A Suncor Energy business

ENERGY EFFICIENCIESENERGY EFFICIENCIESMaximize The Opportunity – Select the Right LubricantMaximize The Opportunity – Select the Right Lubricant

ALBERTA FOREST PRODUCTS ASSOCIATIONALBERTA FOREST PRODUCTS ASSOCIATION

SEPTEMBER 2012

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OBJECTIVE

• This presentation is to review the opportunities in reaching energy efficiencies and prolonging equipment and oil life in the forestry industry.– Traditional thinking

• Indoor: Mono-grade oils• Outdoor: Multi-grade oils

• We will discuss advantages of moving to multi-grade lubricants indoors.

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FORESTRY - INDUSTRY TRENDS• Overall reduction in costs (who isn’t)• Energy consumption reflects a substantial

operational cost for the Forestry industry• Hydraulic systems are becoming smaller but more

efficient resulting in higher temperatures and pressures

• A typical hydraulic pump converts approx 20% of its horsepower into heat, therefore most fluids run at elevated temperatures

• Gear design changes to improve efficiency require gear lubricants to work at higher temperatures.

OPPORTUNITIES FOR CHANGE

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OPPORTUNITIES FOR CHANGE

• The trends and more severe requirements on today’s hydraulic and gear systems can and are met with existing high quality mono-grade (straight-grade, single-grade) oils.

• However, further improvements in performance, as well as an added bonus in energy efficiencies is possible through the use of non-traditional products multi-grade oils in indoor applications.

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FUNCTIONS OF A LUBRICANT

• Reduce FrictionReduce Friction

• Minimize Wear (Keep Moving Surfaces Apart)Minimize Wear (Keep Moving Surfaces Apart)

• Cool Parts (Carry Away Heat)

• Prevent Corrosion

• Disperse Combustion or Oxidation by-products

• Act as a Sealant

• Transmit Power

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• Lubrication is key when sliding (area) contact is present.• Lubricants are used to reduce friction and wear by preventing metal to metal contact.

No Lubricant: High Friction

Full Film (Hydrodynamic) Lubrication: Low Friction

Thin Film (Boundary) Lubrication: Moderate Friction

SteelSteel

SteelSteel

SteelSteel

SteelSteel

SteelSteel

SteelSteel

Air

Oil Film

WHY LUBRICATE?

7*NRC Report published in 1986

FRICTION - 1986 NRC-ACOT REPORT

• $5 Billion* per year is lost in Canada due to friction and wear

• 25 - 30% is recoverable with existing technology

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FRICTION - 1986 NRC-ACOT REPORT

Friction Losses ($million/year)

Wear Losses ($million/year)

Total Losses ($million/year)

Agriculture 321 940 1,261

Electric Utilities 54 189 243

Forestry 111 158 269

Mining 211 728 940

Pulp and paper 105 382 487

Rail Transportation 284 467 750

Trucks and buses 126 860 986

Wood Industries 14 189 203

TOTALS 1,2261,226 3,9133,913 5,1395,139

1986 to 2012 what is the $$ amount today? Significant opportunity to reduce friction losses

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• Viscosity is a measurement of resistance to flow at one temperature.

• Viscosity Index (VI) is a measurement of the rate of change of viscosity over a range of temperatures. In simple terms: it measures how fast the oil thickens up as it gets colder or how fast it thins out as it gets hotter.

• Generally the higher the VI the more all-season the product

LUBRICANT PROPERTIES

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• Viscosity Index is an inherent property of the base oil used to blend a lubricant.– Some oils have naturally higher VI than others (i.e. Group II

or synthetics)

• VI can be improved significantly by blending soluble additives called VI Improvers (VII) into the oil.

• These additives are long polymer molecules which uncoil at high temperatures to increase viscosity, while at low temperatures they form tight “balls” which no longer contribute much to viscosity.

VISCOSITY INDEX

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VISCOSITY INDEX IMPROVER (VII)

Temperature oC (LOG)

Vis

cosi

ty c

St

(LO

G-L

OG

)

Base OilMono-grade Product(i.e. Hydraulic AW)

Base Oil + VIIMulti-grade (all-season) Product

(i.e. Hydraulic MV)Viscosity Index Improver (VII) additive expands with higher temperatures resulting in a

higher viscosity at high temperatures

Potential reduction based on shear stability

(i.e. quality) of VII.

Viscosity increase at low temperatures is relatively small resulting in cold temperature

viscosity near original base oil.

