4 ciba

Indonesia lubeconference_2006

Ciba Specialty Chemicals

Low Treat – Top Tier ASHLESS Additive Technology

For The New Denison HF-0 Specifications

Presentation by:Anil Choudhary

Process & Lubricant Additives


Content

Impact of Industrialization

Changing End User Goals / Requirements

Evolving Hydraulic Specifications

Ashless Additive Technology

Test Results & Conclusion


Content







Growing Industrialization

Is Giving Rise To Increased Demands On…


Reliable Industrial & Mobile Equipment

Size getting smaller

Operating at high temperature

Operating at higher speeds

Increasing system pressure


Changing End-User Goals / Requirements


Maximize…

EquipmentLife

ProductionUptime


Minimize…& Maximize…

Overall maintenance

Production Efficiency


Minimize…

Effluent Treatment

Costs

Disposal


Limit…

Heavy Metal

Contamination

Impact on the

environment


Typical Hydraulic System (schematic)

http://en.wikipedia.org/wiki/Image:Hydraulic_circuit_directional_control.png


Evolving Hydraulic System

Power output

Reservoir Size

System Pressure

Operating Temperature

Clearance Size

Oil Service

Life

Filter Pore size


Content







Impact on Hydraulic fluid

Higher operating temperatures

Challenges robustness & durability of the fluid

Impacts overall performance in protecting the equipment


Hydraulic Oils Stress Index

Increase of oil stress indexbased on hydraulic oil test rig data

0.02.04.06.08.0

10.012.014.016.018.0

1960 1970 1980 1990 2000 2010

Year

Oils

Str

ess

Inde

x


Content








Ref: Machinery Lubrication Magazine, Nov’03


Traditionally Used Hydraulic Fluid Pumps

Radial Piston

Axial Piston

Vane

Gear


Denison T6H20C Hybrid Pump

Incorporates both:Vane & Piston Pump


Content







Clear Development Need

Filterability- In presence of water and

chemical contaminants

Oxidation stability- Improved service life

Corrosion Inhibition- Protection of metal surface

To Meet Evolving Requirements…

Wear protection technology- Extended component life

Hydrolytic stability- Maintains performance

when contaminated with water

Thermal stability- Long service life at high

operating temperatures

Ashless AWHF


Metal-Free / Ashless Additive TechnologyTraditionally ZINC, a heavy metal has been used in anti-wear hydraulic fluid formulations as ZnDTP– Inexpensive lubricant additive,

however not the best solution in terms of various environmental aspects

ASHLESS Technology– Reduces &/or eliminates

substances that have significant aquatic toxicity

– Easily substitutes ZnDTP– Provides better performance


A Better Solution…Ashless ZnDTP

Filterability (formation of solid residues) ++ +

Water compatibility +++ +

Thermo-oxidative stability ++ +

Sludge formation ++ +

Limits Heavy Metal Contamination +++ --

Ease in Effluent treatment +++ --

Benefits ++ +

In Terms Of Environmental Aspects !


0

1

2

3

4

5

0 1 2 3 4weeks

FI ZnDTP

based lube incl. Disp./Detergant

lube based on Ciba

ashless Hydraulic Fluid

Long-term Performance of Hydraulic FluidsTest fluid: lubes plus 1% water; assessment by filtration index


Content







Test Oils

Package & Lubricants Used

AWHF – Package ASHLESS / Metal Free 0.55 % 0.55 % 0.55 %

0.03 %

Balance

Balance

0.03 % 0.03 %

Balance

Balance

--

Group I, SN - NAFTA

Group I, SN - AP

Group I, SN – AP

Group II, HT - AP

Antifoam

Base Stock ISO VG32

Base Stock ISO VG46

Base Stock ISO VG46

Base Stock ISO VG46

Low Treat & No ZnDTP


Wear Protection

Tests commonly used:– Eaton Vickers I-286-S

• Vane Pump 104-C-10 for Industrial Hydr.Sys.

