Lubricants Russia 2005, Moscow, 23. 25.11.

2005
Additive Solutions for Industrial Lubricants
by
Detlef Pazdzior &Achim Fessenbecker
Rhein Chemie / Germany - Division Lubricant Oil Additives (LOA)
[ ]
Content
1. Introduction of Rhein Chemie
2. Additive solutions for industrial lubricants
Anti-hydrolysis additive for esters
Polyurea Powder Technology a newready for usethickener
New Industrial Oil Additive Package optimized for new,
lowSulfur / high VI Base Oils
3. Summary
Chapter 1
Introduction of Rhein Chemie
[ ]
Rhein Chemie Rheinau GmbH
RC is a medium sized chemical company developing and producing additives
for the Rubber, Plastic and Lubricant Industry
Part of the new Lanxess Chemical Company (formerly Bayer AG)
RC turnover > 300 Mio in 2004
RCs Lubricant Oil Additive Division (LOA)
focussed on the industrial side of the lube oil business
Additins for Metalworking Fluids
Additins for Greases
Additins for Industrial Machine Lubrication
European based global supplier
Reliable partner since more than 100 years
[ ]
LOA Division
- Product Portfolio -
Extreme Pressure Additi ves
Light Colored Low Odor
Sulfur Carriers
Anti-Wear Additives
Ash and Ashless AW Additives
(Phosphorus based)
Corrosion Inhibitors
Sulfonates/Carboxylates
Succinic Halfesters,
Amine Phosphates
Metal Deactivators
Anti-Oxidants
Phenolic/Aminic
Specialty Products
Synthetic Esters
Anti-hydrolysis Agents
Additive-Packages
Ash/Ashless R&O/Hydraulic
Multi-Functional MWFs
EP Grease Package
Chapter 2
3 Examples of Additin Solutions
for Industrial Lubricants
[ ]
2.1. Anti-Hydrolysis Additive for Esters
- General Aspects -
Problems with Esters
Degradation in the presence of water
Ester based lubricants attack and dissolve bearing metals (Pb, Zn, Sn) as acidityincreases
Reasons for Hydrol ysis of esters
Kineticallyslowprocess in absence of catalysts
Verytypical autocatalytic process because acids are formed whichthemselves strongly
catalyse the degradation
Simple solution:
Addition of a special carbodiimide which works as acid scavenger removes
the catal yst and stabilizes the ester and protects the bearing metals.
Whydoes it work?
It reacts onlywith acids even in the presence of excess water
(not just neutralizing)
[ ]
2.1. Anti-Hydrolysis Additive
- Hydrolytic Stability Test (ASTM-D 2619) -
192 h
Modified ASTM-D 2619
Base Oil: TMP-Oleate (TAN =0.2 mg KOH/g)
Additive: Carbodiimide
Modification: Time extended to 192 h
No Additive
+0.5% Carbodiimide
+1% Carbodiimide
0 24 48 72 96 120 144 168
0
0.5
1
1.5
2
2.5
3
T
A
N

[
m
g

K
O
H
/
g
]
[ ]
2.1. Anti-Hydrolysis Additive
- Oxidation and Hydrolytic Stability Test (ASTM-D 943) -
T
A
N

[
m
g

K
O
H
/
g
]
500 h 1.000 h 1.500 h 2.000 h
0
1
2
3
4
5
6
7
8
No Additive
1.3% AO
1% Carbodiimide
1% Carbodiimide
1.3% AO
ASTM-D 943
Base Fluid: Saturated C8/C10-TMP-Ester (V40 =32 mm/s; TAN =0.1 mg KOH/g)
[ ]
2.1. Anti-Hydrolysis Additive
- Metal Compatibility Pb/Zn/Sn -
Time [h]
W
e
i
g
h
t

