Group IV base stocks - PAO

UTS SeminarSt Petersburg Sept 13-15, 2011Sandy Reid-Peters

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Topics

• Polyalphaolefins (PAOs)

• What are they?

• How are they made?

• Difference between metallocene and conventional PAO

• Key features of PAO & mPAO and how they compare to mineral oils

• Safety/Regulatory items

• Summary

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• Synthetic high performance base stocks

• Hydrogenated (saturated) olefin polymers

• Manufactured by the catalytic oligomerization of linear alpha olefins

• Wax-free combination of molecules of predetermined chain length

What are PolyAlphaOlefins (PAO)?

Polyalphaolefins have a well defined structure vers us the multiplecomposition of a mineral oil

4

Alpha Olefins

+

Catalyst

Oligomerisation Distillation Hydrogenation

Hydrogen

+

Catalyst

PAO

Monomer

Distillation

PAO manufacturing process

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Conventional PAO Metallocene PAO HVI PAO

• Random distribution of short & long side-chains

Uniform, comb-like structure with absence of short side chains

mPAO base stock builds on ExxonMobil’s metallocene catalyst expertise

PAO molecular structure

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Characteristics of polyalphaolefins

The properties of PAOs that make them so useful are:

High viscosity index

•Low temperature fluidity

•Low volatility

•Good oxidative stability

•Good thermal stability

•Low traction force

•Low toxicity

•Compatibility with other oils & materials

Performance Advantages

•Wide range of applications

•Wide operating temperature range

•Extended service life capability

•Lower maintenance costs

•Energy savings

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Vis

cosi

ty

Temperature, oC

Higher viscosity at high temperature: Offers improved oil film thickness.

Lower viscosity at low temperatureOffers increased fluidity.

PAO

Mineral Oil

Equivalentviscosity

1000 150

Viscosity index

PAO’s typically have a higher Viscosity index than mineral oils

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Viscosity index

Metallocene PAO

Conventional PAO

PIB

Source: BP Amoco data (Re: PIB); ExxonMobil data

mPAO has a higher VI than conventional PAO’s, miner al oils and PIB

9Source: Exxon Mobil data

Viscosity index

High viscosity mPAO provides improved VI when compa red to conventional PAO

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Benefits of high viscosity index

0

1000

2000

3000

4000

5000

6000

0°C

kV, c

St

0

50

100

150

200

250

40°CkV

, cS

t

0

5

10

15

20

25

30

35

100°C

kV, c

St

mPAO PAO Mineral Oil

ISO VG 220 Fluids blended with

Thicker hydrodynamic

film at high temperature

Better protection

Lower Viscosity at low temperature

Better fluidity & energy savings

Source: Exxon Mobil data

High VI offers better protection at high temperatur e and better fluidity at low temperature

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Metallocene PAO

Conventional PAO

PIB

Source: BP Amoco data (Re: PIB); ExxonMobil data

Pour point

mPAO has a lower pour point than conventional PAO, mineral oils and PIB

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Pour point

PAO offers significant benefits in pour point*PAO4, Group IIIA, Group IIIB, Group IIIC, Group IIID are commercially available nominal 4cSt base stocks.

Source: Exxon Mobil data

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mineral oil= solid

Limit of operation

Benefits of low pour point

David Brown Radicon single reduction gearbox (30:1 gear ratio)

Overnight soaking at ambient temperature before start

Source: Exxon Mobil data

PAO can provide advantages over mineral oil in cold climates or low temperature applications

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PAO

Group III

Group II

Projected trends based on typical data points from product data sheets

High temperature volatility – Noack

PAO generally have lower volatility than mineral oi l

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Noack volatility

API SN SpecACEA A1/B1

ACEA A3/B3, A3/B4, A5/B5

PAO offers low volatility to meet current engine oi l specifications*PAO4, Group IIIA, Group IIIB, Group IIIC, Group IIID are commercially available nominal 4cSt base stocks.

Source: Exxon Mobil data

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• Good oxidative stability is essential for applications at elevated temperatures with air contact

• PAO’s show excellent oxidative stability when formulated with suitable antioxidants

B10 Oxidation test (M334-1)Base oil with 2% antioxidant

163°C for 72 Hours4 metal specimens

Air flow 10L/hr

Product

% Vis Change @ 100°CTAN change, mgLead loss, mgSludge

Mineral OilGroup II

215.714.5160.7

moderate

100 cStPAO

1.81.10.2

trace

6 cStPAO

3.50.10.9nil

40 cStPAO

2.60.080.1nil

Oxidation stability

Source: Exxon Mobil data

PAO offers better oxidation stability than mineral oil

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Oxidation stability

0

5

10

15

20

25

A B C D PAO

kV@

100C

incr

ease

, %

PAO offers good oxidation stability under extended service conditions*PAO4, Group IIIA, Group IIIB, Group IIIC, Group IIID are commercially available nominal 4cSt base stocks.

