What is Driving New Lubricant Development - Infraline

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Nov 8, 2013 (3 years and 11 months ago)

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1

A. K. MEHTA

Indian Oil Corporation Ltd.

Technological Developments

in

Lube Industry

2

Worldwide Lubricant Demand

Asia

31%

Australia/Oceania

1%

North America

26%

Central/Eastern

Europe

15%

Western Europe

14%

Latin America

8%

Africa

5%

35.7 MMT in 2002 (Without Marine Oils)

3

TRIBOLOGY IN INDUSTRY

TRIBOLOGY

Friction and Wear


Lubrication

REDUCTION IN COST OF UNIT PRODUCTION

AND LONGER LIFE OF EQUIPMENTS

BEST TRIBOLOGICAL PRACTICES

4

Economic losses due to tribology

(friction and wear)

Study report

National loss

Savings potential

Source




per year

per year


UK 1966

2 billion

515 billion

Jost

(in pounds)


(about 25% of

report




total loss )

FRG 1976

DM 10 billion

DM 5 billion (50% of

Research




T 76


total loss )

report 36,





BMFT

USA 1979

$ 100 billion ($ 20

$ 16 through energy

Final report to



billion due to wear

savings, $ 10 billion

congress



of material )

through wear control

India 1998

Rs. 430 billion ( Rs.

Rs. 106 billion ( Rs. 86

Estimated as



390 billion on energy

billion Conservation,

prescribed



loss & Rs 40 billion

Rs 20 billion by

methodology



due to wear)

controlling wear)

Reference : C.Misra TATA Steel, NLGI India chapter conference at Jodhpur


5

Hydraulic Oil
11%
MWO
9%
Ind. Gear Oil
3%
Miscellaneous
3%
Transformer Oil
4%
Ind. Greases
4%
Compressor Oil
4%
Auto Gear Oil
6%
Auto Greases
1%
Auto Engine Oil
55%
Lubricant Segments (Indian Pattern)

Total = ~ 1 MMT

6

Lubricant Manufacturers :


World’s Largest


TOP 15 PLAYERS



1. SHELL


2. EXXON MOBIL


3. BP
-
CASTROL


4. SINOPEC


5. CHEVRON
-
TEXACO


6. TOTAL


7. LUKOIL


8. FUCHS


9. NIPPON OIL


10. VALVOLINE




11. IDEMITSU


12. CONOCO
-
PHILIPS


13. PdVSA


14. REPSOL
-
YPF


15. INDIAN OIL



RECOGNISED / ESTABLISHED


1700

2003
-
04 Lubricants Industry Sourcebook

7

Lubricant Categories



Industrial Equipments

-

TURBINE OILS

-

HYDRAULIC OILS

-

COMPRESSOR OILS

-

GEAR OILS

-

BEARING OILS




Metal Forming Machines

-

ROLLING OILS


-

CUTTING OILS etc.






Automobiles


-

GASOLINE ENGINE OILS


-

DIESEL ENGINE OILS


-

DG SET LUBRICANTS


-

LOCOMOTIVE OILS etc.



Aviation Lubricants




Greases (industrial &


Automotive)

8

What Drives New Lubricant
Development


Extended life

(Improved vehicle/machinery
performance, less down time and a minimal routine
maintenance)


New engine Design & Economics

(users expect more
for less, Energy efficiency)


Environmental & Social issues

(reduction of emissions,
increased fuel economy,biodegradability/ toxicity
consideration, use of alternate fuels)


Product stewardship

(Lubricant supplier is held
accountable & responsible for their technology)

9

SAGA OF LUBRICANT DEVELOPEMENT

COMPONENT

APPROACH

LAB

EVALUATION

FIELD


PROBLEM

OEM

REQMT

TECH

FORECAST

GENESIS

FORMULATION

DEVELOPEMENT

ADDITIVE

PACKAGE

RIG/ ENGINE

TESTING

FIELD

TRIAL

PRODUCT

LAUNCH

OEM

10

Constituents of a Lubricant


Base Oil (Major)