l
o
s
s

[
m
g
]
0 48 96 144 192 240 288 336
00
-50
-100
-150
-200
-250
-300
-350
Zinc (Zn)
Lead (Pb)
Tin (Sn)
1% Carbodiimide
(Pb + Zn + Sn)
Condition: Static Immersion
Base Fluid: TMP-Oleate (V40=46 mm/s; TAN =0.97 mg KOH/g)
Specimen: Zinc sheets; Tin-coated Iron sheets; Lead sheets;
Sample Size: 500 ml
Temperature: 60 C
[ ]
2.1. Anti-Hydrolysis Additive High Lights
Stabilizes all kinds of esters against hydrolysis
Can be used widely as oil soluble acid scavenger
including acidity reduction e.g. coming fromoxidative degradation
Also applicable in Phosphate Esters and mineral oils and other base
oils
Potential applications
High performance ester lubricants used for hydraulics, gears, aircrafts
Fire resistant inorganic Phosphate esters in fire restistant hydraulics,
aircraft etc.
Refrigerant compressor oil
After treatment / Tank side additive to control acidity
Aciditycontrol in greases
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2.2. Polyurea Powder Technology
- a new ready for use thickener -
Polyurea Grease
Heat
Mechanical Energy
Base Oil
Polyurea Powder
+
Additin M 10411
[ ]
2.2. Polyurea Powder Technology
- The Simple Solution -
No restrictions anymore regarding
Toxicity and workers safety
No special storage facilities
Easy handling in the factory
No special approvals of the authorities
Environment
Readily biodegradable thickener
Your supply chain
Free choice location of where you wish to produce PU greases
Standard grease manufacturing equipment sufficient
Use your existing highly sophisticated PU grease plant for high value added products
and have the standard grades made on powder technology in cheaper plants or vice
versa depending on your companys strategy
Increase your product portfolio without additional investments
[ ]
2.2. Polyurea Powder Technology
- Minimum Manufacturing Requirements -
Vessel for stirring and heating up to 200C
Good homogenisation equipment
M 10411 like other powdered grease additives such as Graphite
requires thorough milling to ensure that the particles are very effectively
broken down (the smaller the better)
Roller Mill, High Pressure Homogenisers (200 400 bars) and others
Handling of powders in bags
The powder technology works in standard grease manufacturing
equipment
[ ]
2.2. Polyurea Powder Technology
- Performance Data -
240 245 Dropping Point [C]
0,38 0,70 Four Ball Wear Scar
1200 rpm/400N/75C/1h
1a
1a
1a
1a
Cu Strip Test
3h/100C
24h/100C
226
230
296
194
207
278
Penetration [1/10mm]
(ASTM-D 217) P
u
P
w
60
Pw60.000
0,53 / 1,98 0,20 / 1,09 Oil Bleeding
18h/168h@40C
+2800 / - 3000 <1400 Four Ball Weld Load
1500rpm / 1 min
Formulated Grease
95% Base Grease
5% Additi ve Package
Base Grease
12% M 10411
88% Naphthenic Oil
(110cst@40C)
[ ]
2.3. Optimized Turbine and Compressor Additive
for new low Sulfur Base Oils
Observation: Base Oil Trend goes towards Group II, III and III+
These base stocks are quite different in composition compared to
Group I (Solvent Neutrals)
Most additive packages today have been developed and optimized for
Solvent Neutral type base stock
Existing standard packages do not give the maximumbenefits due to
different additive response
SN based products are not good enough to pass the newest OEM gas
turbine specs (GEK 107395, DIN 51515 p.2 L-TG)
How to make the most out of these excellent base oils
for industrial applications?
[ ]
0
200
400
600
800
1000
1200
Group I Group II Group III Group III+ Group IV
L
i
f
e

T
i
m
e

[
m
i
n
]
RC I RC New RC Old
C1 C2 C3
2.3. Optimized Additive for new Base Oils
- RBOT Test (ASTM-D 2272) @ 0,4% Additive -
[ ]
2.3. Optimized Additive for new Base Oils
- RBOT Test (ASTM-D 2272) -
0
200
400
600
800
1000
1200
1400
1600
RC New
0,3%
RC New
0,4%
RC New
0,6%
RC Old
0,6%
RC New
0,3%
RC New
0,4%
RC New
0,6%
RC Old
0,6%
L
i
f
e

T
i
m
e

[
m
i
n
]
Limit MAN Turbo
Limit DIN 51515 T.2 (L-TG))
Limit GEK 107395
in Group I
Base Oil
in Group III+
Base Oil
[ ]
2.3. Optimized Additive for new Base Oils
- TOST Test Data (ASTM-D 943) -
4500
4800
5300
4700
8500
12000
5800
7500
0
2000
4000
6000
8000
10000
12000
14000
RC New
0,3%
RC New
0,4%
RC New
0,6%
RC Old
0,6%
RC New
0,3%
RC New
0,4%
RC New
0,6%
RC Old
0,6%
T
i
m
e

t
o

T
A
N

2

m
g
K
O
H
/
g

[
h
]
in Group I Base Oil in Group III+ Base Oill
Limit DIN 51515 P.2 (L-TG)
Limit GEK 107395
[ ]
2.3. Optimized Additive fo new Base Oils
- Conlusions -
Applications for new additive technology / Group III Base Oils
in industrial lubrication
Single shaft gas trubine oils (newstandard GEK107395)
Gas turbines (DIN 51515 L-TG part 2, newsince 2003)
Heavy Duty Turbo Compressors (MAN)
Multigrade / HVI Circulating Oils with extended oil drain
If you are considering to use the higher quality type base
fluids such as Group III, III+ or PAOs
dont give performance advantages away by using old
additive technology
Summary
[ ]
3. Summary
Address some current trends and technical needs on the industrial
lubricant market
Present latest solutions froman RC additive point of view
Growing use of esters as base fluids
Anti-Hydrolysis Additive Carbodiimide
Growing demand for high temperature stable greases
Ready for usePolyurea Thickener Technology
Upcoming base oils Group III and newspecs on gas turbine oils
Specifically optimized additives to get the maximumperformance