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Biofuel Effects on Crankcase Lubricant Performance

Dr. Katherine Richard, Dr. Stuart McTavish, and Keith Strickland

The 5th ICIS Pan-American Base Oils and Lubricants Conference December 3rd & 4th, 2009, Jersey City

Contents
Introduction to biodiesel Biodiesel accumulation in lubricant Potential lubricant issues with use of biodiesel Lubricant formulation approaches for biodiesel Control of negative biodiesel effects in B30 field trial Conclusions

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Introduction
The development and use of renewable energy sources is increasing, driven by mixture of environmental, political and economic factors Global use of 1st generation biodiesel fuel is increasing For vehicles, biodiesel is predominantly used as a fuel extender:
Blended with standard petroleum diesel EU: EN590 currently allows up to 7% biodiesel (B7) USA: B5 is generally accepted and B20 is increasingly available Asia: Increasing mandates and usage across Asia, similar to Europe

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First Generation Biodiesel


First generation biodiesel is a Fatty Acid Methyl Ester (FAME), produced by esterification of vegetable oils

Catalyst

Vegetable Oil

Glycerine (Glycerol)

FAME

Three main feed stocks commonly used:

Palm oil
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Rapeseed oil
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Soybean oil
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Impact of First Generation Biodiesel on Lubricants


Biodiesel can accumulate in the lubricant
Lower volatility than petroleum diesel

The chemical structure of FAME is inherently reactive


Adding a chemically reactive material into the engine oil Type of feedstock can significantly affect FAME chemical properties Results in complex lubrication issues

Three potential issues have been identified for biodiesel applications:


Increases oxidation of lubricants Increased piston deposits Increased corrosion

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Primary Mechanism of FAME Accumulation in Lubricant


Fuel Injector Exhaust gas Diesel particulate filters (DPF)

Fuel sprayed into cylinder after combustion more fuel lands on cylinder wall
Piston Rings

Fuel dissolves in the oil on cylinder wall and is washed down in to the sump

Oil sump

The lower volatility of the FAME leads to a build up of fuel in the sump and dilution of the lubricant

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Potential Impact of FAME Accumulation in Lubricant


Potential biodiesel induced piston deposits

Potential biodiesel induced oxidation of lubricant

FAME and its degradation products are lubricant contaminants Oil Oil sump sump

Potential biodiesel induced soft metal corrosion of bearing surfaces

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Aims of Investigation
To understand the impact of:
FAME level on lubricant performance FAME source / composition on lubricant performance

Identify additive technologies to efficiently control the negative effects of FAME in bench and engine tests Demonstrate control of negative biodiesel effects in a B30 field trial

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Impact of Biodiesel on Oxidation


PDSC Bench Oxidation Test

Increasing levels of FAME reduces oxidation stability of lubricants


> 240 > 240

Oxidation Induction Time, minutes

200

Good

150

Top-tier Mid-tier
100

50

Worse
0 Neat Lube Lube with 10% B0 Lube with 10% B50 Lube with 10% B100

Top-tier lubricants provide increased oxidation stability with FAME

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Impact of Biodiesel on Oxidation


PDSC Bench Oxidation Test

Oxidation stability varies with FAME type, all reduce oxidation stability PDSC Peak Onset
280 270

Top-tier
E6

Good

Peak Onset Temperature / C

260 250 240 230

A3/B3
220 210 200 Neat lube Lube w/ 10% B0 Lube w/ 10% B50 Lube w/ 10% B100

PME RME SME

Mid-tier

Worse

SME shows worst oxidation performance (SME>RME>PME)


Attributed to increasing level of poly-unsaturation

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Impact of Biodiesel on Piston Deposits


TEOST MHT-4 Bench Deposit Test

FAME increases deposits in bench test


40 35 30 mg deposits 25 20 15 10 5 0 Mid-tier Top-tier Neat oil Oil with 10% B50

Worse

Good

Top-tier oils minimise risk of biodiesel-induced deposits

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Impact of Biodiesel on Deposits


Caterpillar 1N Engine Test

Caterpillar 1N test requires artificial addition of biodiesel into the sump to mimic fuel dilution of modern engines & induce biodiesel deposits
400 350 300 Weighted demerits 250 200 150 100 50 0 Top-tier Mid-tier B0 B30 B30 + 5% B100 MAX. LIMIT

Worse

Good

Top-tier oil gives excellent control of biodiesel induced piston deposits with B30 and 5% biodiesel dilution of sump
Biodiesel dilution in sump causes lower quality oil to fail test

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Impact of Biodiesel on Soft Metal Corrosion


HTCBT Bench Corrosion Test
Copper Corrosion
140 120 100 1800 1600 1400 1200

Lead Corrosion

ppm
Lubricant Lubricant + 10% Diesel Lubricant + 5% Diesel + 5% FAME Lubricant + 10% FAME

ppm

80 60 40

1000 800 600 400

20 0

200 0 Lubricant Lubricant + 10% Diesel Lubricant + Lubricant + 5% Diesel + 10% FAME 5% FAME

