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AftonChemical.com
Contribution of Gasoline Particulate Filter (GPF) and Lubricant to the TGDi System Solution
Dr Ian BellApril 2018
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Outline
GPFs: The need for change
What is a GPF?
Engine Oil: Part of the solution
Lubricant impact on GPF function
Summary
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Gasoline Particulate Filters: The Need and the Challenge
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Emission Targets Driving Fundamental Shift in Gasoline Vehicle Technology
1970/90sControl of priority pollutants• Adoption of catalysts and
engine control• Reduce HC, CO, NOx
Mid 2010sFuel Efficiency• Improve FE/CO2 emissions• Engine downsizing and
power enhancement
Late 2010sMore stringent emission regulations• Particulates • RDE
Timeline – Toxic Emissions Standards Passenger Cars
References L to R: Delphi - Worldwide Emissions Standards, Passenger Cars and Light Duty Vehicles 2017-2018; IHS 2015 report, Corning, Gasoline Particulate Filter: A Overview, 2017 LD Emission Control Symposium
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What is a Gasoline Particulate Filter?
Exhaust gas, including PM10 and PM 2.5
Alternatively Open or Plugged Passages
Particle Filtration (and Catalyst Reaction if coated)
Tailpipe Emissions
[Source?]
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What is a Gasoline Particulate Filter?continued
HC2CONOx PM
Inlet
Outlet
CO2 H2ON2
HC2CONOx PM
Inlet
Outlet
CO2 H2ON2
Regen.
HC2CONOx PM
Inlet
Outlet
CO2 H2ON2
Gasoline engines generate particulate emission (soot)GPFs are filters, or ‘traps’, fitted within the exhaust system of vehicles to catch particulate matterGPFs are not DPFs!
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…Including the engine lubricant
GPF: System Optimization for Performance
Packaging
Particulate Filtration Efficiency
Gaseous emission
Calibration
OBD Requirement
Backpressure/Regeneration
Total cost
Successful deployment of GPF technology needs system optimization for
various performance requirements
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Effect of Ash on Backpressure
Ref.: SAE 2012-01-1241 (Shimoda et al)
Backpressure increases with soot and ash accumulation amountLow mileage and dyno aged filters contained far less fully oxidized ash mass than the full useful life (FUL) filterApproximately 50 wt% of the collected ash was not directly related to the oil consumption
How Soot and Ash accumulate
and are managed can
have a marked impact on GPF performance
and ultimately vehicle fuel economy
XRF Analysis of Ash in GPFsEffect of Ash - (Cold Flow Bench)
Ref.: SAE 2017-01-0930 (Lambert et al)
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Initial Insights
Global emission legislation is driving towards more TGDiengines fitted with GPFs Physical removal and oxidation of carbonaceous particulatesAsh (and soot) loading rates / levels are one of several critical factors in GPF efficiencyLubricant formulation characteristics impact GPF filtration efficiency Additive ash contribution
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Lubricants: Part of the System Solution
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Roles of a Lubricant & Lubricant Additives
Lubricate Cool Pressurize
Prevent Wear Reduce Friction Remove Contaminants
Protect the oil
Enhance Performance
Modify Oil Properties
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Inorganic friction modifierIncreased use since mid-’90sParticularly effective in motored-friction tests (fuel economy)
Metal Detergents(sulfonate, phenate, salicylate)
Keeps engines clean, and neutralises combustion-acids.Most chemically efficient way to add base to the lubeRange of surface impacts
Primary, and most effective anti-wear agent (durability)Used for over 80 yearsAlso most cost-effective anti-oxidant
Key Lubricant Additives Adding Ash
ZDDP(zinc dialkyldithiophosphate)
MoDTC(molybdenum dithiiocarbamate)
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Lubricant Formulation Balance
Zero ash lubes are theoretically possible, but practically prohibitiveThankfully, our research evaluations show we don’t need to be so drastic
We must maintain a holistic approach to lubricant formulating
0
2
4
6
8
10
12Emission system durability
Seal compatability
Fuel Efficiency
Corrosion Protection
E-85 Emulsion Retention
Engine Oil Volatility
Engine Sludge Control
Piston CleanlinessTurbo Protection
Oxidative Thickening Protection
Wear Protection (engine)
Wear Protection (Chain Wear) TBD
Aeration Test TBD
Shear stability
Low Speed Pre-Ignition Protection
ILSAC GF-55
ILSAC GF-6A
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Initial Insights
Certain lubricant additives do add ash to the systemThese additives perform several roles that are critical to the effective operation of the engineThe overall vehicle performance and protection is a complex system Lubricant impacts both the engine and GPF operations We need to consider the best overall solution
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Lubricant Impact on GPF: Afton Testing
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Lubricant Ash Impact on GPF Function
Note: Full Scale Engine/Vehicle Ash Loading/System Durability Studies
No significant difference in PM/PN emission, backpressure and fuel consumption between two
lube ash levels in end-of-life performance
Clear impact of ash-loading on GPF backpressure
Poorer particulate filtration rate for
unconditioned GPF
5.0
6.0
7.0
8.0
9.0
0.0
2.0
4.0
6.0
8.0
10.0
12.0
0 100 0 100
OEM High Ash, System B Low Ash, System B
Fuel
cons
umpti
on (L
/100k
m)
Max.
