Industrial Gear Oils. Schäffel - Potentiale der...4 Industrial Gear Oils By revenue (in mn $) By . API group 2.513 153 . 1.447 . 912 . 307 Group I+II. Group III. Group IV (PAO) Group

Dr. David Schäffel UNITI Mineralöltechnologie-Forum April 2017

How Polyalkylene Glycols save energy in industrial gear application

Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017

Table of contents: energy efficiency of industrial gear oils

Industrial Gear Oils 2

Introduction

Performance profile of PAGs

Set up of energy efficiency test

Test results for different base oils

Advantages of Polyglykols at a glance

Introduction


The global industrial gear oil market in 2014 892 kto = 5333 mn$ / CAGR (2014-2020) 1.7%


By

reve

nue

(in m

n$)

By API group

2.513

153 1.447

912

307

Group I+II Group IIIGroup IV (PAO) Group V (PAG)Group V (Esters)

Source: IndustryARC

2.667

2.667

Mineral oil (Group I+II+III)Synthetic

By baseoil

synthetic industrial gear oils market share is as big as for mineral gear oils

synthetics are gaining further market share over mineral oils as they are growing at a higher rate

(2.1% vs. 1.6%)


Industry trends


Productivity increase

High performance

gear oil

Cost reduction

Long lifetime gear oil

Sustainability

Energy efficient gear oil

•new machines • smaller gearboxes • reduced oil reservoirs •higher speeds & loads •higher temperatures

• reduce downtimes • extend oil change

intervals • protect gear and

bearing equipment

• reduce CO2 emission • less energy consumption

• less waste generation

Indu

stry

tr

end

Indu

stry

ob

ject

ive

Impa

ct o

n ge

ar o

il


Requirements for gear oils


Increased stability

Cost reduction

Sustainability

Use of PAG, PAO or ester as

base oil

• improved viscosity-temperature behavior, high viscosity index

• high lubrication performance/high load carrying capacity

• extreme pressure and anti wear performance

• foam & air release control at higher speed

Tech

nica

l re

quire

men

ts

Req

uire

men

ts fo

r ge

ar o

il co

mpo

nent

s

Higher load, speed and

temperatures

• no sludge formation during operation

• high tolerance to water contamination

• rust protection • shear stability • compatibility with

sealings and internal coatings

Advantages against mineral oil-based gear oils * • up to 15% higher gear

efficiency • up to 30% less friction • up to 30% less energy

consumption • Oil change intervals

up to 5 times longer

* Article “Synthetic gear oil selection” by Dennis Lauer on www.machinerylubrication.com

http://www.machinerylubrication.com/


Global Electricity Consumption


- Global consumption on electricity is steadily increasing

- Companies are looking for possibilities to reduce electricity consumption in order to

- reduce energy costs

- achieve sustainability targets

Global Electricity Consumption

Source: International Energy Agency World Energy Outlook 2013

Performance profile of Polyglykols

Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017 Industrial Gear Oils 9

Polyalkylene glycol types & properties

R OHCH2

O

CH3

CH2 CH2

O

OO

OR O

OO

OH

Catalyst

• Shape: linear or branched • Number of functional groups

• Statistical/random copolymer • Mw distribution

Properties: Solubility (cloud point), pour point, viscosity, surface tension….


Polyalkylene glycol types & properties

Viscosity in [mm²/s @ 50°C] Starting alcohol EO/PO-ratio

Key Polyglycols for Industrial Lubricants

• Polyglykol B-Types: Butanol started

• Polyglykol D-Types: Ethanediol started

Polyglykol B 11 / 70

OH

OHOH


Viscosity profile – Viscosity Index (1)

Industrial Gear Oils

79

158 180

205 243 232

90

0

50

100

150

200

250

Mineral Oil Ester PAO PolyglykolB01/150

PolyglykolB11/150

PolyglykolD21/150

minimumrequirement

*

Visc

osity

Inde

x IS

O 2

909

Product Typical values for VI Comment

Clariant´s Polyglykols 200-250 very high Viscosity Index (VI)

Esters and Polyalphaolefins 130-180 significantly lower VI

Mineral Oil ≤ 100 only moderate VI

11

Viscosity-Temperature Behaviour: Viscosity Index (VI)

Polyglykols have the highest VI-Index

Polyglykols are applicable over a wide temperature range

VI of mineral oils can be increased by adding VI-improvers (see shear stability)

