contribution of gasoline particulate filter (gpf) and...

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Contribution of Gasoline Particulate Filter (GPF) and Lubricant to the TGDi System Solution

Dr Ian BellApril 2018

2018 © Afton Chemical Corporation, All Rights Reserved.

http://www.aftonchemical.com/

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Outline

GPFs: The need for change

What is a GPF?

Engine Oil: Part of the solution

Lubricant impact on GPF function

Summary



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Gasoline Particulate Filters: The Need and the Challenge



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Emission Targets Driving Fundamental Shift in Gasoline Vehicle Technology

1970/90sControl of priority pollutants• Adoption of catalysts and

engine control• Reduce HC, CO, NOx

Mid 2010sFuel Efficiency• Improve FE/CO2 emissions• Engine downsizing and

power enhancement

Late 2010sMore stringent emission regulations• Particulates • RDE

Timeline – Toxic Emissions Standards Passenger Cars

References L to R: Delphi - Worldwide Emissions Standards, Passenger Cars and Light Duty Vehicles 2017-2018; IHS 2015 report, Corning, Gasoline Particulate Filter: A Overview, 2017 LD Emission Control Symposium



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What is a Gasoline Particulate Filter?

Exhaust gas, including PM10 and PM 2.5

Alternatively Open or Plugged Passages

Particle Filtration (and Catalyst Reaction if coated)

Tailpipe Emissions

[Source?]

Afton image2018 © Afton Chemical Corporation, All Rights Reserved.


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What is a Gasoline Particulate Filter?continued

HC2CONOx PM

Inlet

Outlet

CO2 H2ON2

HC2CONOx PM

Inlet

Outlet

CO2 H2ON2

Regen.

HC2CONOx PM

Inlet

Outlet

CO2 H2ON2

Gasoline engines generate particulate emission (soot)GPFs are filters, or ‘traps’, fitted within the exhaust system of vehicles to catch particulate matterGPFs are not DPFs!



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…Including the engine lubricant

GPF: System Optimization for Performance

Packaging

Particulate Filtration Efficiency

Gaseous emission

Calibration

OBD Requirement

Backpressure/Regeneration

Total cost

Successful deployment of GPF technology needs system optimization for

various performance requirements



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Effect of Ash on Backpressure

Ref.: SAE 2012-01-1241 (Shimoda et al)

Backpressure increases with soot and ash accumulation amountLow mileage and dyno aged filters contained far less fully oxidized ash mass than the full useful life (FUL) filterApproximately 50 wt% of the collected ash was not directly related to the oil consumption

How Soot and Ash accumulate

and are managed can

have a marked impact on GPF performance

and ultimately vehicle fuel economy

XRF Analysis of Ash in GPFsEffect of Ash - (Cold Flow Bench)

Ref.: SAE 2017-01-0930 (Lambert et al)



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Initial Insights

Global emission legislation is driving towards more TGDiengines fitted with GPFs Physical removal and oxidation of carbonaceous particulatesAsh (and soot) loading rates / levels are one of several critical factors in GPF efficiencyLubricant formulation characteristics impact GPF filtration efficiency Additive ash contribution



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Lubricants: Part of the System Solution



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Roles of a Lubricant & Lubricant Additives

Lubricate Cool Pressurize

Prevent Wear Reduce Friction Remove Contaminants

Protect the oil

Enhance Performance

Modify Oil Properties



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Inorganic friction modifierIncreased use since mid-’90sParticularly effective in motored-friction tests (fuel economy)

Metal Detergents(sulfonate, phenate, salicylate)

Keeps engines clean, and neutralises combustion-acids.Most chemically efficient way to add base to the lubeRange of surface impacts

Primary, and most effective anti-wear agent (durability)Used for over 80 yearsAlso most cost-effective anti-oxidant

Key Lubricant Additives Adding Ash

ZDDP(zinc dialkyldithiophosphate)

MoDTC(molybdenum dithiiocarbamate)



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Lubricant Formulation Balance

Zero ash lubes are theoretically possible, but practically prohibitiveThankfully, our research evaluations show we don’t need to be so drastic

We must maintain a holistic approach to lubricant formulating

0

2

4

6

8

10

12Emission system durability

Seal compatability

Fuel Efficiency

Corrosion Protection

E-85 Emulsion Retention

Engine Oil Volatility

Engine Sludge Control

Piston CleanlinessTurbo Protection

Oxidative Thickening Protection

Wear Protection (engine)

