Pushing the Boundaries with High-Performance Lubricants STLE Frontiers Workshop October 25, 2015

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1 Pushing the Boundaries with High-Performance Lubricants STLE Frontiers Workshop October 25, 2015 Selim M. Erhan

2 Key Discussion Points A look at high molecular weight, additives with high UNLOCK THE FORMULATION polarity. FREEDOM Comparisons of alphaolefin/alphaolefin ester YOU VE BEEN WAITING synthetic, FOR. base stock (ERS 40): properties and One revolutionary molecule performance makes it possible. Elevance Aria WTP 40. No more blending esters and PAOs for additive solubility. New Elevance Aria WTP 40 combines the functionality of synthetic esters and PAOs into a single, high-performance lubricant base stock with significantly improved additive solubility. With the high viscosity, shear stability and elastomer compatibility of El evance Aria WTP 40, you can formulate the wear-resistant, low-foaming solutions your customers need in high-viscosity gear and compressor lubricants. Seize the fr eedom. Learn more and request field trial support at elevance.com/aria Neat base stock (ERS 40) versus PAO Base stock bound (ERS 40) versus blended PAO/ester Fully formulated lubricants Rig test data and model study ERS 40 gear oil formulations 2

3 Tribologist s Description of Lubrication Boundary Regime (1) is where surface interactions dominate Thin-Film Friction (2) Also called mixed lubrication, this consists of both Boundary and EHD, however it is not simply an average of the two regimes Elastohydrodynamic Regime (3) is where fluid rheology dominates

4 Mixed Regime Movement Pressure Movement Overcoming Friction

5 Boundary Regime Severe Pressure

6 EP Mechanism Friction generates heat, which causes a chemical reaction on the surface of the metal.

7 Do we have alternatives? 7

8 FUNCTIONAL GROUPS Functional Groups are like hands and feet

9 FUNCTIONAL GROUPS

10 In very slow starts and very heavy loads oil-starved regions will be vulnerable. 10

11 FUNCTIONAL GROUPS

12 If fluids can not be squeezed into a smaller volume if it can not escape 12

13 General vegetable oil polymerization

14 Microtap Forming Tap 105 % Efficiency on 1018 CRS MCCP Dimer Trimer Polymer

15 Oxidized oils Oil Gardner- Holdt 25 o C CentiStokes Gardner - Holdt 25 o C CentiStokes Soybean K 275 Z Canola K 275 Z Rapeseed K 275 Z Castor - Z CentiStokes x Specific Gravity = Centipoise

16 High Frequency Reciprocating Rig (HFRR) Boundary Regime Force Detector Oscillating Arm with Steel Ball Temperature-Controlled Sample Cell with Steel Disk Surface Boundary Friction Ball Oscillates Across Disk Measure Force to move ball Load Applied by Hanging Weights

17 Boundary Friction oxidized veg oils The friction coefficient for base oil alone is The friction for 5% of the Z viscosity oil is lower than for 10% of the same oil at K viscosity

18 Mini Traction Machine (MTM) A ball and disk in contact are driven independently to create a mixed rolling/sliding contact. The frictional force between the ball and disk is measured by a force transducer. Can Place Steel Ball Or Piece of Friction Material on Arm Friction is Measured by Force Detector Attached to Shaft Holding the Friction Material Disk is Immersed in Oil

19 Thin Film Friction at 75 C with MTM 5% conc 10% conc At a concentration of 5 wt%, canola oil, rapeseed oil, and soybean oil reduce friction. Castor oil and the chlorinated paraffin slightly increase friction. Increasing the concentration from 5 to 10 wt% maintains friction reduction with canola oil, rapeseed oil, and soybean oil, while the chlorinated paraffin still increases friction. The major fatty acids in both canola oil (18 carbon) and rapeseed oil (22 carbon) is mono-unsaturated. The significant reduction in the castor oil is most likely a result of an increase in the soluble, friction-reducing component Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation

