Energy Efficient Hydraulic Fluids

Transcription

1 placeholder title visual Energy Efficient Hydraulic Fluids Reduced Costs in Real Life Applications Thomas Schimmel Evonik Oil Additives

2 Outline Trends and Motivation Fluid Technology: Basis for Efficiency Improvement Field Trials Life Cycle Analysis Conclusions Page 2

3 Trends and Motivation Page 3

4 GHG Emissions and Regulations Oil/Gas Chemicals Construction Forest products Iron and steel Food/Beverages Mining Cement Aluminum Plastics, rubber Textiles Lime Metal casting Semiconductor Industrial US GHG emissions in the US (million mt CO2) for the year 2008 without transportation Source: US EPA 2005 Tier 3 Wide TOW Long drain VI Lift Low Temp 2010 Tier 4i Shear stability Wide TOW Long drain VI Lift Low Temp 2015 Tier 4f Fuel efficiency Shear Stability Wide TOW Long drain VI Lift Low Temp Page 4

5 Volume Growth of Mobile Hydraulic Equipment Sales of hydraulic construction equipment Crawler Excavators number of CE machines sold Rigid Dump Trucks Source: Off-Highway data base Year Page 5

6 Volume Growth of Industrial Hydraulic Equipment Sales of Plastic Injection Molding Machines Units / year Picture by KraussMaffei Performance factors for injection molding equipment Short cycle times/high productivity High accuracy and reproducibility of the molded part High energy efficiency Page 6

7 Hydraulic Equipment is Working Harder Than Ever Smaller and Lighter Equipment Higher Operating Temperature Demand for Higher Efficiency Reduced Noise Levels Picture by KraussMaffei More Stringent Emission Regulations Higher Pressure and Increased Power Output Picture by Schuler Page 7

8 Fluid technology: Basis for efficiency improvement Page 8

9 Hydraulic Pump Efficiency Volumetric efficiency h V Ratio of actual flow rate delivered by a pump to its nominal flow rate = Q Q actual nominal Volumetric power losses correspond to the leakage of the pump Δp Q leakage = α η Mechanical efficiency h = Q nominal Q - Q nominal leakage Ratio of theoretical to actual input torque HM = M M theoretical actual = M Dynamic viscosity in the pump. M theoretical theoretical + M friction Power Loss = a * Viscosity * Speed + b * Pressure Hydromechanical power losses correspond to the extra input torque required to overcome the frictional losses within the pump Page 9

10 Effects of Viscosity on Overall Pump Efficiency Efficiency Volumetric Efficiency h V h Ov = h V * h HM Optimum Operating Range Poor volumetric efficiency Temperature Viscosity Page 10

11 Viscosity Limits at Peak Operating and Start-up Temperatures Manufacturers of hydraulic pumps define the viscosity window. Manufacturer Equipment Minimum mm²/s (cst) Operating Maximum mm²/s (cst) Start-up (Under Load) Maximum mm²/s (cst) Optimum mm²/s (cst) Parker Denison SPO-AM305 Eaton-Vickers Piston Pumps Vane Pumps (low speed and pressure) 30 Mobile Piston Pumps Industrial Piston Pumps Mobile Vane Pumps Industrial Vane Pumps Eaton Gear Pumps, Motors and Cylinders Bosch Rexroth Internal Gear Pumps Vane Pumps Page 11

12 Benefits of High VI Hydraulic Fluids Case 1: Same VG, High VI Kinematic Viscosity, mm²/s 10,000 1, Two oils meeting ISO 46 viscosity requirements HM Oil High VI Oil Minimum Operating Viscosity Minimum Operating Temperature ISO 46 Extended TOW Maximum Start-up Viscosity Hydromechanical Benefits at Low Temperature Maximum Operating Temperature Volumetric Benefits at High Temperature Temperature, C Page 12

13 Benefits of High VI Hydraulic Fluids Case 2: Lower VG, High VI Kinematic Viscosity, mm²/s 10,000 1, Two oils meeting ISO 46 viscosity requirements HM Oil High VI Oil Minimum Operating Viscosity Minimum Operating Temperature Extended TOW ISO 46 Maximum Start-up Viscosity Hydromechanical Benefits at all Temperatures ISO 32 Maximum Operating Temperature Temperature, C Page 13

14 In-Service Viscosity at High Shear Shear stable high VI fluid Non-shear stable fluid Retain high viscosity under very high shear High volumetric efficiency at all conditions Suffer from instantaneous temporary and permanent viscosity loss Low volumetric efficiency Page 14

