling An Evolution in Fuel and

Vehicle Technology

Emission control and energy conservation policies are

drivers for change in vehicle and fuel technology

Fuel additives enable the safe and efficient production,

transport and utilization of fuel

Fuel additives maintain optimal vehicle performance


Current Drivers for Gasoline and Additives

Impact on Fuel Properties – Additives

Loss of Octane

Corrosion – Silver

Improved Stability

Fuel Change

Sulfur Reduction

Emissions Reduction

Reduce Sulfur/Sulfate Emissions

Exhaust Aftertreament Performance

Impact on Fuel Properties – Additives

Increase Octane

Corrosion Distribution Challenges

Fuel Change

Ethanol Blending

Emissions/Energy

Increase Fuel Volume

Reduce Petroleum

Dependence

Renewable Fuel


Decisions for the Motor Industry:

How to Deliver Low Emissions and Low CO2 ( The Octane Challenge: Cameron And Associates)

Engine

Downsized

Direct

Injection

Turbocharged

or

Supercharged

Optimized for 98 RON -

Knock Sensored to run on

95 RON


Evolving Engine Technology to Meet Emission and

Energy Needs Defines Additive Requirements

Technology Cleanliness Challenge for Fuel Additives

Precise A/F control Valves, injectors

Cam Phasing Valve, injector, intake

Variable Valve Lift Valve, injector, intake

Turbocharging Hotter engine, EGR, intake

Cylinder Deactivation Valve and injector

Variable Charge Motion Valves, intake system, charge motion device

Variable Compression Ratio Intake

Hybrids Valve, injector, intake

Gasoline Direct Injection Injectors

Diesel – HSDI Increased diesel use, injectors

Diesel – High Pressure Common Rail Injector coking, injector sticking


Emission Mandates

Energy Efficiency Mandates

Globalization of OEMs,

Suppliers, & Others

Technology Changing Consumer Behavior

KEY GLOBAL TRENDS

Drivers of Continued Industry Change


http://images.google.com/imgres?imgurl=http://www.miamiinternationalexchange.com/yahoo_site_admin/assets/images/globalization.184162836_std.jpg&imgrefurl=http://www.miamiinternationalexchange.com/services&usg=__SO1YJmodOuXlVjZWiYrh1hlZI0M=&h=339&w=514&sz=46&hl=en&start=34&itbs=1&tbnid=MwSI6mGNOgXhZM:&tbnh=86&tbnw=131&prev=/images?q=globalization&gbv=2&ndsp=18&hl=en&sa=N&start=18

March 5 New Product Launch

Branded Additive: Nitrogen Enriched

Marketing Message

“No other gasoline Protects Better”

“NEW Formula with 20% more cleaning agents than before!”

“Delivering (statistically) 0% Gunk = Unsurpassed engine protection”

Under the Nitrogen Enriched campaign and supported by Passionate Experts

Supported by 100 million dollar marketing campaign

Treat Rate: Calculated treat rates based on 20% more cleaning agent claim.

V-Power >6x LAC (previously 5x LAC). Regular is ~3x LAC (previously ~2.5x LAC)


Branded Additive: Invigorate. Also market Amoco brand name for Premium

Marketing Message: Currently marketing “more miles per tank” fuel economy claim

supported by a 4 to 8 mile improvement (keep clean) over low detergent fuels

Relaunching Invigorate Q1 2012 supported by fuel rewards program

$500 million marketing campaign over next 2 years. Want to be #1 marketer east of Rockies

Treat Rate: Not Top Tier registered. BP offers Regular with Invigorate, Silver with

extra Invigorate and Amoco Ultimate with maximum Invigorate


Marketing Message: Low price, high quality, members only

Treat Rate: 5x LAC (~2x Top Tier) at select locations in all grades


Adoption of High Efficiency Gasoline Engine

Technology Continues to Grow

0%

20%

40%

60%

80%

100%

2005 2010 2015 2020

Perc

en

t N

ew

Veh

icle

Sale

s

EU

US

Japan

Designed to use high octane

fuel for optimal fuel efficiency

Operation on lower octane fuel

increased fuel consumption

Direct Injection Engine in

Gasoline Vehicles

1.6L Turbo

Direct Injection

Source: API/Martec, 2010


Nissan DIG Turbo (Nissan Pure Drive)