FAME dilution can result in dramatic increases in copper and lead corrosion using a conventional mid-tier lubricant

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Impact of FAME Source on Soft Metal Corrosion


HTCBT Bench Corrosion Test

200

FAME source can influence extent of biodiesel induced corrosion


2000

COPPER

LEAD

150

1500

ppm Pb
RME SME PME

ppm Cu

100

1000

50

500

RME SME PME

0 Neat lube Lubricant Lube w/ 10% B0 Lubricant + Lube w/ 10% B50 w/ 10% B100 Lubricant + Lube Lubricant +

0 Neat lube Lubricant Lube w/ 10% + B0 Lube w/ 10% B50 Lubricant Lubricant +

10% Diesel

5% Diesel + 5% FAME

10% FAME

10% Diesel

5% Diesel + 5% FAME

Lube w/ 10% Lubricant + B100 10% FAME

Correlation of FAME poly-unsaturation and corrosion


SME > RME > PME

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Control of FAME-Induced Corrosion


HTCBT Bench Corrosion Test

Tailored formulation approaches required to target the soft metal corrosion mechanisms of biodiesel FAME
Copper Corrosion Lead Corrosion
1800 1600 Mid tier 1400 1200 Mid tier Top tier

140 120 100 Top tier

ppm
Lubricant Lubricant + 10% Diesel Lubricant + 5% Diesel + 5% FAME Lubricant + 10% FAME

ppm

80 60 40

1000 800 600 400

20 0

200 0 Lubricant Lubricant + 10% Diesel Lubricant + Lubricant + 5% Diesel + 10% FAME 5% FAME

Biodiesel-induced corrosion can be controlled and minimized by appropriate choice of lubricant additives
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Control of Biodiesel Effects in B30 Field Trial


Demonstrate control of biodiesel in modern engine design with DPF
Drive cycle designed to promote biodiesel build up in lubricant sump In cylinder post injection of fuel for DPF regeneration results in fuel dilution Realistic, but harsh driving conditions

4x Mercedes Benz C220 CDI with DPF


2 vehicles on B30 RME and 2 vehicles on real B0

60,000 km in 6 months, representing 2 oil change intervals


Mixture of city and autobahn driving

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Control of Biodiesel Induced Lubricant Oxidation


B30 Field Trial

Small, insignificant increase in oxidation observed with B30


Analytical method can give higher, false readings in presence of biodiesel

Typical oxidation in ACEA OM646 engine test ranges from 15 to 30 A/cm


30 25 Oxidation (A/cm) 20 15 10 5 0 0 5000 10000 15000 20000 25000 30000

30 25 Oxidation (A/cm) 20 15 10 5 0 30000 35000 40000 45000 50000 55000 60000


Test Distance (km) Car 1 Car 2 Car 3 Car 4

Test Distance (km) Car 1 Car 2 Car 3 Car 4

Top-tier lubricant technology keeps excellent control of biodiesel induced oxidation with B30
17

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Control of Biodiesel Induced Piston Deposits


B30 Field Trial

Low level of biodiesel induced piston deposits observed with B30 With B30, engine cleanliness remains well within acceptable limits

Piston Rating (merit)

Car 1 B0 Car 2 B0 Car 3 B30 Car 4 B30

B0

B0

B30

B30

Vehicle

Top-tier lubricant technology maintains excellent control of biodiesel induced piston deposits and engine cleanliness with B30
18

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Control of Biodiesel Induced Corrosion


B30 Field Trial

Risk of biodiesel induced corrosion increases with FAME dilution from in-cylinder post injection Comparable low copper and lead corrosion levels observed with petroleum diesel and B30
Average Copper Corrosion at ODI Average Lead Corrosion at ODI 50 Car 1 B0 Car 2 B0 Car 3 B30 Car 4 B30 40 Lead (ppm) 30 20 10 Car 1 B0 Car 2 B0 Car 3 B30 Car 4 B30

50 40 Copper (ppm) 30 20 10

B0
0

B0

B30

B30
0 Vehicle

Vehicle

Biodiesel induced corrosion can be controlled and minimized in the field by appropriate choice of lubricant additives
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Overview of B30 Biodiesel Field Trial


No issues observed with vehicle operability with B30
Significant biodiesel accumulation in lubricant observed

Field trial shows top-tier lubricant technology with B30 fuel gives:
Excellent control of biodiesel induced oxidation Excellent control of biodiesel induced deposits & engine cleanliness Provide excellent wear protection Excellent control of biodiesel induced corrosion

Top-tier lubricant technology shown to give excellent all round performance and be compatible with biodiesel blends up to B30

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Summary
The chemical structure of biodiesel is inherently reactive
Adding a chemically reactive material into the engine oil

Increasing levels of biodiesel result in complex lubrication issues


Chemical mechanisms are different with biodiesel and petroleum diesel Biodiesel can cause increased oxidation, deposits and corrosion

High quality lubricants minimize effects of todays levels of biodiesel Impact of future higher levels of biodiesel can be minimized and controlled by selection of appropriate additive technology

This work has been conducted in partnership with Petronas Base Oil SDN BHD

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