* Minimum requirement according to DIN 51517-3 CLP gear oils

VI-improvers


1

10

100

1000

10000

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150

Visc

osity

[mm

2 /s]

Temperature [°C]

Viscosity profile – Viscosity Index (2)


Viscosity-Temperature Graph ISO VG 220

Polyglykol D21/150 has lowest viscosity at 0°C -> easy start up at low temperature (5 times thinner compared to mineral oil at 0°C) Polyglykol D21/150 has highest viscosity at 150°C -> formation of load-carrying lubrication film

(50% higher viscosity compared to PAO)

P. D21/150

ester PAO

min. oil

Viscosity 0°C

[mm2/s]

Viscosity 150°C

[mm2/s]

Mineral Oil 12400 8

Ester 4000 12

PAO 2400 14

Polyglykol D 21/150 2200 22

all base oils: 220mm2/s at 40°C

Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017 13

Conditions: Circumferential speed 8.3 m/s; 90°C, 15 min, 1455 min-1 @ max. 12 workload levels

Workload is regulated through lever

Increase of workload and friction between

gear wheels (Workload levels 1-12)

Forschungsstelle für Zahnräder und Getriebebau (Research centre for gear wheels and gear manufacturing)

Source: Forschungstelle für Zahnräder und Getriebebau

Polyglycols in gear oils: Lubricating property FZG test (DIN ISO 14635-1)

Industrial Gear Oils

Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017 Industrial Gear Oils

Lubrication properties – FZG

7

10

9

12 12

56789

10111213

Mineral Oil Ester PAO P. B01/150 P. B11/150 P. D21/150 min. requ.

Failu

re L

oad

Sta

ge

5400N1

8900N 1

11000N

15800N1

>15800N1

>15800N1

>12 >12

1: normal tooth load Measurements were done by the external institute APL Automobil-Prüftechnik Landau GmbH, Germany

loading of the gear teeth is increased at each load stage 1-12

test pinion

FZG spur gear test machine

14

FZG-Test A/8.3/90 pitch circle speed 8.3 m/s; initial oil temperature: 90°C, 1455 min-1, 15 min

Polyglykols fulfill minimum requirements without any additives (note: use of EP/AW additives can have negative side-effects such as foam formation, corrosion, sludge formation,…)

additives necessary

Set up of energy efficiency test


Polyglykols: Energy savings

What can be adjusted • Stress • Sum velocity • Oil temperature • Slip (∆v)

Testing of PAGs: Zwei-Scheiben Prüfstand (two-disc test rig)


Why was Polyglykol D21/150 selected from Polyglykol range? Results from twin disc test rig


Polyglykol D21 has outstanding low friction coefficient

Lowest friction coefficient of Polyglykol D21 results in lowest oil temperature

Ranking of energy efficiency: Polyglykol D21 > Polyglykol B11 >> Polyglykol B01

Friction coefficient of different Polyglykols twin disc, sum speed 1m/s, T = 40°C

0,000,010,020,030,040,050,060,070,080,090,10

0 5 10 15 20 25 30 35 40 45 50 55

frict

ion

coef

ficie

nt m

slip in %

60

46 42

0

10

20

30

40

50

60

70

oil t

empe

ratu

re in

°C

Oil temperature at the end of the test procedure twin disc, sum speed 1m/s, T = 40°C, 50% slip

P. D21/150

P. B11/150

P. B01/150

P. B01/150

P. B11/150

P. D21/150


Gear oils selected for FZG energy efficiency test formulated gear oils with additive package


Mineral oil PAO Polyglykol

type FVA3+FVA4 + 1% Anglamol99

mPAO mixture + 1% Anglamol99

Polyglykol D21/150 + 4% LA 1655 N

ISO VG 220 220 220

viscosity at 40°C 220 226 237

viscosity at 100°C 18.7 31 43

viscosity index 95 180 238

Density [g/cm³] 0,885 0,885 1,050

ISO VG 220 gear oils based on Mineral oil, PAO and Polyglykol were selected for energy

efficiency testing


Gear box energy losses


no load losses load dependent losses

• energy losses caused by circulation of the gear oil in the gear box

can be influenced by viscosity and density of the lubricant

• energy losses caused by friction between gear teeth

can be influenced by type of base oil

main factor for gear box energy losses are load dependent gear losses

- engineering optimisation of gear boxes lead to energy efficiency improvements

- end user can improve energy efficiency of the gear box by selecting the right lubricant