Back
pres
sure
(kPa
WLTC
Max. Backpressure Fuel Consumption
Source: Afton data 2017
Fresh FreshAged Aged
High Ash Oil Low Ash Oil
Fresh0.000
0.001
0.002
0.003
0.004
0.005
0.006
1.0E+08
1.0E+09
1.0E+10
1.0E+11
1.0E+12
1.0E+13
0 100 0 100
OEM High Ash, System B Low Ash, System B
PM (g
/km)
PN(#
/km)
WLTC
PN PM
CN 6 PN limit
Aged
High Ash Oil Low Ash Oil
Fresh Aged
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Source: API DAP 12/12/17 (Lambert et al)
70%
75%
80%
85%
90%
95%
100%
0 1 2 3 4 5
PN F
iltrati
on E
fficien
cy (%
)
Ash loading (g/L)
Cake filtrationBed filtration
Source: Afton data 2017
Green filtration efficiency needs improvement to meet legislation requirements
Filtration efficiency improves greatly from bed filtration to cake filtration
Ensuring the vehicular emissions for new vehicles with “green” particulate filters may be a significant challenge
Reality Check on Green Filtration Efficiency
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Model Engine Studies on GPF Cores: Formulation Affects Oxidation
PM (soot) oxidation is affected by its composition, temperature, catalyst etc.Increased soot burn-off rate can equate to fuel economy savingsLubricant oil formulation can change oxidation rate
Lubricant oil formulation can impact GPF regeneration rate and hence benefit fuel economy
Source: Afton data 2017
y = 1.5637e0.7616x
R² = 0.996
y = 2.3277e0.2307x
R² = 0.7762
0
5
10
15
20
25
0.00 1.00 2.00 3.00 4.00
Maxim
um so
ot ox
idatio
n rate
(%/m
in)
Ca/P or Mg/P (molar ratio)
Ca Mg
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Vehicle Detergent Composition Comparison: Testing Results of PN and FE
(Ca) (Ca/Mg)
Driving condition (cold start vs. hot start) has significant impact on both PN and FE
Source: Afton data 2017
Cold startHot start
Source: Afton data 2017
0.0E+00
2.0E+11
4.0E+11
6.0E+11
8.0E+11
1.0E+12
1.2E+12
1.4E+12
1.6E+12PN (#/mile)
0.000
0.001
0.002
0.003
0.004PM (g/mile)
30.5
30.0
29.5
29.0
28.0
27.0
27.5
28.5
FE (mpg)
Test Protocol: Cold Start US06-soak (1h)-US06-soak (1h)-US06 -soak (1h)-US06-soak (1h)-US06
A B
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Summary
2018 © Afton Chemical Corporation, All Rights Reserved.
AftonChemical.com
Summary
Global emission legislation is driving towards more TGDiengines fitted with GPFsLubricant formulation characteristics impact GPF filtration efficiencyThe overall vehicle performance and protection is a complex system Lubricant impacts both the engine and GPF operationsGenerally the industry is gravitating to 0.8% Ash lubricants Balancing engine durability and GPF efficiency requirementsGreen filtration sees a potential challenge in attaining low PN targets
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Acknowledgments
Huifang ShaoPaul RansomGuillaume CarpentierBrent CalcutJoe Roos
SAE 2016-01-2287 SAE 2017-24-0135 SAE 2017-01-2366 SAE 2018-01-1258
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Thank you
2018 © Afton Chemical Corporation, All Rights Reserved.