Automotive Market TrendsAny impacts & opportunities for Vamac® & Viton® ?
DuPont Performance Polymers ConferenceDuPont Performance Polymers Conference
May 20May 20th,th, 20102010
AlbergoAlbergo CoccaCocca HotelHotel
SarnicoSarnico ((BgBg)) Laurent LefebvreLaurent Lefebvre
European Automotive Industry : The "Engine of Europe”
Introduction
3
Global Challenges for OEMs
Source Daimler
4
♦Automotive trends
� Fuel price & consumption
� Gas Emission reduction
♦Possible ways to reduce gas emission
� Engine downsizing + Turbo
� New technologies
� Emergence of biofuels
� New lubricants
Agenda
5
Fuel - Crude Oil Price
World Crude Oil Price on April 30th 2010 = 84 $ / Barrel
6
Fuel Consumption
• Transportation is the largest consuming sector of petroleum & the oneshowing the greatest expansion.
• In 2008, 13.7 million barrels per day of petroleum products were consumed for transportation purposes, accounting for 70 % of all petroleum used.
U.S Petroleum consumption by Sector
7
Worldwide CO2 Gas Emission
8
Global Emission Regulations for light vehicles
9
Source ACEA 2007
European automotive emission standards
NOx and PM emission standard for Diesel Engines
Euro 3
Euro 4
Euro 5Euro 6
Euro 2
0
20
40
60
80
100
120
0 100 200 300 400 500 600 700 800
NOx (mg/km)
PM
(m
g/k
m)
10
European automotive CO2 emission trends
11
Gas Emissions
evaporative
exhaust
Yearly average value
57%
43%
source: Ton Cackette, CARB, 4. April 2006
It’s not only Exhaust Gas !!!
According to U.S. Environmental Protection Agency:Evaporative loss is the No 1 Contributor to Total Hydrocarbon Emissions from Cars on Hot Days
12
Evaporative emission regulations in USA
Air Intake Manifold Gasket
Material mainly used
13
�Engine downsizing + Turbo
�New technologies
�The emergence of biofuels
� New lubricants
Possible ways to reduce emissions
14
Engine Downsizing – European market
Automakers are removing cylinders and lowering the displacement of their engines to meet tougher CO2 emissions rules that take effect in Europe in 2012.
Fiat to Offer 500 Minicar Fitted With 2-Cylinder 0.9 L 85 Horse Power Turbo Gasoline
15
Why turbocharger ?
TURBOCHARGED engines used compressed air allowing more air at higher temperature
in the combustion chamber.
Consequences are:
• boosted performances: getting the best available output from more power from smaller
better performing engines
• lower levels of particles in diesel engine emissions
• better control of NOx emissions
In addition, it can increase fuel economy as heat loss & friction increase drastically with
increases in engine size
TURBOCHARGING coupled with high pressure fuel injection makes combustion more
thorough, more efficient and therefore cleaner
Sourcesjust-auto.com
Honeywell Technologies
16
Auto Turbo Market Trends / Europe
EU Light Vehicle Engine Production Forecast
(CSM auto database - Jan 2010)
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
2007 2008 2009 2010 2011 2012 2013 2014 2015
Year
Nu
mb
er
of
en
gin
es
Total Turbo Engines
Total All Engines
European Light Vehicle Turbo Engine Production Forecast
(CSM auto database -Jan 2010)
0
2,000,000
4,000,000
6,000,000
8,000,000
10,000,000
12,000,000
14,000,000
16,000,000
18,000,000
20,000,000
2007 2008 2009 2010 2011 2012 2013 2014 2015
YearN
um
be
r o
f tu
rbo
en
gin
es
Total Turbo Gasoline
Total Turbo DieselGrowing Market
-4%
-19%+11%
+15%
+18%
+10%+10%
+5%
•Turbo Diesel is a mature market in Europe
• Turbo Gasoline is a strong growing market
exhaust gasesTurboCharger (TC)
17
Global Auto Turbo Market Trends
• EU is leading the global auto turbo market
• Is turbo engine short term forecast outside EU too pessimistic?
• Turbo technology is a dynamic & attracting market !!!