Categories of energy losses:

http://www.xtek.com/industrial-gearboxes/mill-pinion-stands.php


FZG energy efficiency test equipment*


energy losses are calculated via measurement of loss torque

*according to the FVA research project 345

Test results for different base oils


1,00%

0,81%

0,68%

0,56%

0,71%

0,57% 0,53%

0,48% 0,45%

0,32% 0,39%

0,45%

0,00%

0,20%

0,40%

0,60%

0,80%

1,00%

Min Oil

PAO

P. D21/150

Load dependent energy losses: speed dependence T = 90°C, load stage 7

Public, Industrial Gear Oils 22

∆0,55%

∆0,49%

∆0,29% ∆0,11%

speed 0,5 m/s 2 m/s 8,3 m/s 20 m/s speed pinion

shaft 130 min-1 522 min-1 2166 min-1 5219 min-1

speed gear shaft 87 min-1 348 min-1 1444 min-1 3479 min-1

Maximum energy efficiency improvement with Polyglykol D21/150 at low speeds

Loss

-pow

er g

ear


0,73% 0,81%

0,91%

0,48%

0,57%

0,67%

0,25% 0,32%

0,40%

0,00%

0,20%

0,40%

0,60%

0,80%

1,00%

Min Oil

PAO

P. D21/150

Load dependent energy losses: load dependence T = 90°C, speed 2 m/s


load stage 5 7 9

torque 94 Nm 183 Nm 302 Nm

tooth normal force 2782 N 5421 N 8927 N

Hertzian press 962 N/mm2 1343 N/mm2 1723 N/mm2

Significant and constant improvement with Polyglykol D21/150 at all loads

∆0,48% ∆0,49%

∆0,51% Lo

ss-p

ower

gea

r


Load dependent energy losses: temperature dependence speed 2 m/s, load stage 7


Temperature 40°C 60°C 90°C 120°C

The higher the temperature, the bigger the improvement with Polyglykol D21/150

1,12%

0,97%

0,81% 0,74%

0,86%

0,71%

0,57% 0,49%

0,72%

0,54%

0,32% 0,25%

0,00%

0,20%

0,40%

0,60%

0,80%

1,00%

1,20%

Min Oil

PAO

P. D21/150

∆0,40%

∆0,43%

∆0,49% ∆0,49% Lo

ss-p

ower

gea

r


Energy efficiency case study extruder for polymer compounding, average engine power 200 KW (63% of max. power, oil volume 70l)


- changing from mineral oil to Clariant Polyglykol D21 based gear oil

- estimated cost savings per year:

200KW * 6700h * 0.15€/KWh * 0.5% = 1005 € (engine power) * (annual operation time) * (electricity costs) * (energy savings) = cost savings per year

Energy cost savings of 1005€ correspond to a gear oil price difference of

0.15 € / KWh (eurostat for Germany 2015) *fluid lifetime of both oils 6700h; longer fluid lifetime of P. D21 not included

14€/l* (1005€ / 70l)

http://ec.europa.eu/eurostat/statistics-explained/index.php/File:Electricity_and_gas_prices,_second_half_of_year,_2013%E2%80%9315_(EUR_per_kWh)_YB16.png




Benefits of Polyglykol D21 at a glance


Excellent energy efficiency

88,4

85,6

81,9

8081828384858687888990

stea

dy st

ate

oil t

empe

ratu

re

oil temperature load stage 7

MIN

PAO

PG D21/150

significant lower friction coefficient compared to B01

up to 0.55% saving on total energy costs vs mineral oil

cost saving of P. D21 in case study corresponds to a gear oil price difference of 14€/l

reduced oil temperature leads to longer fluid lifetime

and less cooling requirements

Reduced Oil Temperature

Many thanks for your attention


Disclaimer


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Material Safety Data Sheets providing safety precautions, that should be observed when handling or storing Clariant products, are available upon request and are provided in compliance with applicable law. You should obtain and review the applicable Material Safety Data Sheet information before handling any of these products. For additional information, please contact Clariant.

For sales to customers located within the United ٭States and Canada the following applies in addition

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Documents

Industrial Gear Oils. Schäffel - Potentiale der...4 Industrial Gear Oils By revenue (in mn $) By . API group 2.513 153 . 1.447 . 912 . 307 Group I+II. Group III. Group IV (PAO) Group