Fluid Technology for Industrial (Closed) Gear and Open Gear Lubricants

Shubhamita Basu, PhD & Carlos Nazario, OMA I

October 15, 2020

9:00am EST (New York) / 2:00pm BST (London) / 6:30pm IST (Mumbai)
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This webinar is being presented by the Lubrizol Corporation for the purpose of providing information
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performance and / or end user requirements for those products are changing and how its products
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About our Speakers
Shubhamita Basu, PhD
North America Product Manager, Industrial Oils

Shubha has been with The Lubrizol Corporation for 13 years in a variety of technical and
commercial roles. In her current role, she manages the hydraulic fluid, industrial gear oil
and turbine oil portfolio. Shubha has worked extensively in developing new molecules
engine oils and limited slip gear oil applications, and has formulated hydraulic fluids and
industrial gear oils and led energy efficiency initiative and environmentally acceptable
lubricant development.

Shubha has a PhD in Chemistry from Case Western Reserve University and a MBA
from Cleveland State University. She has served as the Vice Chair and Chair of the
Center for Compact and Efficient Fluid Power’s (CCEFP) industry executive council, was
a past Chair of Northeast Ohio section of American Chemical Society, has been a part of
the NFPA roadmap committee and is a member of STLE. She has published several
scholarly papers including journal articles and patents and has presented in national and
5 © The Lubrizol Corporation
international conferences.
About our Speakers
Carlos Nazario, OMA I
North America Product Manager, Grease Additives

Carlos has been with The Lubrizol Corporation for over a year. Prior to joining Lubrizol,
he spent approximately 15 years in different technical and commercial roles at a
company that specialized in lubricants for heavy duty, food processing, environmental
and recreational equipment. He has worked extensively in developing and applying new
lubricants for heavy duty equipment in mining applications, both surface and
underground, and has formulated and specialized extreme pressure greases, extreme
pressure gear oils, open gear lubricants, energy efficiency and environmentally-
acceptable lubricants for heavy duty equipment.

Carlos has a Bachelor’s degree in chemical engineering from Universidad de las

Americas, Puebla-Mexico and also has STLE certifications in oil monitoring analysis. He
has presented at various forums and technical conferences for the mining industry in
Latin America as presenter.
6 © The Lubrizol Corporation
 Fluid Technology for
Industrial (Closed)
Gear and Open Gear
Lubricants
Shubhamita Basu, PhD
& Carlos Nazario, OMA I

October 15, 2020

© 2020 The Lubrizol Corporation
Industrial Gear Oil Applications

Mining and quarries Steel mills Indoor mixing Sugar mills

gearboxes

Wind turbines Extruders & gearboxes Outdoor mixing Steel rolling mill gearboxes
gearboxes

IGO fluids see harsh conditions: high loads and speeds, high temperatures,
and high contamination environments
8 © The Lubrizol Corporation
 Emerging Industrial Gear Trends

IGO formulated to meet Increased

the modern demands Productivity

Improved Bearing
White Etching Cracks
Protection

Micropitting Smaller Gearboxes =

protection Higher Power density

15 © The Lubrizol Corporation

 Industrial Gearbox and Gear Oil Growth

Global Industrial Gearbox Market Global Industrial Gear Oil Market

($ bn) (KTONNES)
$55 $53.1 960
946
$50.9 941
$48.8 940 931
$50 922
$46.9 915
$45.0 920
$45
900

$40 880
2020 2021 2022 2023 2024 2020 2021 2022 2023 2024

CAGR 4.22% CAGR 0.84%

Industrial gear oil market is growing at a slower rate than industrial gearboxes

16 © The Lubrizol Corporation Source: Technavio, Kline

Evolution of Industrial Gear Box Sizes

• Gearboxes are getting

smaller than before to
increase efficiency
• Sump sizes are getting
smaller
• Gear oil tends to get hotter
than before in the smaller
sumps