20 Thin Film Friction at 125 C with MTM 5% conc 10% conc At a concentration of 5 wt%, canola oil, rapeseed oil, and soybean oil reduce friction. Castor oil and the chlorinated paraffin slightly increase friction. Increasing the concentration from 5 to 10 wt% maintains friction reduction with canola oil, rapeseed oil, and soybean oil, while the chlorinated paraffin still increases friction. The major fatty acids in both canola oil (18 carbon) and rapeseed oil (22 carbon) is mono-unsaturated. The significant reduction in the castor oil is most likely a result of an increase in the soluble, friction-reducing component Afton Chemical Corporation, All Rights Reserved. Not to be copied, shared, or reproduced in any media without the express written permission of Afton Chemical Corporation

21 Twist Compression Lubricant Starvation Conditions 4. Applied Force 5. Rotation 1. Tool Specimen Moment arm Transmitted Torque 3. Lubricant 2.Workpiece Specimen 6. Leveling Bearing Contact Pattern (Squeeze-film)

22 Twist Compression Test Results Time until failure Lubricant Breakdown Static coefficient of friction Average Coefficient of Friction Coefficient of Friction at Specific Time Friction Factor(s) / Weighted avg. Sheet Damage Tool Damage / Galling Tribochemical Residues

23 COF initial COF average Lubricity additives in naphthenic 10% on TCT

24 PAOs New building blocks and derivatives for the lubricants UNLOCK THE FORMULATION market FREEDOM Comparison of alphaolefin/alphaolefin ester synthetic, YOU VE BEEN WAITING base FOR. stock (ERS 40): properties and performance One revolutionary molecule makes it possible. Elevance Aria WTP Neat 40. base stock (ERS 40) versus PAO No more blending esters and PAOs for additive solubility. New Elevance Aria WTP 40 combines the functionality of synthetic esters and PAOs into a single, high-performance lubricant base stock with significantly improved additive solubility. With the high viscosity, shear stability and elastomer compatibility of El evance Aria WTP 40, you can formulate the wear-resistant, low-foaming solutions your customers need in high-viscosity gear and compressor lubricants. Seize the fr eedom. Learn more and request field trial support at elevance.com/aria Base stock bound (ERS 40) versus blended PAO/ester Fully formulated lubricants Rig test data and model study ERS 40 gear oil formulations 24

25 Differentiated Catalyst Technology Allows for conversion of complex molecules such as fatty acids and esters Traditional Catalyst Our Proprietary Catalyst A Ethylene B C D 2-butene A C Methyl oleate ethylene D B D A C B D 1-decene Propylene Propylene C B 9-decenoic acid methyl ester A 25

26 Elevance Renewable Sciences Building Blocks Enable design of unique lubricant base stocks esterification unsaturated methyl ester metathesis 26

27 New Base Stock Technology Combines the performance of Groups IV and V into one base stock Wide range of viscosities and polarities through synthetic versatility Process: Catalytic polymerization of Linear a-olefins and linear a-olefin esters Performance Benefits Improved additive solvency & formulation compatibility Seal compatibility Low-foaming Reduced wear Lower friction 27

28 Aniline Point Formulation Flexibility - Additive Solvency ERS 40 s Balanced Solvency Enables Creation of Robust Formulations Balanced aniline point for improved formulation compatibility and performance ERS 40 PAO 40 Ester Group I Proup II Test Method: ASTM D611 Base Stocks 28

29 Formulation Simplicity with ERS 40 Versus PAO 40/Ester Blends Performance of PAO/ester blend versus ERS 40 (bound ester) base stocks Conventional Lubricant With PAO 40 PAO 40 Base Stock Lubricant with ERS 40 ERS 40 Base Stock Compatibilizing Agent (Ester) Formulation Freedom eliminating need to use ester to blend additives Additive Package Additive Package 29

30 ERS 40 Shows Increased Shear Stability Versus PAO/ester blend PAO with bound ester forms thicker film at contact than PAO/ester blends Rheological performance, 100 C Kv100 C= cSt ERS 40 mpao 40/ester PAO 40/ester 30