* Mineral Based


(Conventional, Non
-
conventional)

* Synthetic Based

* Part Synthetic


Additives


Detergents


Dispersants


Anti
-
wear/EP


Anti
-
oxidants


Rust/Corrosion Inhibitors


Friction Modifiers


VI Improvers


PPDs

11

Automotive Design Trends


Impact on lubes

TREND/NEED


LUBRICANT IMPACT


HIGH PLACEMENT OF IMPROVED OXIDATION/THERMAL STABILITY

TOP RINGS




REDUCED PISTON &


IMPROVED BORE POLISH PROTECTION

LINER CLEARANCES



DURABILITY



IMPROVED DEPOSITS AND WEAR PROTECTION


NEW FUEL INJECTORS


SHEAR STABILITY/FOAM CONTROL


RETARDED TIMING


IMPROVED SOOT CONTROL


“DRY” ENGINES


LONGER OIL LIFE

12

European OEM Drain Interval
Recommendations


OEM



Normal


Extended


Future Aim

MACK


40,000 KM


--


58,000 KM


MERCEDES BENZ


HIGHWAY


20,000 KM 45,000 KM

80,000 KM

CITY



9,600 KM

30,000 KM
--


VOLVO


24,000 KM

40,000 KM

60,000 KM

13

Lube Drain Intervals
-

Indian
Scenario


PCMOs:


Up to 5000 kms with API SC/CC level of oil in 70s to
10000 kms with higher performance grades tending
towards 15000 kms with
extended warranty


DEOs:

FROM 5000 KMS WITH API CC LEVEL

18000
-
20000 KMS WITH API CF LEVEL

OEM specific DRAIN INTERVAL include

45000 KMS TO 60000 KMS FOR VOLVO VDS TO VDS2

14


OEM DEMANDS ON NEW GENERATION
INDUSTRIAL LUBES

CUSTOMER’s NEED OIL FEATURES REQUIRED

MAXIMUM EQUIPMENT LIFE

LEAST MACHINE DOWNTIME
GOOD OXIDATION AND

EXTENDED OIL LIFE (10
-
20 YEARS)
THERMAL STABILITY






RUST INHIBITION OF THE SYSTEM
GOOD ANTIRUST PROPERTY



NO SYSTEM CORROSION
GOOD METAL COMPATIBILITY




EXCELLENT SURFACE ACTIVITY

ADEQUATE WATER / AIR SEPARATION
OF THE OIL TOWARDS ANTIFOAM

OF SYSTEM OIL
DEMULSIBILITY & AIR RELEASE


PROPERTIES



MINIMAL WEAR
GOOD ANTIWEAR PERFORMANCE


15

New Performance Requirements of Major
Industrial Lubricants

LUBRICANTS

NEW FEATURES

Hydraulic Oils

Superior thermal stability and insitu
filterability

Gear Oils

Sustained EP performance including micro
petting resistance with energy efficiency
characteristics

Compressor Oils

Anti
-
wear high temperature resistance

Bearing Oils

Improved demulsibility retention

Turbine Oils

Extra long life

FORMULATIONS BASED ON TAILOR MADE


LOBS
-
ADDITIVE COMBINATION



16

How New Lubricant Development

is Achieved ?


Use of base stocks with improved quality (shift
from conventional Group I to Group II & III
category)


Use of synthetic base oils (Group IV & V)


Use of multi
-
functional additives with novel
chemistry


Use of unique combinations of additives
(understanding basis additive
-
additive
interactions)