15 Pump Efficiencies with High VI Hydraulic Fluids (all ISO VG 46) Parker Denison T6CM Vane pump results Overall Efficiency Improvement vs ISO VG 46 HM, [%] VI 150 VI 150 VI 150 VI 200 VI 200 VI 200 Highly shear stable (polymer A) medium shear stable (polymer B) 150 bar 200 bar 250 bar non shear stable (polymer C) Highly shear stable (polymer A) medium shear stable (polymer B) non shear stable (polymer C) Source: IFK 2006 Page 15

16 Field Trials Page 16

17 Field Tests for Efficiency in Hydraulic Equipment: Literature Reports Lead author Neveu Firm name Forum OEM Equipment Reported efficiency improvement Evonik Oil Additives STLE 2007 Mid sized excavator up to 18% Guerzoni Shell Hydraulics and Pneumatics, 2009 Injection molding 13.9% Hannon ExxonMobil STLE 2010 Small excavator, Injection molding Skid steer loader up to 6% up to 2.2% up to 4% Anon Hydrotex Press release 2010 Injection molding 13.5% Battersby Shell NFPA 2011 Telehandler 4% Schimmel Evonik Oil Additives ivt International Off- Highway - China Edition 2013 Mid sized excavator up to 20% Schrode Schrode GmbH DYNAVIS Testimonial, Youtube 2013 Mid sized excavator 10% Page 17

18 Concept of Efficiency Testing Equipment Hydraulic Excavator or Plastic Injection Molding Machine Oil fill for trial / single batch of fuel Standard plastics or standard gravel stone Set-up and operation Accurate oil change with sample analysis Redundant accurate energy / fuel consumption measurement Duration of operation Amount of work performed Run replicates, operator variation for non-automated equipment Hydraulic Fluids Monograde High VI fluid Shear stable high VI fluid Page 18

19 Excavator Field Trial Design Digging/Grading Earth/gravel moving with full and reduced power Truck loading Earth/gravel moving Exemplary daily schedule 45% 35% 10% 10% Idling Keep engine running without action Travelling with empty bucket Page 19

20 Efficiency Results: Digging for 20 80% & 100% Throttle Operator moves maximum possible full bucket with 90 swivel at 80 or 100% throttle over 20 minutes ISO 46 monograde ISO 46 VI 162, low shear stability ISO 46 VI 172, very high shear stability Buckets / L % + 31% Buckets / hour % throttle % throttle Efficiency Productivity Page 20

21 Calculated Cost Savings in Excavator Application Annual savings with a fleet of 10 excavators Page 21

22 Injection Molding Field Trial Design Clamp and Mold Hydraulic motor Trial 1: pump calibration Extruder Trial 3: Dosing Hydraulic pump Valve Trial 2: Measure electric power consumption over whole cycle and PIM process steps Close mold Build up clamp force Extruder forward Keep pressure Extruder back Cooling Open mold Eject plastic part Page 22

23 Injection Molding Trial: Fluid and Temperature Variation Field Trial Set Up Field Trail Set up reference oil candidate Shear Stable 1 high candidate VI Fluid 2 reference oil for each oil we run 44 C low three temperatures medium 35 C 30 C high for each temperature we run two test cycles Eurompa60 Slow cycle variation Fast cycle Page 23

24 Injection Molding Trial Results Power Consumption Power Consumption [% of monograde at reference temperature] ISO VG46, monograde ISO VG32, highly shear stable, high VI Automated processes keep productivity constant -> Reduced power consumption equals efficiency improvement % low 30 mid high Temperature Temperature Calculated annual cost savings for one machine: h operation / year - 10 kw power consumption L Oil reservoir - 2 years oil change interval Page 24

25 Life Cycle Analysis Page 25

26 Life cycle Analysis Energy and material input Energy and material input Raw Materials Manufacturing Further processing at Customer Use Phase Transport Transport Transport Transport Disposal/ Recycling Process emissions waste by products Process emissions waste by products Page 26

27 Cradle-to-Grave Analysis Monograde Shear stable high VI fluid Savings Savings: GWP [mt CO 2 /cycle] mt CO 2 per cycle and excavator Conditions: 2000 working hours of an excavator with 8% higher efficiency Multigrade oil Page 27

28 Conclusion Page 28

29 Conclusions 1. Methods to measure the efficiency of hydraulic equipment were presented and applied to an excavator and plastic injection molding. 2. Shear stable, high viscosity index hydraulic fluids offer: Significant energy savings for equal work Potentials for productivity increase Reduction of GHG emissions. 3. Cost advantages and emission reductions make the use of shear stable high VI fluids attractive. Page 29

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