17 © The Lubrizol Corporation

Oil Life vs. Higher Operating Temperature
• Higher operating temperature can adversely impact oil life
‒ Additive packages get used up faster
• Depleted additive package can cause durability issues like scuffing, micropitting
‒ Viscosity of the fluid changes with temperature leading to poor film
thickness
• Poor film thickness impacts tribological properties leading to untimely
failure of parts
• Reducing operating temperature by even a few degrees can help
maintain the oil life longer and ensure the durability of gearboxes

18 © 2020 The Lubrizol Corporation

The Lubrizol Corporation
 Cost of Gearbox Downtime | Case Study

Case Study: Cost of Gearbox Failure in a Steel Mill

Source: Major Global Steel Manufacturer

Minimum production downtime 2.5-3 hours

Minimum production downtime cost $200,000 per hour

TOTAL $600,000

This does not include parts or labor costs.

Labor costs can be excessive if contractors are required to make the repairs.
Downtime costs do not increase linearly with mill size; they increase exponentially.

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 How to Solve the Issue of High Operating
Temperature?

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 Common Ways to Solve This Issue
PAO
Thickener

~98% PAO

Base Oil +
Thickener Mineral Oil COST COST

x3 x6
Relative cost versus API Group II

Switching to a full-synthetic formula thickened with PAO100 or mPAO150 is costly!

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 Synthetic IGO Market is Growing
Global IGO, KTONNES Mineral vs Synthetic Split
1000
Synthetic
800 23%

600 Synthetic
26% Mineral
400 77%

200
Mineral
0 74%
2020 2021 2022 2023 2024
Mineral Synthetic
Mineral Synthetic

Synthetic IGO lubricants set to grow at +5.2% CAGR

22 © 2020 The Lubrizol Corporation

The Lubrizol Corporation Source: Technavio, Kline
 Alternative Way to Formulate Synthetic IGO
Experimental design
• Test plan
• Total four fluids
‒ Traction coefficient
‒ Reference fluids
measurement
• Mineral oil reference fluid
‒ Shear stability
• Commercial Synthetic reference fluid
‒ Temperature reduction and
‒ Test fluids in PAO-6 base oil energy efficiency testing
• Fluid formulated with unique performance
polymer (PP)
• Fluid formulated with PAO-100

All fluids were formulated to ISO VG 320

23 © 2020 The Lubrizol Corporation

The Lubrizol Corporation
 Formulation
Fluid A Synthetic Reference 1 Reference 2
Fluid
Base Oil 73.2 wt% 32.2 wt% Mineral Synthetic
PAO-6 PAO-6
Thickener/ 25 wt% 66 wt% Bright Stock Commercial
Viscosity Modifier Performance PAO-100
Polymer
Additive Package 1.8 wt% 1.8 wt% Commercial Commercial
Lubrizol Lubrizol Additive Additive
Performance Performance package package
Additive Additive

24 © The Lubrizol Corporation

 Traction Coefficient Data

Fluid A
Fluid A

Fluid A with unique performance polymer helps lower traction coefficient of the fluids

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 Test Rig Configuration

Test rig developed to differentiate fluids

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 Measuring Temperature Reduction
Oil Temperature [°C] vs Speed [RPM]
High Torque • Fluid A with PP based runs
60
Fluid A with PP
significantly cooler than a mineral
58
PAO-100
Mineral Oil Based
oil based formula
56
Commercial Synthetic
54
Oil Temperature [°C]

52
• Formula with PP runs somewhat
50

48
cooler than other synthetics
46

44

42

40
Speed [RPM]

Significant heat dissipation noticed for Fluid A with PP

27 © The Lubrizol Corporation

 Measuring Energy Efficiency Improvement
Efficiency [%] vs Viscosity [cSt]
High Torque, High Speed
A clear advantage in efficiency
76 was seen with PP when comparing
Fluid A with PP
74 PAO-100 formulations thickened with other
Mineral Oil Based
72 Commercial Synthetic thickener/viscosity modifier types
70 – Up to 2% improvement over
Efficiency [%]

68
other synthetics
66 – Up to 8.5% improvement over
64
mineral oil based reference
62

60
50 100 150 200 250 300 350
Viscosity [cSt]

