industrial gear oils. schäffel - potentiale der...4 industrial gear oils by revenue (in mn $) by ....
TRANSCRIPT
Dr. David Schäffel UNITI Mineralöltechnologie-Forum April 2017
How Polyalkylene Glycols save energy in industrial gear application
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Table of contents: energy efficiency of industrial gear oils
Industrial Gear Oils 2
Introduction
Performance profile of PAGs
Set up of energy efficiency test
Test results for different base oils
Advantages of Polyglykols at a glance
Introduction
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
The global industrial gear oil market in 2014 892 kto = 5333 mn$ / CAGR (2014-2020) 1.7%
Industrial Gear Oils 4
By
reve
nue
(in m
n$)
By API group
2.513
153 1.447
912
307
Group I+II Group IIIGroup IV (PAO) Group V (PAG)Group V (Esters)
Source: IndustryARC
2.667
2.667
Mineral oil (Group I+II+III)Synthetic
By baseoil
synthetic industrial gear oils market share is as big as for mineral gear oils
synthetics are gaining further market share over mineral oils as they are growing at a higher rate
(2.1% vs. 1.6%)
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Industry trends
Industrial Gear Oils 5
Productivity increase
High performance
gear oil
Cost reduction
Long lifetime gear oil
Sustainability
Energy efficient gear oil
•new machines • smaller gearboxes • reduced oil reservoirs •higher speeds & loads •higher temperatures
• reduce downtimes • extend oil change
intervals • protect gear and
bearing equipment
• reduce CO2 emission • less energy consumption
• less waste generation
Indu
stry
tr
end
Indu
stry
ob
ject
ive
Impa
ct o
n ge
ar o
il
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Requirements for gear oils
Industrial Gear Oils 6
Increased stability
Cost reduction
Sustainability
Use of PAG, PAO or ester as
base oil
• improved viscosity-temperature behavior, high viscosity index
• high lubrication performance/high load carrying capacity
• extreme pressure and anti wear performance
• foam & air release control at higher speed
Tech
nica
l re
quire
men
ts
Req
uire
men
ts fo
r ge
ar o
il co
mpo
nent
s
Higher load, speed and
temperatures
• no sludge formation during operation
• high tolerance to water contamination
• rust protection • shear stability • compatibility with
sealings and internal coatings
Advantages against mineral oil-based gear oils * • up to 15% higher gear
efficiency • up to 30% less friction • up to 30% less energy
consumption • Oil change intervals
up to 5 times longer
* Article “Synthetic gear oil selection” by Dennis Lauer on www.machinerylubrication.com
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Global Electricity Consumption
Industrial Gear Oils 7
- Global consumption on electricity is steadily increasing
- Companies are looking for possibilities to reduce electricity consumption in order to
- reduce energy costs
- achieve sustainability targets
Global Electricity Consumption
Source: International Energy Agency World Energy Outlook 2013
Performance profile of Polyglykols
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017 Industrial Gear Oils 9
Polyalkylene glycol types & properties
R OHCH2
O
CH3
CH2 CH2
O
OO
OR O
OO
OH
Catalyst
• Shape: linear or branched • Number of functional groups
• Statistical/random copolymer • Mw distribution
Properties: Solubility (cloud point), pour point, viscosity, surface tension….
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017 Industrial Gear Oils 10
Polyalkylene glycol types & properties
Viscosity in [mm²/s @ 50°C] Starting alcohol EO/PO-ratio
Key Polyglycols for Industrial Lubricants
• Polyglykol B-Types: Butanol started
• Polyglykol D-Types: Ethanediol started
Polyglykol B 11 / 70
OH
OHOH
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Viscosity profile – Viscosity Index (1)
Industrial Gear Oils
79
158 180
205 243 232
90
0
50
100
150
200
250
Mineral Oil Ester PAO PolyglykolB01/150
PolyglykolB11/150
PolyglykolD21/150
minimumrequirement
*
Visc
osity
Inde
x IS
O 2
909
Product Typical values for VI Comment
Clariant´s Polyglykols 200-250 very high Viscosity Index (VI)
Esters and Polyalphaolefins 130-180 significantly lower VI
Mineral Oil ≤ 100 only moderate VI
11
Viscosity-Temperature Behaviour: Viscosity Index (VI)
Polyglykols have the highest VI-Index
Polyglykols are applicable over a wide temperature range
VI of mineral oils can be increased by adding VI-improvers (see shear stability)
* Minimum requirement according to DIN 51517-3 CLP gear oils
VI-improvers
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
1
10
100
1000
10000
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150
Visc
osity
[mm
2 /s]
Temperature [°C]
Viscosity profile – Viscosity Index (2)
Industrial Gear Oils 12
Viscosity-Temperature Graph ISO VG 220
Polyglykol D21/150 has lowest viscosity at 0°C -> easy start up at low temperature (5 times thinner compared to mineral oil at 0°C) Polyglykol D21/150 has highest viscosity at 150°C -> formation of load-carrying lubrication film
(50% higher viscosity compared to PAO)
P. D21/150
ester PAO
min. oil
Viscosity 0°C
[mm2/s]
Viscosity 150°C
[mm2/s]
Mineral Oil 12400 8
Ester 4000 12
PAO 2400 14
Polyglykol D 21/150 2200 22
all base oils: 220mm2/s at 40°C
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017 13
Conditions: Circumferential speed 8.3 m/s; 90°C, 15 min, 1455 min-1 @ max. 12 workload levels
Workload is regulated through lever
Increase of workload and friction between
gear wheels (Workload levels 1-12)
Forschungsstelle für Zahnräder und Getriebebau (Research centre for gear wheels and gear manufacturing)
Source: Forschungstelle für Zahnräder und Getriebebau
Polyglycols in gear oils: Lubricating property FZG test (DIN ISO 14635-1)
Industrial Gear Oils
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017 Industrial Gear Oils
Lubrication properties – FZG
7
10
9
12 12
56789
10111213
Mineral Oil Ester PAO P. B01/150 P. B11/150 P. D21/150 min. requ.