Regional Light Vehicle Turbo Engine Production Forecast
(CSM Automotive Database- Jan 2010)
0
5,000,000
10,000,000
15,000,000
20,000,000
25,000,000
30,000,000
2007 2008 2009 2010 2011 2012 2013 2014 2015Year
Nu
mb
er
of
turb
o e
ng
ine
s b
y r
eg
ion
Total All turbo engines in South America
Total All turbo engines in North America
Total All turbo engines in Japan
Total All turbo engines in APEJ
Total All turbo engines in Europe
Turbo Manufacturers : Garrett, Borg Warner, Holset, Ishikawa, Mitsubishi, ToyotaNew comers : JV Bosch/Mahle, Daimler
18
Evolution of Technical Requirementsfor Turbo Hoses in diesel vehicles
Sourc
e: V
alé
o, G
arr
ett a
nd B
org
Warn
er
Charge air
cooling power (kW)
Turbocharging
pressure (bars)
���� The trend to higher compressed air pressure is confirmed with current
level at 2.5 bars, inducing a temperature of 205 °°°°C���� Twin-Turbo still limited to a very small number of top-class vehicles
35
30
25
20
15
10
5
40
Indir. injection dir. injection EURO 4 EURO 5 EURO 6 1990 2000 2005 2009 2014
3.5
3.0
2.5
2.0
1.5
1.0
0.5
bars
�
�
�
�
�
�
�
�
10 kW
15 kW
22 kW
30 kW
1.5 bar
1.9 bar
2.5 bar
3.5 bar
NO TURBO
4.0
130 °°°°C
165 °°°°C
205 °°°°C
250 °°°°CDouble
TURBO
Power (kW)
low
tem
peratu
re
mediu
m
tem
peratu
re
high
tem
peratu
re
Hot side
19
Elastomers choice for Turbo Hose
220
200
180
160
140
120
100
240
Lowte
mpera
ture
s
High te
mpera
ture
s
ECO
135 °°°°C(150 °°°°C)
AEM
140-165 °°°°C(180 °°°°C)
Mediu
m te
mpera
ture
s
HT ACM
170-180 °°°°C
(190-200°°°°C)
FKM/VMQ
200-220°°°°C(230°°°°C)
Low temperature
turbocharger hose
with CM, CR,
NBR
Cost of the part
Temperature (°°°°C)
FVMQ/VMQ
180-200 °°°°C(210°°°°C)
HT AEM
170-180 °°°°C
(190-200°°°°C)
Cold side turbo hose Hot side turbo hose
20
�Engine downsizing + Turbo
�New technologies
�The emergence of biofuels
�New lubricants
Possible ways to reduce emissions
21
So
urc
e:
gre
en
carc
on
gre
ss.c
om
/em
issio
ns for particle reduction :
High pressure
diesel fuel injection
Injection Combustion
Optimization ofthe combustion
chamber
Diesel particle filter
New technologies to limit emissions
22
Sensor Hoses for Diesel Particle Filter
Hose made of Vamac®
�Sensor hose between pressure sensor and DPF
�Temperature and exhaust gas
�Materials used : FKM, FKM/VMQ, VMQ, AEM
23
So
urc
e:
gre
en
carc
on
gre
ss.c
om
/em
issio
ns
for NOx destruction :
Exhaust gas treatment (with urea addition)NOx catalyst
New technologies to limit emissions (con’t)
AdBlue® system is generating new applications for elastomers & thermoplastics
24
Why AdBlue® System ?
25
Selective Catalytic Reduction (SCR)
26
New technologies to limit emissions (con’t)
There are emission control technologies currently available to enable
compliance of diesel motor vehicles to the next level of requirements
So
urc
e:
gre
en
carc
on
gre
ss.c
om
/em
issio
ns
for NOx reduction :
Increased recirculated gas in EGR (Exhaust gas recirculation)
High pressure direct gasoline injection
27
Exhaust Gas Recycling Loops
High Pressure Loop (HPL) Low Pressure Loop (LPL)
Engine Engine
HPL
LPL
20% max. of EGR 50% max. of EGR
70% max. of Exhaust Gas Recirculating
Turbo Turbo
High PressureHigh Temperature (> 200°C)Mainly metal pipes
Low PressureLow Temperature (< 150°C)Mainly flexible rubber / plastic tubes+ rubber seals
EGR loops should bring new applications for elastomers & thermoplastics in a near future
28
Blow-By Gas is a leakage flow between the piston and the cyclinder wall
originated through the pressure difference between combustion chamberand the crankcase. Blow-By Gas accumulates with oil & fuel particles.
In the past, Blow-By Gas was released into the
environment. Nowadays, only closed crankcaseventilation systems are allowed.
Blow By Gas composition varies and depends on :
*engine types, fuel or diesel engine (fuel more critical)*engine performance and management*driving style (speed, r.p.m, number of cold starts)*design of ventilation (dead areas, air volume flow)
Closed Crankcase Ventilation System
Blow-By Gas Origin
29
Air management: more acids in the future ???
