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Reducing Lubricant Ash Impact on Exhaust Aftertreatment with a Oil Conditioning Filter

Sloan Automotive Laboratory

2009 Directions in Engine-Efficiency and Emissions Research (DEER) ConferenceAugust 6th, 2009

Simon A.G. Watson and Victor W. Wong, MITDarrell Brownawell

and Scott P. Lockledge, Lutek

LLC.Scott Harold, Ciba Specialty Chemicals

•

Ash negatively effects aftertreatment

systems:–

Increases fuel consumption and exhaust back pressure

–

Phosphorus may chemically deactivate catalysts

–

Periodic cleaning requirements and possible engine damage

Lubricant Derived Ash


Diesel Particulate Filter Ash Deposits:

(Aravelli, DEER 2006)

Inlet Outlet

(Sappok, 2009)

•

Lubricant additives are the source of most DPF ash:–

Detergents–

Zinc Dialkyldithiophosphate

(ZDDP)

•

Detergents contribute about 75% of ash found in DPF’s

(CaSO4

) •

Lower detergent levels significantly reduces DPF ash

Reducing Ash Accumulation in DPF’s


Typical DPF Ash Composition:

XRD analysis of DPF ash from a CJ-4 lubricant(Sappok, 2009)

Are there any alternatives for additives that do not contribute to DPF ash?


•

Strong Base Oil Filter–

Strong base is anchored in the filter–

Strong base in filter immobilizes acids–

Releases nothing–

Selectively sequesters acids only

•

Ashless

Antiwear–

Provides protection from wear without contributing to sulfated ash (ASTM D874)

Test Program


•

Long-duration steady-state testing to investigate the potential benefits of filter conditioning with reduced ash oils

•

Three long-duration tests:–

Test 2 –

Zero Detergent oil, Strong base filter -

300 hrs–

Test 3 –

Zero Detergent oil, Standard oil filter -

82 hrs–

Test 1 –

CI-4 PLUS oil, Standard oil filter -

318 hrs (Reference)

Load 100%FPSpeed 1800 rpmFuel 15 ppm Sulfur Diesel

Lubricants1. Experimental Zero Detergent

Formulation2. Fully Formulated (CI-4 PLUS)

Test Parameters

Experimental Zero-Detergent Oil Formulation


Component DescriptionBase Oil Blend of Americas Core Group I

Detergent NoneDispersant PIBSA/PAM (~10% of formulation)

Antiwear Ashless phosphorus and sulfur containing additives

Additional Corrosion Inhibitors None

Description of the Components in the Zero Detergent Oil:

Lubricant Properties


Element Zero Detergent CI-4 PLUS

Ca 0 3130Mg 0 10Zn 0 1350P 480 1490

Property Zero Detergent CI-4 PLUSSAE Grade 15W40 40WAPI Gravity 29.1 28.9

Viscosity @ 40°C [cSt] ~ 146Viscosity @100°C [cSt] 15.2 14.9Sulfated Ash [%] (D874) 0.057 1.35

TBN [mg KOH/g] (D2986) 5.5 10.2

Elemental Analysis (ASTM D4951):

Lubricant Properties:

Test Engine


•

Specifications:–

Single Cylinder–

Naturally Aspirated–

Air Cooled–

No EGR–

Maximum Power 5.5 kW–

Direct Fuel Injection–

Displacement 0.773 L–

Compression Ratio 15.5:1–

Sump Capacity 2.4 L

Lister Petter TR1 Generator Set

Test Procedure


•

Lubrication system cleaned with triple flush between tests•

Routine maintenance performed every 24 hours

•

Parameters measured every 24 hours:•

Oil Consumption (oil mass measurement)•

Fuel Consumption•

Oil Temperature•

Crankcase oil samples extracted every 48 hours:

•

For Tests 1 -

~17 g•

For Tests 2 and 3 -

~38 g •

Samples are extracted through the dipstick opening

0

400

800

1200

1600

2000

0 100 200 300 400Elapsed Operating Time (hours)

To

tal O

il C

on

sum

pti

on

Test 1 - CI-4+, Standard FilterTest 2 - Zero Detergent, Strong Base FilterTest 3 - Zero Detergent, Standard Filter

0

0.2

0.4

0.6

0.8

1

1.2

1.4

1.6

0 100 200 300 400Elapsed Operating Time (hours)

So

ot

(% w

Test 1 - CI-4+, Standard Filter

Test 2 - Zero Detergent, Strong Base Filter

Test 3 - Zero Detergent, Standard Filter

Oil Consumption and Soot Contamination


3.61 g/hr

5.93 g/hr

5.49 g/hr

Oil Consumption Soot Content

•

Mean oil temperatures of tests are equal•

Mean fuel consumption of tests are equal

y = 0.0028x + 0.9475R2 = 0.9791

y = 0.0088x + 1.1427R2 = 0.8841

y = 0.0028x + 0.5572R2 = 0.983

0.0

0.5

1.0

1.5

2.0

2.5

0 50 100 150 200 250 300 350Elapsed Operating Time (hours)