Failu
re L
oad
Sta
ge
5400N1
8900N 1
11000N
15800N1
>15800N1
>15800N1
>12 >12
1: normal tooth load Measurements were done by the external institute APL Automobil-Prüftechnik Landau GmbH, Germany
loading of the gear teeth is increased at each load stage 1-12
test pinion
FZG spur gear test machine
14
FZG-Test A/8.3/90 pitch circle speed 8.3 m/s; initial oil temperature: 90°C, 1455 min-1, 15 min
Polyglykols fulfill minimum requirements without any additives (note: use of EP/AW additives can have negative side-effects such as foam formation, corrosion, sludge formation,…)
additives necessary
Set up of energy efficiency test
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017 Industrial Gear Oils 16
Polyglykols: Energy savings
What can be adjusted • Stress • Sum velocity • Oil temperature • Slip (∆v)
Testing of PAGs: Zwei-Scheiben Prüfstand (two-disc test rig)
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Why was Polyglykol D21/150 selected from Polyglykol range? Results from twin disc test rig
Industrial Gear Oils 17
Polyglykol D21 has outstanding low friction coefficient
Lowest friction coefficient of Polyglykol D21 results in lowest oil temperature
Ranking of energy efficiency: Polyglykol D21 > Polyglykol B11 >> Polyglykol B01
Friction coefficient of different Polyglykols twin disc, sum speed 1m/s, T = 40°C
0,000,010,020,030,040,050,060,070,080,090,10
0 5 10 15 20 25 30 35 40 45 50 55
frict
ion
coef
ficie
nt m
slip in %
60
46 42
0
10
20
30
40
50
60
70
oil t
empe
ratu
re in
°C
Oil temperature at the end of the test procedure twin disc, sum speed 1m/s, T = 40°C, 50% slip
P. D21/150
P. B11/150
P. B01/150
P. B01/150
P. B11/150
P. D21/150
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Gear oils selected for FZG energy efficiency test formulated gear oils with additive package
Industrial Gear Oils 18
Mineral oil PAO Polyglykol
type FVA3+FVA4 + 1% Anglamol99
mPAO mixture + 1% Anglamol99
Polyglykol D21/150 + 4% LA 1655 N
ISO VG 220 220 220
viscosity at 40°C 220 226 237
viscosity at 100°C 18.7 31 43
viscosity index 95 180 238
Density [g/cm³] 0,885 0,885 1,050
ISO VG 220 gear oils based on Mineral oil, PAO and Polyglykol were selected for energy
efficiency testing
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Gear box energy losses
Industrial Gear Oils 19
no load losses load dependent losses
• energy losses caused by circulation of the gear oil in the gear box
can be influenced by viscosity and density of the lubricant
• energy losses caused by friction between gear teeth
can be influenced by type of base oil
main factor for gear box energy losses are load dependent gear losses
- engineering optimisation of gear boxes lead to energy efficiency improvements
- end user can improve energy efficiency of the gear box by selecting the right lubricant
Categories of energy losses:
http://www.xtek.com/industrial-gearboxes/mill-pinion-stands.php
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
FZG energy efficiency test equipment*
Industrial Gear Oils 20
energy losses are calculated via measurement of loss torque
*according to the FVA research project 345
Test results for different base oils
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
1,00%
0,81%
0,68%
0,56%
0,71%
0,57% 0,53%
0,48% 0,45%
0,32% 0,39%
0,45%
0,00%
0,20%
0,40%
0,60%
0,80%
1,00%
Min Oil
PAO
P. D21/150
Load dependent energy losses: speed dependence T = 90°C, load stage 7
Public, Industrial Gear Oils 22
∆0,55%
∆0,49%
∆0,29% ∆0,11%
speed 0,5 m/s 2 m/s 8,3 m/s 20 m/s speed pinion
shaft 130 min-1 522 min-1 2166 min-1 5219 min-1
speed gear shaft 87 min-1 348 min-1 1444 min-1 3479 min-1
Maximum energy efficiency improvement with Polyglykol D21/150 at low speeds
Loss
-pow
er g
ear
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
0,73% 0,81%
0,91%
0,48%
0,57%
0,67%
0,25% 0,32%
0,40%
0,00%
0,20%
0,40%
0,60%