17

Need to Shift to Group II+

Base Stocks


-
Superior additive response

-
Wide temperature operability

-
Excellent oxidation stability

-
Lower volatility

-
Improved environment friendliness




Group II Plus Base Stocks

DEPENDENCE ON CHEMISTRY OF LOBS HYDROCARBONS


18

Beneficial Properties of Synthetics


Excellent Viscosity
-
Temperature Behavior


Flow Behavior at Low Temperature


High Thermal Stability



High Oxidation Stability


Low Volatility


Wide Temperature Range of Applications

19

Lubricating Greases
-
Scenario


Lubricating greases constitute only 2
-
3% total lube
market


Total worldwide volume around 7,00,000 MTPA


India constitute around 8
-
10% of total worldwide
volume


Lubricating greases have advantage over oils


Needs simple lubrication system


Acts as sealant & Avoids dirt & dust ingress


INDIA IS POTENTIAL GROWTH MARKET

20

Lubricating Greases
-
Trends



Modern machinery operates



high temperatures, heavy loads, high speeds


Requirement met through high performance greases


Li
-
complex, Al
-
complex, Ca
-
complex, Poly urea etc.


Demand for high performance greases increasing


Fill for life concept emerging


Increasing trend to use bio
-
degradable greases in
Europe


Synthetic Oil based greases in use for specialized
applications

21

INNOVATIVE APPROACHES IN

LUBRICANT TECHNOLOGY



Optimal use of base oil class



Use of multifunctional additives



Combinatorial Chemistry based on Neural Networks


for developing new chemistry additives



Use of EHD film studies for optimising additive


dosage



Understanding molecular level interactions of


additives to achieve end performance



Possible use of Liquid Crystals for improved


lubrication



Electro
-
rheological fluids (in the area of industrial


lubricants)


22


IndianOil’s

Novel Products

23


R&D

is

the

sole

technology

provider

for

Servo
R

brand

lubricants


Over

2000

formulations

developed

since

inception

and

currently

450

grades

of

lubricants/greases

API/

DEF

/

US

MIL/

JIS

/

DIN

/

ACEA

/

ILSAC/LMOA

etc

specifications

are

being

marketed
.



Gasoline

&

Diesel

,

Rail

Road,

Marine,

Coolant,

2
T,

Turbine
,

Gear,

Hydraulic,

Textile

Oils,

Metal

Working

Fluids

etc

Salient

features


Novel

products

having

long

life



Energy

efficient

products


Eco
-
friendly

products

SERVO
-

THE MARKET LEADER


24

-

First Indian 140 TMT Plant commissioned at Haldia
Refinery to produce Gr II LOBS through catalytic iso
-
dewaxing route.


-

Initial batches of 70 SSU, 150 SSU & 500 SSU produced


-

Quality meets International Gr II LOBS specs.


GROUP II LOBS



New Indian Source

25

Railroad

Oil

(Servo

RR

606
MG)


Breakthrough

in

multi
-
grade

technology

replacing

the

mono
-
grade

lubricants

for

the

first

time

In

India
.


Expected

to

save

several

crores

per

year

to

Indian

Railways

on

account

of

savings

in

fuel

and

lube

consumption
.

Marine

Oil

(Servo

Marine

XXXX)



Marine

oil

technology

-

closely

guarded

by

multinationals


First

ever

indigenous

technology

developed

based

on

R&D

efforts


Captured

a

market

share

of

more

than

40
%

since

its

launch

in

1998
.