Efficiency improvement over reference fluid and PAO 100 with PP based fluid

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 Treat Cost vs. Performance

Thickening
power

Treat
rate

Lower treat rate leads to lower total formulating cost

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 Performance Overview

Thickener/ Operating
Treat Traction Shear Energy
Viscosity
Rate Coefficient Stability Temperature Efficiency
Modifier
PP +++++ ++++ +++ ++++ ++++
PAO-100 + +++ ++++ +++ +++

+++++ = Best + = Worst

PP performed better than PAO-100 and offered significant savings in net treat cost

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 Can this PP be Used in Formulating a More
Cost-effective Synthetic Gear Oil?

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 Synthetic Formulation with Group III Base Oil

With
Synthetic
Performance
with PAO
Polymer PP

Viscosity
ISO VG 320 ISO VG 320
Grade
Commercial Synthetic
74.5 wt% 6 cSt
Base Oil 32.2 wt% PAO
GIII
1.8 wt% 1.8 wt%
Additive performance performance
additive additive
66 wt% PAO
Thickener 23.7 wt% PP
150 Gr III Synthetic + PP

Fluid A with PP ran significantly cooler

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 Temperature Reduction in FZG Test

PP Based Synthetic Gr I + Bright Stock

Fluid A with PP produces 17 °C cooling compared to standard gear oil

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 What is this PP?
This PP is a versatile polymer with superior thickening efficiency and
shear stability
• Excellent performance in low traction/high
efficiency, thermal and oxidative stability, NSF
H1 approved
• Versatile applications include industrial
gear oil, automotive gear oil, open gear lube and
hydraulic fluid

Serves as a viscosity modifier and base oil

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 Application of a Unique Performance
Polymer in Open Gear Lubricants

38 © The Lubrizol Corporation

The Lubrizol Corporation
 How Big Can They Be?

Example Diameters:
13.2 m/43.5 ft;
16 m/52.5 ft;
30 m/98.5 ft

Technician doing
inspection

~ $950,000 USD cost; up to 12 months for manufacturing

39 © The Lubrizol Corporation
The Lubrizol Corporation
 Open Gear Systems and Their Lubricants –
Stationary Equipment
Type II

• General Operating Conditions

‒ High loads
‒ Single direction operation
‒ Low to moderate peripheral velocity (7-9 m/s)
‒ Operating temperature range ~ 50-80 °C
‒ Potential for misalignment

• General Lubrication Requirements

Boundary Lubrication
‒ Chemistry for boundary and mixed lubrication
(initial operation)
‒ High viscosity for full film lubrication
Full film lubrication
Mixed Lubrication
Hydrodynamic (hydrodynamic)

40 © The Lubrizol Corporation

The Lubrizol Corporation
 Open Gear Lubricants Evolution Over Time
• Asphaltic + Solid Lubricants + Solvent
Key Issues: • Mobile Machine (Type 1)
• Heat & Spray • Semi-fluid grease, “low” viscosity oil
• Removal, and solid lubricant
• Chlorinated solvents • Low Temp Pump
• Hanging loads (Shock)
• Lowest consumption
1955 1985

2010s
1975 2000 2020s

OGL dictated by end use and type / lubrication • Stationary (Type 2)

need – very specific to be effective • High Viscosity Fluid
• Compounds • Full film or Hydrodynamic lubrication
• Grease • Wear and Load carrying
• Easy tooth inspection and disposal

41 © The Lubrizol Corporation

The Lubrizol Corporation
 Open Gear Lubricants Type II Specifications and
Market

• ANSI/AGMA 9005-E02- Industry Specification

• METSO/OUTOTEC
• FL Smidth
• Fuller
• Allis-Chalmer
• Davenport
• Polysius
• Louisville Dryer

Global open gear lubricant market: 12,000 MT

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The Lubrizol Corporation
 How to Improve High Viscosity Open Gear
Lubricants Type II Performance with New
Performance Polymer