Source: Exxon Mobil data

B10 Oxidation test (M334-1)Base oil with 1% anti-oxidant

163°C for 72 Hours4 metal specimens

Air flow 10L/hr

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Oxidation stability

0

50

100

150

200

250

0 10 20 30 40 50 60

Hours

kV@

100C

incr

ease

, %

A

B

C

D

PAO

PAO again shows good oxidation stability in engine oil screening test

In house bulk oxidation testBase stock with 1% antioxidant

165°CIron catalyst

Air flow 500mL/min

Test limit

*PAO4, Group IIIA, Group IIIB, Group IIIC, Group IIID are commercially available nominal 4cSt base stocks.

Source: Exxon Mobil data

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EHL & traction

Pressure

Traction Coefficient

PAO Oil

Mineral Oil

%Slide-Roll Ratio

Energy losses are determined by the

characteristics of the oil under high pressure

Low traction base stocks save energy over most of

the meshing cycle

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MTM traction coefficient @ 60C

0

0.005

0.01

0.015

0.02

0.025

0.03

0.035

0.04

0.045

0.5 0.75 1 1.25 1.5

Pressure, GPa

Tra

ctio

n C

oeff

icie

nt

ABCDPAO

PAO offers lower traction which helps with energy s aving in EHL contacts

Test Speed - 2ms -1

*PAO4, Group IIIA, Group IIIB, Group IIIC, Group IIID are commercially available nominal 4cSt base stocks.

Source: Exxon Mobil data

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Energy saving with PAO gear oil

• Polyethylene extruder gearbox in North America* powered by 12,700 hp (9.47MW) electric motor

• Satisfactory operation with standard product.

• Electrical motor shutdown due to high bearing temperature (>85C) when handling high density material – reduced throughput to maintain operations.

*Source: “Extruder lubricant upgrades allow higher throughput and reduce motor loads”www.plantservices.com 24/10/2008

Motor bearing oil upgraded to fully PAO synthetic oil.

Measured reduction in bearing temperature (81°C � 75°C on standard material & < 78°C for high density material)

Production benefit of $3600/hour

Gearbox subsequently changed to synthetic gear oil

3.1% energy savings �

$2210/hr electric cost savings

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• Low toxicity

• Hydrolytically stable

• Excellent additive response

• Compatible with mineral oils, Esters and Alkylated Naphthalene

• Meet FDA Requirement under 21 CFR 178.3620(b) Technical White Mineral Oil

• Can be used to formulate lubricants for incidental food contact• NSF Approval For Incidental Food Contact (USDA H1)• Listed in the NSF White Book (http://www.nsf.org/usda/Listings.asp)• Kosher approved• Halal approved

Other key features of PAO (applicable to ExxonMobil grades)

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Indu

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Rot

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Air

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Gas

Com

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Hyd

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Ref

rige

ratio

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ompr

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Gre

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Turb

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Hea

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Hyd

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Flui

dsM

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ubric

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PAO 2 nnnn • nnnn • • nnnn nnnn

PAO 4 nnnn nnnn nnnn nnnn • • • • nnnn • nnnn

PAO 6 nnnn nnnn nnnn nnnn nnnn nnnn • nnnn nnnn nnnn

PAO 8 nnnn • • nnnn nnnn • nnnn • nnnn

PAO 10 • • • nnnn • nnnn • •

PAO 40 nnnn nnnn nnnn nnnn nnnn • nnnn • •

PAO 100 nnnn nnnn nnnn nnnn nnnn • •

PAO 150 nnnn nnnn nnnn nnnn nnnn • nnnn •

n Most common application uses

n Less commonly used

PAO typical applications

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Except as otherwise specified, all charts included in the presentation are based on ExxonMobil data.

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Backup

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CCS viscosity (ASTM D6293)

0

500

1000

1500

2000

2500

3000

3500

A B C D PAO

CC

S V

isco

sity

@-3

5C,

mP

a

All products meet CCS requirements for 0W grades bu t

PAO offers a clear benefit in low temperature start ing

OW limit = 6200mPa@-35C5W limit = 6600mPa@-30C

S o u r c e : E x x o n M o b i l D a t a

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MRV viscosity (ASTM D4684)

0

10000

20000

30000

40000

50000

60000

A B C D PAO

MR

V V

isco

sity

@-3

5C,

mP

a

0

10000

20000

30000

40000

50000

60000

A B C D PAO

MR

V V

isco

sity

@-4

0C,

mP

a

5W limit = 60,000 mPa@-35°C 0W limit = 60,000 mPa@-40°C

All products meet MRV requirements for 5W grades

Some products challenged to meet 0W grade requireme nts

PAO again offers clear benefits for low temperature oil flow

S o u r c e : E x x o n M o b i l D a t a