Exhaust Fresh air
Inletmanifold
Turbocharger
Exhaust manifold
Air filter
Intercooler
‚Cold‘ hose between IC and AIM
Vacuum tube (molded) or shortconnector between air filter and
turbo charger
Crankcase ventilation hose forclosed PCV system
„Hot“ hose between turbo and intercooler
AIM seals
EGR & Blow-by contact with Euro 6
EGR contactwith Euro 6
EGR contactwith Euro 6
Blow-by gascontact with Euro 4
EGR contactwith Euro 4
30
Summary – New Technologies
It is widely believed that these solutions
should prove largely sufficient for the majority of OEMs to reach Euro VI phased-in compliance from 2012.
31
Hybrids & Electrical vehiclesAuto battery cables insulated with Vamac®
Vamac® ethylene acrylic elastomer (AEM) has been chosen by Huber + Suhner AG, Switzerland, a leading supplier of automotive cable systems, as insulation for battery cables supplied to Fiat, Ford, Jaguar, GM/Holden and Renault, and also to insulate screened cables for hybrid prototypes and the fully electric Tesla Roadster.
Vamac® AEM was specified mainly because of its high temperature and fluids resistance in tough automotive operating environments from -40°C to +150°C, involving hot motor and gearbox oils, battery acid, salt water and cleaning solvents, and for its flexibility and abrasion resistance in confined spaces. In addition, the compatibility of Vamac® with fillers or flame retardants, and ease of cross-linking with electrons, were other important selection criteria.
The move to hybrid vehicles
RADOX battery cables with Vamac® have become standard equipment at Fiat, Ford, Jaguar, Renault, and the Holden Division of General Motors. Now, in the transition to hybrid motor technology, Huber + Suhner are working closely with GM in the USA and selected European OEMs to supply screened battery cables for hybrid prototypes, several of which are expected to go into serial production soon.
The company has also won an assembly project for Tesla Motors Inc. to provide screened and non-screened battery cables with insulation of Vamac® for its groundbreaking Tesla Roadster — claimed the first production battery electric vehicle to travel more than 200 miles per charge, and with zero tailpipe emissions. Huber + Suhner will shortly supply cables for the Tesla Model S all electric family sedan as well.
32
�Engine downsizing + Turbo
�New technologies
�The emergence of biofuels
�New lubricants
Possible ways to reduce emissions
33
New Environmental legislationNew Environmental legislation
Driving down both vehicle exhaust & evaporative emissions
Driving the use of oxygen-containing fuels & Biodiesel
���� Ethanol
� E6 & E85 in favor in California, E10 & E85 in rest of USA
� E10 in Europe, India and China
���� Oxygenates
� MTBE has been legislated out in the USA, but still used in Europe
� ETBE and Methanol as well
���� Biodiesel (B5 to B20)
� Improves diesel fuel emissions
� Reduces diesel engine wear (inherent lubricity of FAME’s)
Environmental regulations are becoming global in scope
34
Europe & EurasiaBiodiesel: 4 to 76 Billion litres (2020)
Focus on Biodiesel RME + import from Asia� pure biodiesel: EN 14214� for blends: EN 590 ���� B7 to B10
Source: Dept of Energy and DuPont/BP estimates
Asia PacificBiofuels: 7 to 114 Billion litres(2020)
90% Ethanol ex corn & sweet potatoes (E10)10% Biodiesel ex jatropha & palm oilIn China: B5 & B10 (not yet normalized)
North AmericaBiofuels: 16 to 114 Billion litres(2020)
90% Ethanol ex sugar cane10% Biodiesel ex soya (SME) & sunflower� pure biodiesel: ASTM D975� for blends: ASTM D6751
���� B5 common���� B10 & B20 available
South AmericaBiofuels: 15 to 27 Billion litres (2020)
Ethanol ex sugar cane: E10 to E97� pure biodiesel: DOU25062007� for blends: DOU05112007
� B2 to B5
BioBio--Fuels Trends by RegionFuels Trends by Region
35
Example : Biodiesel feed stocksExample : Biodiesel feed stocks
Jatropha
Rapeseed
Palm & Coconut Canola Sunflower
AlgaeKelpSoybean
36
Environmental Benefits of Biofuels
�Reduce the CO2 emission (less greenhouse effect) compared with pure gasoline/diesel�Biodiesel is bio-degradable and non-toxic product�Biodiesel is a renewable energy source �Reduce our dependence on fossil fuels
Greenhouse Gas Emissions : Biofuels compared to conventional fuels
Source: “Bilan énergétiques et gaz à effet de serre des filières de production des biocarburants”
