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PPT SHELL
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Copyright of Royal Dutch Shell plc 1
HYDRAULIC FLUIDS FOR MINING EQUIPMENTS
Augusto Fernandes Product Application Specialist
Copyright of Royal Dutch Shell plc 2
Hydraulic System Designs
DEMAND FOR NEWER FLUIDS
Power Output
System Pressure
Operating Temperature
Energy Efficiency
Hydrostatic Drives
Low Speed High Torque
Motors
Reduced Environmental
Impact
Oil Service Life
Expectation
Emissions Controls
Reservoir Size
Downtime & Idle at
Start-up
Finer Filtration
INCREASED STRESS ON HYDRAULIC FLUID
Trends
Copyright of Royal Dutch Shell plc 3
Trends
Hydraulic Fluid Selection
Multiple options for selection of hydraulic fluids.
Selection of hydraulic fluid often a commodity driven purchase decision.
Consider life-cycle maintenance costs.
Key need to consider application challenges and demands on lubricant prior to selection and rationalization on site.
Copyright of Royal Dutch Shell plc 4
Hydraulic Pump Testing Trends
General anti-wear Vickers V104C (Vane Pump)
Denison HF-0 (T5C Vane Pump; P46 Piston Pump)
Vickers 35VQ25 (Vane Pump);
Vickers PVH 57 (Piston Pump)
Denison HF-2 (T6C vane Pump; Water);
Bosch Rexroth A2F
Denison HF-0 (T6H20C Hybrid Vane/Piston);
Komatsu Hitachi 35+35 Pump test
Bosch Rexroth piston pump (TBD)
140 bar/80C
207 bar/95C;
250 bar/0-230 bar/95C
0-250 bar (vane) + 280 bar (piston) /110C
0-250 bar/80C
345 bar/75C-100C
TBA STRESS ON OIL
Trends
Copyright of Royal Dutch Shell plc 5
Implications for Hydraulic Fluids
As equipment designs and environmental legislations change, specifications for hydraulic fluids are becoming more demanding.
Recognition of the need for more differentiated performance specifications driving more differentiated products in all areas.
Hydraulic fluids design is constantly evolving.
Shift in experience of work force.
Implications
Copyright of Royal Dutch Shell plc 6
Different OEMs Recommend Different Oils
Implications
Major manufacturers are split between use of engine oil type fluids and hydraulic type fluids.
Both fluid types can work very well in mobile equipment depending on design and application.
As always, the starting point for fluid selection is the manufacturers recommendation.
OEM Primary Recommendation Secondary
Recommendation
Komatsu Engine Oil Hydraulic Oil
Caterpillar Engine Oil Hydraulic Oil
Hitachi Hydraulic Oil -
JCB Hydraulic Oil -
Liebherr Engine Oil/ATF -
Terex Engine Oil Hydraulic Oil
Manitou Hydraulic Oil -
Volvo CED Hydraulic Oil -
Copyright of Royal Dutch Shell plc 7
Mobile And Static Systems Impact Operational Severity
Mobile Hydraulic Systems Industrial (Static) Hydraulic Systems
High Pump Capacity/Small Reservoir Large Oil Reservoir
No time for air/water separation Time for air/water separation
High operating pressures Mostly lower operating pressures
Variable operating temperatures Mostly operating under constant temperatures
Harsh environment Relatively clean environments
Usually pressurised reservoir Reservoir more or less open to air
Hydrostatic drives often present Less likely to have hydrostatic drives
Implications
Copyright of Royal Dutch Shell plc 8
Leadership
Shell Solutions to These Challenges Energy Efficiency
Improving the energy efficiency of hydraulic systems is a major focus for many OEMs and operators as a way to help reduce operating costs.
Need to develop robust and statistically relevant procedures to evaluate efficiency benefits through use of hydraulic fluids and control variables.
ASTM D7721-11 Standard Practice for Determining the Effect of Fluid Selection on Hydraulic System or Component Efficiency (June 2011).
Formation of CCEFP multidisciplinary committee.
Shell has developed computer based modeling techniques and controlled field based tests to compare the energy efficiency and fuel economy benefits of different hydraulic fluids.
Copyright of Royal Dutch Shell plc 9
Leadership
Shell Solutions to These Challenges Energy Efficiency
Improving the energy efficiency of hydraulic systems is a major focus for many OEMs and operators as a way to help reduce operating costs.
