Jan 17, 2015
Major changes in last decade- for the environment
• New Accords and Protocols
• Automobile Industry – Radical changes
• Environment restrictions
Hussam Adeni [email protected]
5 Major changes in the last decade
• Montreal Accord
• Euro IV and Euro V fuels
• Engine configurations
• Stringent API specifications
• Kyoto Protocol
Hussam Adeni [email protected]
5 Major changes in the last decade
• Montreal Accord• Largely for refrigerants
• Euro IV and Euro V fuels
• Sulphur reduction in fuels
• Engine configurations• Fuel injection mechanism
• Higher operating speeds and pressure
Hussam Adeni [email protected]
5 Major changes in the last decade
• Stringent API specifications• API CJ-4 specifications
• Kyoto Protocols
• Green House Gas (GHG) emissions
Hussam Adeni [email protected]
1. Montreal Accord – 1995/96
• Treaty structured around halogenated hydro carbons known to play a role in Ozone depletion
• Treaty deals with phase-out Management Plan for
1. Chlorofluorocarbons (CFC’s),
2. Carbon Tetra chloride (CCl4),
3. Hydrochloroflourocarbons (HCFC’s)
Hussam Adeni [email protected]
1. Montreal Accord – 1995/6
• Treaty structured around widely used halogenated hydrocarbons now known to play a role in Ozone depletion
• Targets HCFC’s, CFC’s, CCl4 used as
1. Refrigerants,
2. Solvents,
3. Blowing agents for plastic/foam manufacture
4. Fire extinguisher.
Hussam Adeni [email protected]
1. Montreal Accord – 1995/6
• Update - 2006
• Largely implemented across the world
• R – 134 A successfully identified as alternative refrigerant.
• Widely used today in Air conditioners used in automobiles, in house and office AC’s and in industries.
• Montreal compliant solvents and fire extinguishers have been developed & are in use today in many applications
Hussam Adeni [email protected]
2. Euro IV and Euro V fuels- Role of fuels
Three major function in an IC engine• Energy source to drive engine
• Coolant for injector
• It is the lubricant for fuel pump & injectors
In addition, fuels should be compatible with gaskets and seals in the system
• Good compatibility --> expansion or marginal swelling.
• As a result, there will no leakage of fuels, gas & oil
Hussam Adeni [email protected]
2. Euro IV and Euro V fuels- Environmental demands
Under the Clean Air Act –– Sulphur in fuels to be reduced 15 ppm
• Most developing countries: Sulphur in fuels approx. 2000 ppm till the early 90’s
• Many have now implemented 50 ppm sulphur in all fuels.
• Developed countries have progressively moved to 10 ppm Sulphur in Fuels
Hussam Adeni [email protected]
2. Euro IV and Euro V fuels- Diesel
Hussam Adeni [email protected]
DieselEuro I1993
Euro II1996
Euro III 2000
Euro IV2005
Euro V2009
Poly aromatics -Vol%,Max
N/A N/A 11 11 11
Sulphur ppm, Max 2000 500 350 50 (10)*
19
Cetane number - Min 49 49 51 51 51
Density@15 ºC, kg/m² 35- 100 35-100 60-70 60-70 60-70
Distillation -79.5@ 15º C 370 370 360 360 360
Reduction of Sulphur results in reduction of aromatics, this robs the fuel of its lubricity. Damaging fuel injectors, whose replacement cost $ 100 each, there are 8 nos in an engine. Dosing with Fuel additives , a quick remedy
2. Euro IV and Euro V fuels- Gasoline - Petrol
Hussam Adeni [email protected]
GasolineEuro I 1993
Euro II1996
Euro III2000
Euro IV2005
Euro V2009
Aromatics - Vol%, Max No limit No limit 42 35 35
Olefins - Vol %, Max No limit No limit 18 18 18
Benzene - Vol%, Max 5 5 1 1 1
Oxygen - Vol%, Ma 2.5 2.5 2.7 2.7 3.7
Sulphur – ppm,Max 1000 500 150 50 (10)*
10
RON - Min 91 91 91 91 91
RVP - kPa 35 - 100 35 - 100 60 - 70 60 - 70 60 - 70
Lead - g/Lt, Max 0.013 0.013 None None None
2. Euro IV and Euro V fuelsHydro treatment- Sulphur removal
•Sulphur in fuels is removed at the refinery by stripping
•Process of stripping of sulphur is called
• Hydrotreatment
Hussam Adeni [email protected]
2. Euro IV and Euro V fuelsPitfalls of - Sulphur removal
•Unfortunately - sulphur reduction also removes
• Natural lubricity compounds
• Natural conductivity properties
• It changes combustion properties
• Biocide property of sulphur
Hussam Adeni [email protected]
2. Euro IV and Euro V fuelsImplication – loss of lubricity
• No protective barrier between
metal surfaces• Could lead to damage of vital engine
components
• Some vital components are• Fuel pump
• Fuel injectors
• Valves & ports
•Hussam Adeni [email protected]
2. Euro IV and Euro V fuelsImplication – ASTM and lubricity
• In 2005, ASTM had put in a
lubricity specification• ASTM D 975 for middle distillates
• ASTM D 6079 is widely used for other fuels
• Wear scar value is 520 microns or less
• OEM’s in Europe suggested 420 or less
• Fully synthetic esters widely accepted component in fuel additives
•Hussam Adeni [email protected]
2. Euro IV and Euro V fuelsImplication - Sulphur removal
•Natural conductivity properties• Conductivity is decreased
• Static charge may build up while fuel is being pumped
• Probably danger of ignition from static electricity
• Essential that fuels are dosed with special conductivity additives
Hussam Adeni [email protected]
2. Euro IV and Euro V fuelsImplication - Sulphur removal
• It changes combustion properties
• Hydro treatment may reduce Cetane in
diesel to the 40’s
• Modern Diesel engines are computer controlled and deliver optimal combustion in the range of 45 to 51.