31 Improved Performance - Formulated Lubricant Formulation Comparison: 75W90 GL-5 Lubricant Based on ERS 40 Versus PAO 40 ERS 40 has bound ester versus PAO requires ester to be blended in ERS 40 maintains higher viscosity provides increased options for viscosity grade Formulation Composition ERS 40 PAO 40 ERS 40 (%) PAO 40 (%) PAO 4 (%) Ester (%) Additive package (%) C

32 Formulation Flexibility - Additive Solvency ERS 40 Unique Molecule Provides Additive Solvency & Compatibility Base Stocks ERS 40 PAO 40 PAO 40/ 10% ester Clarity, brightness and color demonstrate excellent solubility of additives Fully Formulated GL-5 Gear Lubricant 6% GL-5 Add pack No compatibilizers added Compatibilizers added 32

33 Base Stock Performance: Tribology Bench Tests EHL MTM Rheometer 33 MPR

34 Improved Performance - Base Stock ERS 40 Shows Increased Film Thickness at Low Speeds Indicating Improved Boundary Lubrication EHL fluid film measurement, 100 C* At 100C; 40N PAO 40 40N (a) ERS 40 40N 34 *EHL test was done by Dr. Girma Biresaw, USDA

35 Coefficient of friction Ball wear scar, diameter um Benefits of Bound Versus Blended Ester ERS 40 Demonstrated Excellent Friction and Wear Performance ERS 40 shows improved wear and friction results when compared to blended PAO 40/Ester and mpao 40/Ester Base Oil Friction properties at 100 C 600 Wear performance at 100 C Wear of neat base stocks, Kv100C= Friction of base stocks, Kv100 C= cst PAO 40 mpao 40 ERS 40 0 PAO mpao ERS Slide/roll ratio, % MTM mini traction machine test Wear Tracks 35

36 Micropitting Rig (MPR) Test Conditions: Mimic Wind Turbine Realistic Contact Pressure & Film Thickness Temperature = RT - 135C Velocity = 0-4m/s Load= N (3GPa) SRR = 0-200% ~1x10^6 contact cycles/hour *MPR test was done by Dr. Aaron Greco, ANL

37 Improved Performance - Base Stock MPS Predicts Reduced Micropitting with ERS 40 as a Base Stock ERS 40 shows reduced micropitting as evidenced by no horizontal and diagonal blue wear scars PAO 40 ERS 40 Sample: Pure ERS 40 and PAO 40, Kv100 C of 38.1cSt MPR Micropitting test: 90C, 300N, 3m/s, SRR=20%, 4hr *MPR test was done by Dr. Aaron Greco, ANL 37

38 No Foaming Seen in Formulated Lubricant Containing ERS 40 ASTM D892 Foaming Tendency Foam Stability Base Stock in API GL-5 Foam Volume, ml Foam Volume, ml Formulated API GL-5 Gear Lubricant Seq I 24 C Seq II 93 C Seq III 24 C Seq I 24 C Seq II 93 C Seq III 24 C PAO 40/ester mpao 65/ester ERS

39 Improved Performance Formulated Lubricant Increased cleanliness with ERS 40 based API GL-5 formulations Versus PAO 40/ester (adipate or TMP) blends GL-5 Spec PAO 40/ester ERS 40 Adipate TMP Sludge > % Visc Inc. < Varnish > Automotive Gear Oil Oxidation Test, L-60-1 (ASTM D 5704) 39

40 Key Application Performance Insights Market drivers for high performance lubricant UNLOCK technology THE FORMULATION FREEDOM New building blocks and derivatives for the YOU VE BEEN WAITING lubricants FOR. market One revolutionary molecule makes it possible. Elevance Comparison Aria WTP 40. of synthetic high viscosity base stocks - properties and performance No more blending esters and PAOs for additive solubility. New Elevance Aria WTP 40 combines the functionality of synthetic esters and PAOs into a single, high-performance lubricant base stock with significantly improved additive solubility. With the high viscosity, shear stability and elastomer compatibility of El evance Aria WTP 40, you can formulate the wear-resistant, low-foaming solutions your customers need in high-viscosity gear and compressor lubricants. Seize the fr eedom. Learn more and request field trial support at elevance.com/aria Neat base stock Base stock blends with compatibilizers Fully formulated lubricants Rig test data and model study of formulated gear oils 40