Zn-Based Mineral Oil
Zn-Free Synthetic Oil 2
Zn-Free Synthetic Oil 1
Lower coefficient of friction with specially formulated synthetic hydraulic fluid
Bette
r
Komatsu WH613 Telescopic Handler
1.4
1.0
1.2
1.9
1.8
-1.5 -0.5 0.5 1.5 2.5 3.5 4.5 5.5
1
2
3
4
5
Fuel saving (% consumption vs. Tellus S2 M 46)
Test phase number
Tellus S4 ME 46 (Run 4)
Over a working day* Tellus S4 ME 46 gave fuel savings of 1.5% - 1.9% when compared to a typical antiwear hydraulic fluid (ISO type HM).
*working day result significant at 99% confidence level.
Copyright of Royal Dutch Shell plc 10
Leadership
Shell Tellus S4 ME 68 Hagglunds Motors Energy Efficiency
Barrick Gold, a large mining company in Western Australia, have been conducting a trial of Tellus S4 ME 68 (formerly Tellus EE) in a conveyor system powered by Hagglunds hydraulic motors.
Careful measurement of energy consumption before and after converting to Tellus S4 ME 68 has demonstrated an energy saving of 5.3% relative to Tellus S2 M 68.
Bette
r
Copyright of Royal Dutch Shell plc 11
Leadership
Shell Solutions to These Challenges Tackling Low Residence Times
Compliance with emission regulations on off-highway vehicles requires additional treatment devices space becomes a factor reduce hydraulic reservoir sizing to fit space remaining.
Reservoir size decreasing from a 4:1 or 3:1 ratio of sump size to flow rate to now less than 1:1 very low oil residence time in tank.
Lubricants with improved air release performance allow for improved system design and minimizes effective compressibility.
* Compared to requirements included in DIN 51 525 HLP specification
ISO VG 46 Hydraulic Fluids
Bette
r
Copyright of Royal Dutch Shell plc 12
Leadership
Shell Solutions to These Challenges Temperature Operating Window
High equipment availability, including reduced time for start-up is a major driver for mobile equipment operators.
Equipment operated and exposed to wide temperature swings during winter or overnight can be exposed to major stresses upon start-up.
Pump cavitation as a result of very high fluid viscosity at start-up can significantly reduce pump life.
Hydraulic fluids possessing excellent low temperature fluidity, a high viscosity index and being shear stable help in protecting pumps at low start-up temperatures.
Copyright of Royal Dutch Shell plc 13
Leadership
Pump Efficiency
Shell Tellus S4 ME displays excellent shear stability and resistance to thinning in service.
high viscosity index without the use of Viscosity Index Improver Additives
Thinner fluid at high temperatures causes:
High wear rates of pump parts
High leakage
System failure Ef
ficie
ncy
Viscosity
Optimum Operating Range
0
2
4
6
8
10
12
14
16
18
Vis
co
sit
y L
oss (
%)
Shell Tellus EE Oil A Oil B
Shell Tellus EE
Oil A
Oil B
Bette
r
ISO VG 46 Fluids
Loss of Reliability
Loss of Productivity
Increased Costs
Shell Tellus S4 ME
Shell Tellus S4 ME
Copyright of Royal Dutch Shell plc 17
Leadership
Hydraulic Fluid Consumption
Blown hydraulic hoses and leaking seals on hydraulic cylinders are major contributors to high hydraulic oil consumption on mobile equipment: Increases oil consumption.
can reduce pump/system efficiency.
Non-availability of equipment and unplanned downtime.
safety hazard.
environmental hazard.
Smart hoses like Eaton Life Sense hydraulic hose condition monitoring system: A hose-condition sensor continuously
monitors hose conditions via electrical measurement technology-sends alert to user.
Copyright of Royal Dutch Shell plc 18
Minimizing Environmental Impact
Specifications and Ecolabeling.
Utilization of renewable raw materials.
Significant fines from EPA for discharges to the environment.
Positive steps for license to operate for companies.
Consideration for ore handling ship loaders and unloaders.
Implications
Copyright of Royal Dutch Shell plc 19
Shell Solutions to These Challenges Biodegradable Lubricants
Synthetic ester based biodegradable hydraulic fluid designed with a measured bio-based content of over 80% m/m (ASTM D 6866) exceeding USA Federal Procurement requirement for bio-based hydraulic fluids (USDA Bio-preferred program limit of 44%)
Low ecotoxicity towards marine and plant life
Performance
low temperature fluidity for low temperature start-up wider temperature operating window
Anti-wear characteristics exceeding mineral oil limits imposed by OEMs
Compatibility with yellow metals, seals, hoses
Resistance to deposit formation with long fluid life
Shell Naturelle Hydraulic Fluid HF-E 32
Cam ring at the end of the test the original
machining marks are still clearly visible