TA

N (

mg

KO

H/

Test 1 - CI-4+, Standard Filter, Colorimetric Titration

Test 2 - Zero Detergent, Strong Base Filter, Colorimeteric Titration

Test 3 - Zero Detergent, Standard Filter, Colorimetric Titration

Total Acid Number


Fully Formulated, Standard Filter

Zero-Detergent,Strong Base Filter

Zero-Detergent,Standard Filter

y = -0.0037x + 8.4521R2 = 0.7123

y = -0.0076x + 8.1965R2 = 0.9371

y = -0.0236x + 7.6R2 = 1

4.00

4.50

5.00

5.50

6.00

6.50

7.00

7.50

8.00

8.50

9.00

0 50 100 150 200 250 300 350

Elapsed Operating Time (hours)

pH

Un

it

Test 1 - CI-4+, Strong Base Filter



Lubricant Acidity





0

2

4

6

8

10


TB

N (

mg

KO

H/

Test 1 - CI-4+, Standard Filter, ASTM D-5984Test 2 - Zero Detergent, Strong Base Filter, ASTM D-5984Test 2 - Zero Detergent, Strong Base Filter, ASTM D-2896Test 3 - Zero Detergent, Standard Filter, ASTM D-5984Test 3 - Zero Detergent, Standard Filter, ASTM D-2896

Total Base Number




Zero-Detergent, Standard Filter

0

2

4

6

8

10

12

14

16


Mg

Co

nce

ntr

atio

n (

p

Test 1 - CI-4 PLUS, Standard Filter



Magnesium Concentration





y = 0.0268x + 12.171R2 = 0.9721

y = 0.0241x + 18.064R2 = 0.3299

y = 0.2134x + 15.428R2 = 0.8306

7

12

17

22

27

32

37

42

47


Oxi

dat

ion

Nu

mb

er (

Ab

s

Test 1 - CI-4 PLUS, Standard Filter



Oxidation





y = 0.278x + 13.795R2 = 0.9409

y = 0.0688x + 15.808R2 = 0.9807

0

5

10

15

20

25

30

35

40

45


Visc

osity

at 1

00C

(cSt

)

Test 1 - CI-4 PLUS, Standard Filter, ASTM D-445Test 2 - Zero Detergent, Strong Base Filter, ASTM D-445Test 3 - Zero Detergent, Standard Filter, ASTM D-445Linear (Test 3 - Zero Detergent, Standard Filter, ASTM D-445)Linear (Test 2 - Zero Detergent, Strong Base Filter, ASTM D-445)Linear (Test 1 - CI-4 PLUS, Standard Filter, ASTM D-445)

Viscosity





0

20

40

60

80

100

120

140

160


Co

rrec

ted

Fe

Co

nce

ntr

atio

n ( Test 1 - CI-4+, Standard Filter

Test 2 - Zero Detergent, Strong Base FilterTest 3 - Zero Detergent, Standard Filter

Engine Wear





0

10

20

30

40

50

60

70

80

90


Co

rrec

ted

Met

al C

on

cen

trat

ion

Test 1 - CI-4+, Standard Filter, Pb

Test 2 - Zero Detergent, Strong Base Filter, Pb

Test 3 - Zero Detergent, Standard Filter, Pb

Test 4 - CI-4+, Strong Base Filter, Pb

Bearing Wear Metals


T2, Pb

T3, Pb

T3, PbT1, Pb

Four Ball Wear Tests


0.00

0.20

0.40

0.60

0.80

1.00

Zero Detergent,Fresh Oil

CI-4+, Fresh Oil Test 1 - CI-4+,Standard Filter -

318 hours

Test 2 - ZeroDetergent,

Strong BaseFilter - 300

hours

Test 3 - ZeroDetergent,

Standard Filter -82 hours

Ave

rage

Wea

r Sca

r Dep

th (m

m)

Conclusions

•

Under the test conditions used in this study, the strong base filter had a significant and beneficial effect on the rate of oil degradation

•

The strong base filter reduced lubricant acidity by absorbing acidic contaminants in the lubricant

•

The filter performs an acid control function similar to that provided by over-based detergents, when used with a zero-

detergent oil

•

The zero-detergent oil (formulated with ashless antiwear additives) and the CI-4 PLUS oil provide similar levels of wear protection after aging with the strong base filter.

•

With more development, it may be possible use a zero detergent oil in combination with a strong base filter; providing adequate engine protection while minimizing lubricant ash effects on aftertreatment systems



•

Caterpillar•

Chevron

•

Ciba Specialty Chemicals•

Cummins

•

Detroit Diesel

This research is supported by the MIT Consortium to Optimize Lubricants and Diesel Engines for Robust Emission Aftertreatment

Systems

•

Komatsu•

Lutek

LLC.

•

Sud-Chemie•

Valvoline

•

Ford

We thank for the following organizations/companies for their support:

Acknowledgements

•

Department of Energy –

Vehicle Technologies Program

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