41 Improved Performance - Formulated Lubricant Formulation Comparison: 75W90 GL-5 Lubricant Based on ERS 40 Versus PAO 40 ERS 40 has bound ester versus PAO requires ester to be blended in ERS 40 maintains higher viscosity provides increased options for viscosity grade Formulation Composition ERS 40 PAO 40 ERS 40 (%) PAO 40 (%) PAO 4 (%) Ester (%) Additive package (%) C

42 Coefficient of friction Diameter of ball wear scar, um Improved Performance - Formulated Lubricant ERS 40 Improved Friction and Reduced Wear in Formulated Gear Oils A 75W90 gear lubricant formulation tested at 100C on MTM 0.03 COF versus slide/roll ratio, 100 C 800 MTM Wear PAO 40/ester GL-5 (75W90) ERS 40 GL-5 (75W90) Slide/roll ratio, % 0 ERS 40 GL-5 (75W90) PAO 40/ester GL-5 (75W90) 42

43 Improved Performance Formulated Lubricant Strong L-37 (ASTM D6121) Load Evaluation Pass Showing Performance Under Extreme Pressure and Load Gear Rating Pinion Ring API GL-5 MT-1 Limits Wear min. Rippling min. Ridging min. Pitting + Spalling min. Scoring Deposits Report Corrosion Report Discoloration 9 8 Report Overall Rating PASS PASS 43

44 Additive Film thickness, nm Improved Performance - Formulated Lubricant ERS 40 Increased Rate and Thickness of Additive Deposition Improved molecular architecture and polarity contribute to faster and increased additive deposition MTM-SLIM additive film measurement (ZDDP model system) Series1 Series Rubbing time, min ERS 40 +1%ZDDP PAO 40/ester +1%ZDDP 44

45 Key Take-Aways Polymeric molecules with multiple polar points are very effective in the mixed UNLOCK THE regime moving into the boundary regime FORMULATION FREEDOM YOU VE BEEN WAITING FOR. The form stronger and thicker adsorbed One revolutionary molecule makes it possible. Elevance Aria WTP 40. fluid films and intramolecular interactions No more blending esters and PAOs for additive solubility. New Elevance Aria WTP 40 combines the functionality of synthetic esters and PAOs into a single, high-performance lubricant base stock with significantly improved additive solubility. With the high viscosity, shear stability and elastomer compatibility of El evance Aria WTP 40, you can formulate the wear-resistant, low-foaming solutions your customers need in high-viscosity gear and compressor lubricants. Seize the fr eedom. Learn more and request field trial support at elevance.com/aria The molecular design with chemically bound ester shows advantages over the PAO/ester blends in additive compatibility, seal compatibility, foam control, friction, wear, excellent cleanliness and tribological performance 45

46 Acknowledgments Colleagues at Elevance Renewable Sciences Dr. Ali Erdemir and Dr. Aaron Greco at Argonne National Laboratory Tribology Group Dr. Girma Biresaw at USDA National Center for Agricultural Utilization Research Dr. Mark Devlin and Dr. Carl Bennett at Afton Chemical 46

47 Thank you.

48 ERS 40: A High-Performing Base Stock Combines chemical and physical properties of PAO and ester into one high-performing base stock Base Stock Property ERS 40 KV 100 C, cst (ASTM D445) 39 KV 40 C, cst (ASTM D445) 349 Viscosity Index (ASTM D2270) 162 Pour Point, C (ASTM D97) -30 Aniline Point, C (ASTM D611) 99 Dielectric Constant 25 C (ASTM D294)

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