Options for OEMs to Improve Fuel Economy

www.autonews.com/apps/pbcs.dll/article?AID=/20090519/ANA02/905199971/1186

TECHNOLOGY COMPARED WITH IMPROVEMENT IN FUEL

EFFICIENCY

Gasoline direct injection plus turbocharging

Multiport fuel injection up to 12%

Dual-clutch transmission Automatic transmission up to 10%

Cylinder deactivation Using all 8 cylinders 7%

Continuously variable valve timing

Fixed valve settings 5%

Hybrid electric Traditional 25 - 50%

Stop-start system Idling 5%

5+ speed transmission 4-speed 3 - 4%

Diesel engine Gasoline engine 25 - 30%

Different combinations of these technologies for different markets


http://www.autonews.com/apps/pbcs.dll/article?AID=/20090519/ANA02/905199971/1186



Direct Injection Gasoline Growth


Direct Injection Gasoline

Fuel injected at high pressure directly into

cylinder instead of intake port

Improves Fuel Economy, Increases power,

lowers exhaust emissions

Increased air charge volume gives more

power.

Evaporative cooling allows the compression

ratio to be raised, providing a higher level of

thermodynamic efficiency

Improved knock resistance permits more

aggressive ignition curves

Source: Ford Motor Company


Source: Tom McCarthy, “Ford’s Perspective on Future Engines and Their Fuels,” U. of Wisc. Engine Research Symposium, 2011.


Used with permission from API

• Fuel/air mixed before entering cylinder

• Requires stoichiometric air:fuel mixture

• Efficient 3 way catalyst - low emissions

• Fuel/air mixed inside cylinder

• Increases power and improves FE

• NOX and particulate emissions can be

challenging

Port Fuel Injection Direct Injection

Direct Injection Gasoline (DIG)


Wall-guided injection vs. Spray-guided injection

Wall-guided injection

Intake side mounted location

Cooler tip temperature

Less fuel impingement on spark plug

Higher spray impingement on cylinder

walls

Increased probability of oil dilution

Spray-guided injection

Centrally mounted location

Higher injector tip temperature

Higher ignition stability over the

engine operating map

High degree of mixture stratification

possible


Direct Injection Combustion Modes

Homogenous Charge

Used in high-load operation

Stoichiometric air/fuel ratio

Fuel charge is uniform in the

combustion chamber

Stratified Charge

Used in part-load operation

Lean air/fuel ratio mixture

Fuel charge is locally rich at

the spark plug


Benefits Challenges

DIG Opportunities


DIG Overview

DIG engines are liable to fuel related deposit formation

There is no industry accepted test for such deposits

PFI has ASTM D5598-01, ASTM D6421-99a and TOP TIER Fuel Injector Fouling

Initial Performance Standard

It cannot be assumed that additives suitable for PFI engines will protect DIG

engines

Need for a method to determine additive performance in DIG

SEM showed that a high LTFT does correlate with a heavily deposited fuel

injector and the deposits are stable

Further investigation showed highly deposited injectors slows the start of

injection and the effects the spray pattern


Determining fuel injector fouling

Track the increase in Long Term Fuel Trim (LTFT) via OBD-2

• LTFT is an ECM algorithm for adaptive fuel trim

– To compensate for the reduced flow through a plugged injector, the

injector must stay open for a longer time

-15

-10

-5

0

5

10

15

20

25

0 5 10 15 20 25 30 35 40 45 50

Lon

g Te

rm F

ue

l Tri

m, %

Test Time, hrs

2008 Pontiac Solstice Test Summary

08PS2-2

DIG Fuel Injector Fouling


Injector Photographs

New General Motors 2.0L Ecotec injector: X-Ray


SEM Photos

New injector


Direct Injector Deposits

Base fuel

LTFT=18.7%

Afton additive

LTFT= 0%


Direct Injection Gasoline Engines – Injector

Cleanliness

Direct injection gasoline (DIG)