0,80%
1,00%
Min Oil
PAO
P. D21/150
Load dependent energy losses: load dependence T = 90°C, speed 2 m/s
Public, Industrial Gear Oils 23
load stage 5 7 9
torque 94 Nm 183 Nm 302 Nm
tooth normal force 2782 N 5421 N 8927 N
Hertzian press 962 N/mm2 1343 N/mm2 1723 N/mm2
Significant and constant improvement with Polyglykol D21/150 at all loads
∆0,48% ∆0,49%
∆0,51% Lo
ss-p
ower
gea
r
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Load dependent energy losses: temperature dependence speed 2 m/s, load stage 7
Public, Industrial Gear Oils 24
Temperature 40°C 60°C 90°C 120°C
The higher the temperature, the bigger the improvement with Polyglykol D21/150
1,12%
0,97%
0,81% 0,74%
0,86%
0,71%
0,57% 0,49%
0,72%
0,54%
0,32% 0,25%
0,00%
0,20%
0,40%
0,60%
0,80%
1,00%
1,20%
Min Oil
PAO
P. D21/150
∆0,40%
∆0,43%
∆0,49% ∆0,49% Lo
ss-p
ower
gea
r
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Energy efficiency case study extruder for polymer compounding, average engine power 200 KW (63% of max. power, oil volume 70l)
Industrial Gear Oils 25
- changing from mineral oil to Clariant Polyglykol D21 based gear oil
- estimated cost savings per year:
200KW * 6700h * 0.15€/KWh * 0.5% = 1005 € (engine power) * (annual operation time) * (electricity costs) * (energy savings) = cost savings per year
Energy cost savings of 1005€ correspond to a gear oil price difference of
0.15 € / KWh (eurostat for Germany 2015) *fluid lifetime of both oils 6700h; longer fluid lifetime of P. D21 not included
14€/l* (1005€ / 70l)
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Benefits of Polyglykol D21 at a glance
Industrial Gear Oils 26
Excellent energy efficiency
88,4
85,6
81,9
8081828384858687888990
stea
dy st
ate
oil t
empe
ratu
re
oil temperature load stage 7
MIN
PAO
PG D21/150
significant lower friction coefficient compared to B01
up to 0.55% saving on total energy costs vs mineral oil
cost saving of P. D21 in case study corresponds to a gear oil price difference of 14€/l
reduced oil temperature leads to longer fluid lifetime
and less cooling requirements
Reduced Oil Temperature
Many thanks for your attention
Dr. David Schäffel, UNITI Mineralöltechnologie-Forum, April 2017
Disclaimer
Industrial Gear Oils 28
This information corresponds to the present state of our knowledge and is intended as a general description of our products and their possible applications. Clariant makes no warranties, express or implied, as to the information’s accuracy, adequacy, sufficiency or freedom from defect and assumes no liability in connection with any use of this information. Any user of this product is responsible for determining the suitability of Clariant's products for its particular application. ٭Nothing included in this information waives any of Clariant’s General Terms and Conditions of Sale, which control unless it agrees otherwise in writing. Any existing intellectual/industrial property rights must be observed. Due to possible changes in our products and applicable national and international regulations and laws, the status of our products could change.
Material Safety Data Sheets providing safety precautions, that should be observed when handling or storing Clariant products, are available upon request and are provided in compliance with applicable law. You should obtain and review the applicable Material Safety Data Sheet information before handling any of these products. For additional information, please contact Clariant.
For sales to customers located within the United ٭States and Canada the following applies in addition
NO EXPRESS OR IMPLIED WARRANTY IS MADE OF THE MERCHANTABILITY, SUITABILITY, FITNESS FOR A PARTICULAR PURPOSE OR OTHERWISE OF ANY PRODUCT OR SERVICE.
© 2016 Clariant International Ltd, Rothausstrasse 61, 4132 Muttenz, Switzerland ® Product and service marks protected by Clariant in many countries