Price Waterhouse Coopers / Institut Français du Pétrole
0
20
40
60
80
Gra
m o
f C
O2
/ M
J
- 70%- 60%
Gasoline
Ethanol e
xwheat
ETBE ex
wheat
VOME e
xra
peseed
Ethanol e
xsugar beet
ETBE ex
sugar beet
Diesel f
uel
VOME e
xsunflo
wer
37
List of FKM applications in Fuel System
• Fuel Filter Seal
• Fuel Injector O-ring• Fuel Rail Seal
• Quick Connect O-ring
• Filler Neck Hose• Fuel Vapour Line• Fuel Return Line
• Fuel Tank Valve Seal• Fuel Sender Seal
• Fuel Cap Seal
38
�Engine downsizing + Turbo
�New technologies
�The emergence of biofuels
�New lubricants
Possible ways to reduce emissions
39
Automotive lubricant composition:
- base oils (75% to 85 %) : mineral or semi-synthetic or FULLY SYNTHETIC
- package of additives (15% to 25%) : viscosifiers, anti wear, antioxidants, detergents, corrosion inhibitors, dispersing agents, anti-foaming agents, alkalinity, anti freeze agents, extreme pressure agents
Automotive Engine Oils
40
New lubricants
�Lubricants classified 0W20, 0W30 & 5W30 (fuel economy) & low SAPS* oils to meet EURO V standards (including diesel particle filter technology)
�Higher market share for automatic transmissions in Europe, Transmission systems with more gears (e.q. VW 7-speed transmission) using new synthetic ATFs (Dexron VI)
*SAPS = last generation lubricants based on Low Sulphated-Ash, Phosphorus and Sulphurtechnology fully compatible with diesel particle filter
New engine oil with Euro V
41
Cylinder(Engine Block)
Cylinder Head
Oil Pan
Cylinder Head Cover(Rocker Cover, Cam Cover)
Engine Composition – Static Seals & Gaskets
Oil Filter
4. Rubber Gasket
3. Rubber Gasket
4 main engine static rubber seals & gaskets:
2. Rubber Gasket
1. Rubber Gasket
Additional engine static seals & gaskets : • Front cover gasket• Oil filler cap seal• Oil drain plug• Grommets
NBRAEMACMLSR
NBRHNBRAEMACMFKM
NBRAEMACM
NBRHNBRFKM
42
Trends: More aggressive fluids in the engine and in the engine oil:
- New synthetic oils for fuel efficiency & higher temperature exposure- Higher level of Blow-by and EGR acid condensates- Presence of fuel/biofuel in engine oil
New opportunities in engine seals for High Performance Elastomers (=FKM, AEM, HT-ACM): Cam Cover, Front Cover, Oil Pan, …
Trends in Engine Static Seals & Gaskets
•Heat resistance > 135°C•Low temperature ( -30°C to -40°C)
•Oil resistance (low viscosity)
•Sealing performance(Compressive Stress Relaxation)
43
Conclusion: Auto Market Dynamics & Trends
Trend: Replacement of low to medium performance elastomers by High
Performance Elastomers (FKM, AEM, HT-ACM)
Oil Resistance% Swell in IRM 903 Oil
No Req 170 120 100 80 60 40 20 10
Butyl
HeatRes.70 hrs
70
100
125
200
225
250
Styrene ButadieneNatural Rubber
Neoprene
Vamac®
Viton®
Silicone
EPDM
Fluorosilicone
Polyacrylate (ACM)
HNBR
Epichlorohydrin
NBR
NBR/PVC
CPE
V Solutions SpaceSealing & Hose Applications
HiTemp-ACM
150
175
165
Applications with
min. temperature
requirements of
165 degrees
Applications
with reduced
swell
- V Solutions products are well represented in the ‘150°C and plus’ – area - Vamac® & Viton® offers excellent performance for new requirements
44
The information set forth herein is furnished free of charge and is based on technical data that DuPont believes to be reliable and falls within the normal range of properties. It is intended for use by persons having technical skill, at their own discretion and risk. This data should not be used to establish specification limits nor used alone as the basis of design. Handling precaution information is given with the understanding that those using it will satisfy themselves that their particular conditions of use present no health or safety hazards. Since conditions of product use and disposal are outside our control, we make no warranties, express or implied, and assume no liability in connection with any use of this information. As with any product, evaluation under end-use conditions prior to specification is essential. Nothing herein is to be taken as a license to operate or a recommendation to infringe on patents.
Caution: Do not use in medical applications involving permanent implantation in the human body. For other medical applications, discuss with your DuPont customer service representative and read Medical Caution Statement H-50103-3.
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