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VISCOSITY INDEX IMPROVER (VII)

Temperature oC (LOG)

Vis

co

sit

y c

St

(LO

G-L

OG

)

Mono-grade ProductMono-grade Product(i.e. Hydraulic AW 32)(i.e. Hydraulic AW 32)

Multi-grade ProductMulti-grade Product(i.e. Hydraulic MV 32)(i.e. Hydraulic MV 32)

-20 10040

OEM Recommended

Operating Range

Gain in effective operating temperature rangeGain in effective operating temperature range

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OPPORTUNITIES FOR CHANGE

• Although all indoor components may see benefits of multi-grade oils the two biggest opportunities in the forestry industry are:– Hydraulics

– Gear systems

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VISCOSITY IMPACT - HYDRAULICSV

isco

sity

(cS

t)

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INDUSTRIAL GEAR APPLICATIONS

• Basic Principles• Rolling at the pitch point• Sliding occurs above and below the pitchpoint

Original animation by Doug Wrighte, UWAModified by Fluid Life

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HYDRAULIC PUMP EFFICIENCY

Volumetric Efficiency: All pumps have internal leakage paths.Mechanical Efficiency: Energy is consumed to rotate pump and overcome fluid frictional losses.The amount of mechanical and volumetric loss in a pump is primarilya function of the fluid’s viscosity and lubricity properties.

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HYDRAULIC PUMP EFFICIENCY

Ref: Evonik Industries

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SHEAR STABILITY IS IMPORTANT

Ref: Evonik Industries

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SHEAR STABILITY IS IMPORTANT

Ref: Evonik Industries

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OEMS LIMITS ON SHEAR STABILITY

OEM Max Shear LossEaton/Vickers 10% 20 hr KRLPoclain 10% 40 min SonicJCB OEM 10% 20 hr KRLVolvo Construction 12% 20 hr KRLParker/Denison 15% 20 hr KRLKomatsu HK-1 12% 20 hr KRLCaterpillar TO-4 15% 20 hr KRLBosch/Rexroth 15% 20 hr KRLSauer/Danfoss 15% 40 min SonicDin 51524 Part 3/ ISO 6473 HM Type3 15% 40 min SonicKubota UDT 15% 250 cycle Kurt OrhbanJohn Deere 40 min Sonic Vis @ 100C min of 7.2 cst

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INDUSTRY - TEST RESULTS

Ref: RohMax

COMPONENTTEST OILS

% ENERGY SAVINGSMono-grade Multi-grade

Gear Pump

Eaton L2 Series 2550

ISO 46

VI 100

ISO 46

VI 150>4

Vane Pump

Denison T6C

ISO 46

VI 100

ISO 46

VI 150>5

Piston Pump

Komatsu HPV 35+35

ISO 46

VI 100

ISO 46

VI 150>15

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INDUSTRY – TEST RESULTS

Source: Evonik Industries

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INTERNAL HYDRAULIC OIL TESTS

IMPROVEMENT AW vs. MV

0

1

2

3

4

5

6

50 60 70 80

Temperature C

% Im

pro

vem

ent

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GEAR OIL TESTS RESULTS

GL-5 80W-90

Synthetic Blend 75W-90

Synthetic 75W-90

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FIELD TEST RESULTS

• Test results indicated a fuel savings of 3.8% ($8740)

SAE 10W Mono-grade Multi-grade ISO 32

Hours of Work / Drain Interval Hours 4000 4000

System Volume (gallons) 67.4 67.4

$/gallon $11.70 $6.09

$/litre $3.10 $1.61

Cost of Oil ($) $789 $411

Energy Efficiency Gain 0% 2.8%

Fuel Consumed (gallons) 24,459 21,114

Fuel Costs ($/gallon) $2.50 $2.50

Total Fuel ($) $61,148 $52,785

TOTAL COSTS $61,936 $53,196

Field trial done by vendor on a medium size excavator with dual piston pump feeding 3 piston motors (tracks and swivel) plus boom, stick and bucket cylinders (5000 psi / 345 bar max.) Each product ran for 4 days (~6 hours / day)

Results above are extrapolated to 4000 hrs using a Denison T6CM pump (B10 cartridge, 2000 rpm, 200 bar, 70oC) to benchmark field trial products and internal multi-grade. Since the efficiency of the pump is based on viscometric properties of the fluid at certain temperatures and pressure conditions, data can be accurately extrapolated from the field trial and bench tests to other products.

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SUMMARY

• Significant opportunities are available to improve energy efficiencies by changing to multi-grade oils in applications otherwise suitable for mono-grade products.

• Multi-grade hydraulic and gear oils that are shear stable will maintain viscosity and allow operations to run under wider temperatures

• Improved shear stability results in improved energy efficiencies

• Although much of the test results shown in this presentation are related to mobile equipment, the opportunities of energy efficiencies are relevant to all equipment based on the lubricant technology.

• Selecting the right multi-grade oil saves money.

Thank-you for your time & interest