INNOSPEC RESEARCH UPDATE. Nigel Broom 2017

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Rudolf Briggs
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2 FUTURE CHALLENGES FUEL

4 March 2015

5 HYDRO-TREATMENT Composition Changes Aromatics / Olefins Diminished Solvency Properties

6 HYDRO-TREATMENT Composition Changes Aromatics / Olefins Saturated Hydrocarbons Poorer Low Temperature Properties

7 HYDRO-TREATMENT Composition Changes Aromatics / Olefins Saturated Hydrocarbons Polar Compounds Natural Biocides, Stabilizers, Lubricants

8 TYPES OF DEPOSITS

9 INTERNAL DIESEL INJECTOR DEPOSITS (IDID) RECENT HISTORY OF IDID PROBLEMS 2007 IOSP w/ OEM notes injector problems in NY City Transit. Problems also in Europe (Spain, France, Denmark) 2008 IOSP introduces ECOCLEAN 2009 Lz, Afton, Deere present engine data to Industry 2010/11 IOSP develops in-house surrogate tests for various deposits IOSP introduces next generation ECOCLEAN 2012 Wide industry acceptance of multi-faceted problem 2015 Continued growth in market for IDID detergents

10 DIESEL DEPOSITS PROBLEMS ASSOCIATED WITH HPCR Low End Cost High End Cost Problem Result (Class 8) (Heavy Duty/Mine Haul Truck) Vehicle-dependent fuel filter blocking Shortened PMI $10 $300 Injector sticking Downtime, Maintenance Warranty issue $250 Up to $35,000* Power loss Diminished drivability $100 $1,000 Economy deficits Increased fuel spend ($) $100 $1,000 Diminished lube oil life Increased oil spend ($) $50 $9,000 Increased emissions Compliance issue - Unknown Fuel pump gumming Downtime, Maintenance Warranty issue $250 $4,000 Excessive DPF Plugging/Regen Downtime, increased fuel spend, maintenance $300 $3,000 EGR valve sticking Downtime, Maintenance Warranty issue $250 $2,000 Fuel line corrosion Downtime, Maintenance Warranty issue $250 $1,200 * Catastrophic injector failure Problem of Downtime = $$$$

11 DIESEL DEPOSITS WHERE HPCR DEPOSITS CAN ACCUMULATE INJECTOR Pressure pin, DMV Needle Push Rod Nozzle body Injection orifice

12 INTERNAL DIESEL INJECTOR DEPOSITS TYPES OF INJECTOR DEPOSITS Deposit Carbonaceous Description -Caused by HPCR degrading fuel (dehydrogenation) -Most common type of deposit -Can occur alone or with MC deposits

regions via small orifices* 200 C Heat is generated (friction) and / or shear (jetting) 260-300 C Hydrogen abstraction + Heat

13 INTERNAL DIESEL INJECTOR DEPOSITS CARBONACEOUS DEPOSITS ~ 150 C Caused by oxidation and degradation of ULSD due to increased temperatures and pressures of modern HPCR diesel engines HPCR injectors require passage of fuel from high to low pressure regions via small orifices* 200 C Heat is generated (friction) and / or shear (jetting) C Hydrogen abstraction + Heat + Pressure GRAPHITE + Time Carbonaceous FUEL * Bosch ISBN , 1995 Point source temperatures can be much higher (1000 C)

INTERNAL DIESEL INJECTOR DEPOSITS TYPES OF INJECTOR DEPOSITS Deposit

(dehydrogenation) -Most common type of deposit -Can occur alone or with

-Can occur with carbonaceous deposits Effect of temperature/pressure in

14 INTERNAL DIESEL INJECTOR DEPOSITS TYPES OF INJECTOR DEPOSITS Deposit Carbonaceous Metal Carboxylate Description -Caused by HPCR degrading fuel (dehydrogenation) -Most common type of deposit -Can occur alone or with MC deposits -White, soapy deposits -Caused by excursion events and sodium -Can occur with carbonaceous deposits Effect of temperature/pressure in newer HPCR injection systems increases the amount of deposits formed (all types)

15 INTERNAL DIESEL INJECTOR DEPOSITS METAL CARBOXYLATES Deposit Build-up on Diesel Metering Valve or Nozzle Needle Injector stuck closed Injector stuck open Nozzle Needles Bosch-DDC Injector Under-fueling Over-fueling no power/no start Catastrophic engine damage Caused by excursion events & Na DMV/Armature Plate