Wear Protection (Chain Wear) TBD

Aeration Test TBD

Shear stability

Low Speed Pre-Ignition Protection

ILSAC GF-55

ILSAC GF-6A



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Initial Insights

Certain lubricant additives do add ash to the systemThese additives perform several roles that are critical to the effective operation of the engineThe overall vehicle performance and protection is a complex system Lubricant impacts both the engine and GPF operations We need to consider the best overall solution



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Lubricant Impact on GPF: Afton Testing



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Lubricant Ash Impact on GPF Function

Note: Full Scale Engine/Vehicle Ash Loading/System Durability Studies

No significant difference in PM/PN emission, backpressure and fuel consumption between two

lube ash levels in end-of-life performance

Clear impact of ash-loading on GPF backpressure

Poorer particulate filtration rate for

unconditioned GPF

5.0

6.0

7.0

8.0

9.0

0.0

2.0

4.0

6.0

8.0

10.0

12.0

0 100 0 100

OEM High Ash, System B Low Ash, System B

Fuel

cons

umpti

on (L

/100k

m)

Max.

Back

pres

sure

(kPa

WLTC

Max. Backpressure Fuel Consumption

Source: Afton data 2017

Fresh FreshAged Aged

High Ash Oil Low Ash Oil

Fresh0.000

0.001

0.002

0.003

0.004

0.005

0.006

1.0E+08

1.0E+09

1.0E+10

1.0E+11

1.0E+12

1.0E+13

0 100 0 100

OEM High Ash, System B Low Ash, System B

PM (g

/km)

PN(#

/km)

WLTC

PN PM

CN 6 PN limit

Aged

High Ash Oil Low Ash Oil

Fresh Aged



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Source: API DAP 12/12/17 (Lambert et al)

70%

75%

80%

85%

90%

95%

100%

0 1 2 3 4 5

PN F

iltrati

on E

fficien

cy (%

)

Ash loading (g/L)

Cake filtrationBed filtration


Green filtration efficiency needs improvement to meet legislation requirements

Filtration efficiency improves greatly from bed filtration to cake filtration

Ensuring the vehicular emissions for new vehicles with “green” particulate filters may be a significant challenge

Reality Check on Green Filtration Efficiency



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Model Engine Studies on GPF Cores: Formulation Affects Oxidation

PM (soot) oxidation is affected by its composition, temperature, catalyst etc.Increased soot burn-off rate can equate to fuel economy savingsLubricant oil formulation can change oxidation rate

Lubricant oil formulation can impact GPF regeneration rate and hence benefit fuel economy


y = 1.5637e0.7616x

R² = 0.996

y = 2.3277e0.2307x

R² = 0.7762

0

5

10

15

20

25

0.00 1.00 2.00 3.00 4.00

Maxim

um so

ot ox

idatio

n rate

(%/m

in)

Ca/P or Mg/P (molar ratio)

Ca Mg



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Vehicle Detergent Composition Comparison: Testing Results of PN and FE

(Ca) (Ca/Mg)

Driving condition (cold start vs. hot start) has significant impact on both PN and FE


Cold startHot start


0.0E+00

2.0E+11

4.0E+11

6.0E+11

8.0E+11

1.0E+12

1.2E+12

1.4E+12

1.6E+12PN (#/mile)

0.000

0.001

0.002

0.003

0.004PM (g/mile)

30.5

30.0

29.5

29.0

28.0

27.0

27.5

28.5

FE (mpg)

Test Protocol: Cold Start US06-soak (1h)-US06-soak (1h)-US06 -soak (1h)-US06-soak (1h)-US06

A B



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Summary



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Summary

Global emission legislation is driving towards more TGDiengines fitted with GPFsLubricant formulation characteristics impact GPF filtration efficiencyThe overall vehicle performance and protection is a complex system Lubricant impacts both the engine and GPF operationsGenerally the industry is gravitating to 0.8% Ash lubricants Balancing engine durability and GPF efficiency requirementsGreen filtration sees a potential challenge in attaining low PN targets

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Acknowledgments

Huifang ShaoPaul RansomGuillaume CarpentierBrent CalcutJoe Roos

SAE 2016-01-2287 SAE 2017-24-0135 SAE 2017-01-2366 SAE 2018-01-1258



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Thank you



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