• Cetane boosting additives now essential for peak performance
Hussam Adeni [email protected]
2. Euro IV and Euro V fuelsImplication - Sulphur removal
•Biocide property of sulphur
• Widely used today as antiseptic
• Used in many drugs and medicines
• Sulphur controls fungal growth in fuel tanks.
• Fuels now need to be treated with biocides to prevent fungal growth in fuel storage tanks
Hussam Adeni [email protected]
3. Engine configuration- Radical changes
Three major function in an IC engine• Energy source to drive engine
• Coolant for injector
• It is the lubricant for fuel pump & injectors
In addition, fuels should be compatible with gaskets and seals in the system
• Good compatibility --> expansion or marginal swelling.
• As a result there will be no leakage of fuels, gas & oil
Hussam Adeni [email protected]
3. Engine configuration- Radical changes
Evolution of fuel/injector/exhaust mechanism
• Naturally aspirated (NA)
• Turbo charged
• Exhaust Gas Recirculation (EGR)
• Direct injection (DI)
• Common Rail Direct Injection (CRDI)
Hussam Adeni [email protected]
3. Engine configurationRadical changes - psi
Dramatic increase in Operating pressures
– Early diesel engines – 600 psi
– Current CRDI – 30,000 psi
Hussam Adeni [email protected]
3. Engine configurationRadical changes – Cat. converter
Engine manufacturers proposed reduction of treat level of Zinc-Phosphate and Calcium sulphonates
– Engine manufacturers sought extension of life
for catalytic converters
– Research showed interference to life of catalytic converters from additives in lubes
– ZDDP – Anti wear
– Over based Calcium – Detergency
Hussam Adeni [email protected]
4. API CJ-4 requirementsHistory of Lube additives
Since 1975 triboapplications utilized solid boundary additive in the carrier oil acting as a barrier of molecules between moving parts with the following:
1. ZDDP (Zinc Di Thiophosphates)
2. Phosphorous
3. Sulphur
4. Calcium sulphonates
Hussam Adeni [email protected]
4. API CJ-4 requirementsUsed oil disposal issues
These additives had the disadvantage of being:
• Highly toxic – difficult to dispose
• Sacrificial – Deplete on use
• Inert – Do not react with metal alloys
• Become acidic – due to oxidation and water
• Also corrosive – furthering micro-pitting
Hussam Adeni [email protected]
4. API CJ-4 requirements
API CJ-4 demands
• Lube manufacturers use up to 1% ZDDP
• Zinc-Phosphate levels at 1% are for all practical purposes negligible
• Treats of 1% ZDDP packages likely to have little impact on reducing wear
Hussam Adeni [email protected]
4. API CJ-4 requirements
Alternative EP additives consisting of Graphite, Molybdenum have come into prominence
• Graphite & Molybdenum have little lubricating value as they are not reactive
• Under heavy pressure will press out
• Will lead to metal to metal contact
• Research is going on for alternative compounds for use as anti wear additives
Hussam Adeni [email protected]
5. Kyoto Protocol
• Proposed reduction of Green House Gases (GHG)
• Major constituent of GHG identified
• Major sources for GHG emitters identified
• Incentive for reduction of GHG
Hussam Adeni [email protected]
5. Kyoto Protocol
• Proposed reduction of Green House Gases (GHG)• Country wise and industry wise data
collated.
• Reduction targets – broadly agreed upon
• Major constituent of GHG identified• Carbon dioxide – CO2
• Nitrogen Oxides - NOx
• Major sources for GHG emitters identified
• Incentive for reduction of GHG
Hussam Adeni [email protected]
5. Kyoto Protocol
• Proposed reduction of Green House Gases (GHG)• Country wise and industry wise data
collated.
• Reduction targets – broadly agreed upon
• Major constituent of GHG identified• Carbon dioxide – CO2
• Nitrogen Oxides – NOx
Hussam Adeni [email protected]
5. Kyoto Protocol
• Major sources for GHG emitters identified
• Aviation Industry
• Power Plants
• Auto Industry
Hussam Adeni [email protected]
5. Kyoto Protocol
• Incentive for reduction of GHG• To users who register, document and reduce
GHG emissions
• ISO 14064 initiated to document reduction
• Tradable “Carbon Credits” to offset bulk GHG emitters
• Bulk users in Auto related industry likely to be major beneficiary
Hussam Adeni [email protected]