– Eaton Vickers M-2950-S• Vane Pump 35VQ25A for

Mobile Hydr.Sys.

– ‘New’ Dension HF-0• Denison T6H20C Hybrid

pump> dry & wet phase, > Also HF-1, HF-2

Extends Component Life


0 20 40 60 80 100 120

Phase 1: Dry(D-T6H20C- HP @ 10-250 bar, 110°C)Phase 2: Wet(D-T6H20C-HP @ 10-250 bar, 80°C)

Weight loss of vanes (mg)(V35VQ25A @ 207 bar, 93.3°C)

Weight loss of ring (mg)(V35VQ25A @ 207 bar, 93.3°C)

Weight loss of vanes (mg)(V104-C-10 @ 140 bar, 66°C)

Weight loss of ring (mg)(V104-C-10 @ 140 bar, 66°C)

New ASHLESS AWHF Package

Weight loss (mg)

Vickers V 104-C-10 & 35VQ-25A pump test + Denison T6H20C Hybrid Pump(run under standard, high temperature and low load conditions)

Wear Protection - Results

Pass

Pass

7

53

4

1115

75

Typical Rejection Limit

50

Performance Achieved At Low Treat & No ZnDTP


Hydrolytic Stability

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5

Weight loss of Copper(mg/cm2)

Total Acidity of Water(mg KOH/g)

Denison Rejection Limit

New ASHLESS Package

Beverage Bottle Test: ASTM D 2619

Ashless Technology Ensures Water Compatibility

0

0.2


Thermal Stability

Cincinnati Machine Rejection Limit

Sludge mg/100 ml0 5 10 15 20 25

Group I

Group II

New ASHLESS Package

12

Cincinnati Machine Test: P70 Procedure A168 hours at 1350 C

Ashless Technology Reduces Sludge Formation


Filterability

Time (seconds)

Denison Filterability Test: TP- 02100

Procedure A: No waterFiltration Time

0 100 200 300 400 500 600

Denison rejection limit

New ASHLESS PackageProcedure B: 2% waterFiltration Time

103

Ashless Technology Reduces Filter Blockage


Oxidation Stability

0 500 1000 1500 2000 2500 3000 3500

Time in minutes

Minimum DIN 51 524 Standard

TOST Life test: ASTM D 943 - Time to 2 mg KOH/g950c; H20; Fe & Cu catalysts

4200

New ASHLESS Package

Group II

Group I

Ashless Technology Extends Service Life


Corrosion Inhibition

Ashless Technology Protects Metal Components

1bCu Corrosion Prevention(ASTM D 130) Cu Strip (rating)3 hours, 100 °C

Typical Rejection Limit

New ASHLESS Package

Rust Prevention(ASTM D 665) 24 hours, 60 °CProcedure A: Distilled waterIron Rod (rating)Procedure B: Synthetic seawater, Iron Rod (rating)

1a

Pass

Pass


Filterability

Ashless technology reduces filter blockageand is compatible with Zn compounds

Test Result Specification

Denison Filtration Dry t = 120 sec t < 600 sec

Denison Filtration Wet t = 120 sec t < 600 sec

Afnor Filtration Dry FI = 1.0 FI < 2.0

Afnor Filtration Wet FI = 1.1 FI < 2.0

Ca Compatibility FI = 1.0 FI < 2.0


Content







Specially Formulated Additive Packages

Top-tier chemical technology

Needed to blend Anti-Wear Hydraulic Fluids

Important for providing required durability

And performance retention under most strenuous operating conditions


ConclusionsThe new ASHLESS Additive Technology clearly provided performance features equal to ZnDTP technology

ASHLESS Technology results in valuable long term benefits such as:

Lower disposal & effluent treatment costs

Reduced heavy metal contamination (environment)

This is…


Vital For Our Future.


Ciba Specialty Chemicals

Delivering Better SolutionsFor The

Environment

Thank you !

Any Questions ?

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