Top Tier Automotive Lubricants

26

-
SERVO

SUPERIOR

SJ
-
FUEL

EFFICIENT

SJ

SERIES

PCMOs

-
SERVO

PREMIUM


LONG

DRAIN,

HIGHER

PERFORMANCE

DIESEL

ENGINE

OILS

-
SERVO

2
T

SUPREME
-

LOW

SMOKE

2
T

OILS

WITH

JASO

FC

CERTIFICATION


-
SERVO

GEAR

HP

ALPHA
-

EXCLUSIVE,

HIGH

PERFORMANCE

MANUAL

TRANSMISSION

OIL

-
SERVO

TRANSTRAC
-

HIGH

PERFORMANCE,

WET

BRAKE

TRACTOR

TRANSMISSION

OIL

-
SERVO

TRANSMISSION

C
4



ALLISON

APPROVED

TRANSMISSION

OIL

FOR

HEAVY

EARTH

MOVERS


Top Tier Automotive Lubricants

contd…

27





Top Tier Industrial Lubricants

PRODUCT
NAME


SPECIAL FEATURES

1. Servoprime G



10,000 hours D
-
943

2. Servopress


100 RR



Antiwear type Long life
compressor oil

3. Servomesh EE


Series



Energy efficient Industrial gear
oil

4. Servospin EE


Series



Energy efficient textile spindle
oil

5. Servosystem


HLP Series



Antiwear Hydraulic oil with
enhanced thermal stability

28


Unique Synthetic Grades from
Servo

PRODUCT NAME


SPECIAL FEATURES

1.
Servosynco E


series



Seven fold increase in service life

2. Servosyngear


series



High load carrying capacity



Recommended for high temperature


applications

3. Servosyngear


RR series



Approval from Indian Railways for
Traction Motor Gear case

4. Servotherm


S


series



Higher thermal stability & longer service
life

29



PRODUCT NAME


SPECIAL FEATURES

5. Servotextile oils



Spinfinish oils




High temperature


chain lubricant




Gear oil for


Comber Gear box



Proven field performance for synthetic
fibres


Excellent oxidation stability, low
volatility




Extended oil service life & oil
conservation

Contd..

30

Indian Grease Market


Indian Markets over 60,000 MTPA


Products available for almost all type of applications


Steel, railways, defence, automotive, mining etc.


Indian Manufactures greases based on latest chemistries


Sulfonate complex, Al
-
complex, Mixed based etc.


Indian market cost sensitive


Conventional mineral oil based greases popular


Gap Areas


Synthetic oil based greases


Bio Degradable greases


Poly Urea based greases

31

NOVEL GREASES FROM IOC


PRODUCT NAME


SPECIAL FEATURES

1.
Servogem
Super HT



High temperature application for steel
plants

2. Servogem RR3



Axle Box Bearing of Railways

3. Servogrease


CG 10



Girth Gear Lubrication

4. Servogem WR2





Superior Water resistance

32


LUBE TECHNOLOGY
-

CHRONOLOGICAL TRANSFORMATION

TIME

INPUTS

LOBS

-

SN

HC

XHVI

SYNTHETICS

ADDITIVES


OEM, INTERNATIONAL STANDARDS


ENGINE AND RIG TESTING


COMPLEXITY AND COSTS

LUBRICANTS

SEVERITY

LEVEL

Gp I

Gp II

Gp III

Gp IV

33

34

LIQUID CRYSTALS


POSSIBLE USE IN
LUBRICANTS



VISCOUS JELLY LIKE MATERIALS THAT RESEMBLE
LIQUIDS IN CERTAIN RESPECTS ( VISCOSITY) AND
CRYSTALS IN LIGHT SCATTERING & REFLECTION



EFFECTS


-
LIQUID PHASE CAN ALTER THE VISCOSITY

-
HIGH PRESSURE IN THE LUBRICANT GAP BETWEEN

-
THE CONTACT FACES CAN TIGGER A FRICTION & WEAR
REDUCING VISCOSITY INCREASE


APPLICATIONS

-
TEST RIG TRIAL DATA : FRICTION VALUES QUARTER OF
MINERAL OIL & EVEN BELOW ESTER BASED PRODUCTS

-
CAN BE USED FOR GEAR BOX LUBRICATION





35

ELECTRO
-
RHEOLOGICAL FLUIDS


THESE ARE FLUIDS WHOSE PROPERTIES, IN PARTICULAR
VISCOSITY CAN BE INFLUENCED BY ELECTROMAGNETIC FIELDS




CURRENTLY NO COMMERCIAL APPLICATIONS,IN FUTURE THEY
CAN REPRESENT A SUBSTANTIAL MARKET FOR SYNTHETIC
FLUIDS



A POTENTIALLY COMMERCIAL FLUID WILL REQUIRE CAREFUL
COMBINATION OF THE CONTINUOUS AND DISPERSED PHASES



APPLICATIONS


-
HYDRAULIC CONTROLS ,CLUTCHES OR SHOCK
ABSORBERS