16 FUTURE CHALLENGES INJECTOR TRENDS

17 INTERNAL DIESEL INJECTOR DEPOSITS EVOLUTION OF FUEL INJECTION PRESSURES FOR HEAVY-DUTY Advanced high-pressure high-flexible FIE Pressure at nozzle - bar Common rail Unit pump Unit injector Inline pump source - Bosch SAE Oct. 2008

18 TYPICAL HIGH PRESSURE COMMON RAIL (HPCR) FUEL SYSTEM Common Rail High pressure pump Pressure-side filter Injectors Lift pump Suction filter Fuel tank Return Injected fuel Returns Modern engines have recirculation system fuel experiences high temperatures and pressures which lead to deposits throughout the system

19 INJECTOR TRENDS HEAVY DUTY INJECTION CAPABILITIES TO 2020 EPA EURO 2 US07-10 EURO 4/5 US EURO 6 More nozzle holes Decreased hole diameter 1500 bar 1995 CARB/US 2020 EURO bar 2007 Fewer nozzle holes Increased hole diameter Source: Graham, et al; Delphi Automotive, SAE

20 INJECTOR TRENDS CHALLENGES Light and heavy duty injectors will operate at higher pressures Greatly increased fuel stressing Injector tolerances will greatly reduce Injectors more sensitive to trace deposits Multiple injection events for Emissions control, power and economy Increased need to maintain injectors clean

21 FUTURE CHALLENGES FILTER DEPOSITS

FUTURE CHALLENGES FILTRATION INCREASING DEMAND ON FUEL CLEANLINESS Modern diesel engines require very clean fuel Hard particles can damage internal

22 FUTURE CHALLENGES FILTRATION INCREASING DEMAND ON FUEL CLEANLINESS Modern diesel engines require very clean fuel Hard particles can damage internal components Increasing pressure upstream to increase fuel filtration LOCATION Filter Porosity Bulk INLET 4 25 m Bulk OUTLET 4 10 m Dispenser 10 m (or none) Engine 2 5m

FUTURE CHALLENGES IOSP FILTER STUDIES Possible Causes of Filter Blocking Microbial

Wax Catalyst (biodiesel) Glycerides (biodiesel) Sterol Glucosides (biodiesel)

Over the last few years almost 700 filters have been analysed 162 field filters in

23 FUTURE CHALLENGES IOSP FILTER STUDIES Possible Causes of Filter Blocking Microbial Contamination Dirt Metal Carboxylate salts Carbonaceous deposits Icing Paraffin Wax Catalyst (biodiesel) Glycerides (biodiesel) Sterol Glucosides (biodiesel) Polyethylene (biodiesel) FAME saturates (biodiesel) Innospec Fuel Filter Studies Over the last few years almost 700 filters have been analysed 162 field filters in 2014/15 Many of these causes are found IN MOST CASES NO SINGLE ATTRIBUTABLE CAUSE IS PRESENT

24 PRIMARY FILTER PLUGGING COMPONENTS AUGUST 2014 JULY 2015 (162 FILTERS) Microbial 40% Other 11% Filtration Issue 4% Degraded Diesel and Biodiesel 23% Biodiesel Impurities 2% Paraffin Wax 13% Carbonaceous 7% Carboxylates 19% Inorganic 11%

25 SECONDARY FILTER PLUGGING COMPONENTS AUGUST 2014 JULY 2015 (162 FILTERS) Biodiesel Impurities 2% Degraded Diesel and Biodiesel 32% Filtration Issue 3% Other 9% Inorganic 23% Microbial 24% Carboxylates 22% Carbonaceous 16% Paraffin Wax 10%

FUTURE CHALLENGES PROGRESS WITH FILTER DEPOSIT ANALYSIS FTIR spectroscopy for filter deposit analysis is well known Diamond ATR spectroscopy now allows insitu analysis of the deposit surface DW10B

26 FUTURE CHALLENGES PROGRESS WITH FILTER DEPOSIT ANALYSIS FTIR spectroscopy for filter deposit analysis is well known Diamond ATR spectroscopy now allows insitu analysis of the deposit surface DW10B filters showed a build up of black deposits at end of test Use of a novel deposit control additive significantly reduced black deposits These additives are effective in preventing injector deposits, and deposits throughout the fuel system. Fuel + Zinc Fuel + Zinc with Detergent

INTERNAL DIESEL INJECTOR DEPOSITS

INTERNAL DIESEL INJECTOR DEPOSITS INTRODUCTION IDID What is it? DW10C CEC engine test development DW10C engine testing Innospec testing Vehicle Testing Conclusions INTERNAL DIESEL INJECTOR DEPOSITS (IDID)