engines have fuel introduced

directly to combustion chamber

Injectors can coke causing

injectors to open longer to inject

proper fuel amount

Coking can lead to loss of

power, higher emission and

reduced fuel efficiency

Properly designed fuel additives

required to control coking - 10

- 5

0

5

10

15

% C

han

ge in

Op

enin

g

Time

Base Fuel

Additized Fuel

Increased

Coking


Base fuel

Base fuel + PFI* only additive

Base fuel + additive optimized for PFI* & DIG

Both additives have excellent PFI engine IVD performance

% S

hif

t in

LT

FT

Direct Injection Gasoline (DIG) Performance


DIG Dirty-up / Clean-up Test

Dirty up with base fuel.

Clean up with additive use


73% restoration

Mini Cooper DIG Vehicle – Injector clean-up


VAG DIG vehicle – Injector clean-up

-5

0

5

10

15

20

25

30

0 20 40 60

LT

FT

, %

Test Time, hrs

VW Golf 1.4 TSI

55 % restoration

-5

0

5

10

15

20

25

30

0 10 20 30 40 50 60 L

TF

T, %

Test Time, hrs

AUDI A4

47.5% restoration


LTFT response to a range of additives


Additive “A” Treat Rate Effects


Engine Designs and Cleanliness

Engine technologies changing

DISI, Downsizing, Pressure Charging etc

• More stress on fluids including fuel

Appetite for detergent chemistries is changing

Gasoline additives need to protect older PFI and latest DISI with one fuel.

Additives with good PFI performance may not protect DIG engines against

injector deposits.

Additive companies and Fuel Marketers must ensure that their

products support the introduction of new vehicle technologies

Afton has developed a proprietary test for DIG performance, and

which can be extended to represent a Clean Up test.

The test has the potential to be able to provide performance discrimination

that corresponds to in-service experience

The use of a performance additive package can provide improved

power and fuel efficiency in DIG engines


Example Performance Benefit with Fully

Formulated Package

104

108

112

116

120

Base fuel + Additive @ 2000km

To

rqu

e,

Nm

Torque (Power) increase Fuel consumption decrease

6.9

7

7.1

7.2

7.3

7.4

7.5

7.6

Base fuel + Additive @ 2000km

Fue

l co

nsu

mp

tio

n, l

/100

km


Direct Injection Gasoline Testing

Keep-Clean testing

Dramatically reduces the shift in LTFT (measure of injector

plugging)

66% Improvement

83% Improvement


Providing improved DIG performance

Direct Injection Gasoline Testing

0%

1%

2%

3%

4%

5%

6%

7%

8%

2008 VW Jetta 2008 Pontiac Solstice

Sh

ift

in L

TF

T%

Keep-Clean Testing

Additive A

DIG Additive

Company Confidential


Key Point Summary

DIG is the future of engine technology

Better Fuel Economy is driving DIG demand

Many DIG vehicles on the road today

Exponential growth expected

DIG technology development is essential

DIG opportunity

Evidence of DIG deposit related problems in the field

Issues likely to grow as DIG continues to penetrate market

• Detergent additive system will be critical in controlling deposit forming

tendencies

• Detergent Chemistries respond differently

• Higher additive treat rates may be necessary for optimal vehicle

performance


Key Point Summary con’t

Clean Fuel solutions are complicated and are exemplified by biofuels

Gasoline/ethanol blends are increasing and will vary in performance depending on the source of the ethanol

Emission control and energy conservation policies are drivers for change in vehicle and fuel technology

Fuel Additives enable the evolution of fuel and engine technology to meet these needs in a cost effective manor

Fuel additives provide means to effectively and efficiently modify fuel properties

Maintain optimal engine performance and reduce emissions

Higher additive treat rates may be necessary for optimal vehicle performance


Muchas Gracias!!!

Preguntas???

Ron Fricke

Fuels Technical Associate

[email protected]

(804) 788-5069


next generation gasoline developmentsource: api/martec, 2010 confidential and proprietary. this...

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