43 © The Lubrizol Corporation

The Lubrizol Corporation
 Alternative Way to Formulate Synthetic OGL Type II
Experimental design
• Test plan
• Total 4 fluids
‒ Basic performance tests
‒ Reference fluids
‒ Kinematic viscosity at
• Grease type OGL
different temperatures
• HV PIB-Mineral type OGL
‒ Calculate theorical film
• 2-Test fluids thickness at typical gear
• Fluid formulated with PAO-8 sets operational
• Fluid formulated with unique performance temperature
polymer (PP) ‒ Temperature reduction and
energy efficiency

44 © The Lubrizol Corporation

The Lubrizol Corporation
 Technology Highlight
Physical properties
Performance Polymer
Test Lubricants Design
Appearance Bright & Clear
OGL type II
Viscosity @ 40 °C, cSt 40,000 End Use Stationary Mills
OGL A: 14,000 cSt
Viscosity @ 100 °C, cSt 2,000 Viscosity Grade(s) @ 40 °C
OGL B: 20,000 cSt
Tackiness, EP, AW,
Viscosity Index 297 Performance Attributes-
WH, RI & CI and low
Additive system
Flash Point, COC, °C 295 temperature fluidity
Shear Stability Index 15

45 © The Lubrizol Corporation

The Lubrizol Corporation
 Technology Highlight
Results
Test OGL A OGL B
ASTM D2270 VI 264 280
ASTM D2596
Weld Point (kg) 620 800+
LNSL (kg) 160 200
LWI (kg) 120 190
ASTM D2266 ≤ 0.40 ≤ 0.35
ASTM D4048 (24 h, 100 C) 1B 1B

Considerable improvement observed in performance and formulation costs

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The Lubrizol Corporation
 OGL Candidates Formulations: 60oC Film Thickness
Kinematic viscosity @ Initial Lubrication vs. Asperity Height
operational temperatures 8 OGL B- 21,000
40,000 @ 7.63 µ
7
Kinematic Viscosity, cSt

35,000

ASPERITY HEIGHT, MICRONS

6 OGL A-14,000
30,000
@ 5.88 µ
25,000 5
20,000 OGL B:-21,000 cSt 4
15,000
10,000 OGL A-14,000 cSt 3 Grease type
OGLs:
5,000 2 2.35 µ-2.80 µ
0 PIB-Mineral
40 50 60 70 80 90 100 1 Fluid type
Temperature, °C OGLs: ~ 1.80 µ
0

Superior lubricant film thickness at initial and operational temperatures

47 © The Lubrizol Corporation
The Lubrizol Corporation
 Low Temperature Characteristics – Lincoln Ventmeter
Test
Pumpability, Lincoln ventability test, max PSI @
Lowest anticipated ambient temperature.
30 seconds
1800
1600
1400
Pressure, psi

1200 PIB-Mineral type OGL,

1000 20,000 cSt
800 OGL B-21,000 cSt
600
400
OGL A-14,000 cSt
200
0
22 10 0 -1 -6 -12 -15
Temperature, °C

Significant improvement in low temperature pumpability properties for better cold flow
48 © The Lubrizol Corporation
The Lubrizol Corporation
 Temperature and Energy Performance Measurement

Comparing Mineral and OGL formulations A and B

Presented improvement in operational temperature (Cooler) and in energy
consumption

Significant improvement in operational temperatures and energy consumption

49 © The Lubrizol Corporation
The Lubrizol Corporation
 Key Takeaway Points – New Polymer Technology
• Fully synthetic formulations
• High viscosity index
• High kinematic viscosity at high operational temperatures
• Excellent film thickness at initial and operational temperatures
• Significantly reduces operational temperature and increases energy
efficiency
• Good low temperature pumpability- no heater system needed

50 © The Lubrizol Corporation

The Lubrizol Corporation
 In Summary
• New fluid technology can improve traction coefficient, film thickness,
energy efficiency and temperature reduction
– In-house tests developed can demonstrate differentiation

• This unique performance polymer is versatile and can be used in

hydraulic fluid and automotive gear oils as well

Performance enhancement without increase in cost

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 Q&A

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