FUCHS ACADEMY

Automotive Lubricants

| 03.2020 | Isando, South Africa | Product Management Automotive

WARM WELCOME!

…to the 2020 FUCHS Academy!

Introduce yourselves!

• Your name

• Which
branch/department?

• Current role?

• Years of experience
with Auto lubes?

• Random fact about

yourself

l3
AGENDA

What will we do in the next days?

Rules for the meeting

l5
FUCHS Academy Automotive Lubrication 2020
 Strictly
Confidential!
This presentation is for FUCHS-internal training purposes only!

The information given is confidential!

FUCHS does not own the rights for artworks and pictures used, therefore these must not be
used for external distribution or publication in any form.

Version 03/2020

l7
Agenda

01 Basic of Lubricants
Tasks and Requirements

Base Oils
02 Types and Classification

Additives
03 Types and Classification

Suggestions – Discussion – Questions

04 Feedback
Automotive Lubricants
Module A: Basics of Lubricants

03.2020 | Isando, South Africa | Product Management Automotive

01 Automotive Lubricants
Tasks and Requirements
Workshop
Where are Lubricants needed?

▪ Please form Groups

▪ Please mark the lubricating points of an automotive vehicle and name

different “lubricant types” (product names also)
▪ 1) …
▪ 2) …

▪ Please prepare a chart with your results

▪ Presentation of your group results

l 11
Automotive Lubricants
FUCHS in der Praxis – PKW
Where are Lubricants needed?

l 12
Workshop
Tasks of Lubricants

▪ Please form Groups

▪ Please name the main functions of lubricants on cards

(one card each)
▪ 1) …
▪ 2) …

▪ Please prepare a display wall with your (sorted)

results

▪ Keep the clustered results for later!

l 13
Engine Oil
Tasks/ Requirements

1. Lubrication 4. Flushing
Reduce friction and minimize wear Remove abrasion out of the contact zone

2. Cooling 5. Cleaning
Conduct frictional heat Dissolve impurities and deposits

3. Protection
Corrosion protection

l 14
Transmission Oil
Tasks/ Requirements

1. Lubrication 4. Flushing
Reduce friction and minimize wear Remove abrasion out of the contact zone

2. Cooling 5. Cleaning
Conduct frictional heat Dissolve impurities and deposits

3. Protection 6. Power transmission

Corrosion protection Extreme pressure behaviour

l 15
Automotive Lubricants
Content
Detergent/
Dispersant
Additive Antioxidant
EP/AW
10 – 40%
Friction Modifier
PPD
VI-Improver
Anti Foam
Corrosion Protection

Mineral (SN)
Base Oil Semi Synthetic*
60 – 90% HC-Synthetic (HC)

Synthetic
(PAO/Ester)

l 16
* undefined mix of base oils
02 Base Oils
Types and Classification
Base Oils
Mineral Base Oils

▪ Based on feedstock Crude Oil as a „Natural Product“. This substance

is not of uniform quality but consists of several thousands of
hydrocarbon compounds.

▪ Differ in quality and composition caused

by their origin.

▪ Must be refined before usage as a lubricant.

Modern mineral base oils are the result of a
long and complex distillation and refining
processes.

▪ Additives must strengthen their good properties and must balance

their disadvantages.
l 18
Base Oils
Mineral Base Oils

▪ Typical Composition of Raw Oil = f (origin)

Raw Oil
Natural
gas

H2O
l 19
 Base Oils
Base Oil Components
H3C CH3
Paraffinic
CH3
CH3
Naphthenic

Aromatic

Carbon distribution (IR): CP CN CA

Naphthenic Oils 45% 44% 11%
Paraffinic Oils 62% 31% 7%
Hydrocrack Oils 75% 25% 0%

l 20 Mineral oil is a complex non defined mixture of these components

 Base Oils
Base Oil Components

paraffinic naphthenic aromatic

Viscosity Index high middle low

Cold Temperature Behaviour poor good good

Volatility low middle high

Oxidation Stability good good poor

Thermal Stability middle good high

Additive Response middle good high

Elastomer/Plastics Compatibility good good poor

Toxicity low middle high

l 21
Base Oils
From crude oil to base oils
Mineral
Gp. I/II

„Hydrocrack “
Gp. III

„Semi-Synthetic“*???

Synthetic
Gp. IV/(V)

l 22
*undefined mix of base oils
Base Oils
Average Refinery Output

l 23
Base Oils
Average Refinery Output

l 24
Base Oils
Refining Processes

Most common Refining Processes are:

▪ Solvent Extraction

▪ Solvent Dewaxing

▪ Hydrogenation
▪ Hydro Finishing
▪ Hydro Cracking

l 25
Base Oils
Solvent Extraction

▪ Solvent Extraction means a physical separating process.

▪ By using an appropriate solvent unwanted components (like

Aromatics) can be removed (extracted).

EXTRACTION
Base Oil + Arom. Solvent Neutrals (SN)

Solvent Solvent. + Arom.

▪ Examples: SN 100, SN 150, SN 600

l 26
Base Oils
Solvent Dewaxing

▪ Long chain paraffinic hydrocarbons (Wax) crystallize at low

temperatures

➔ poor cold temperature base oil Viscosities

▪ This crystallisation effect can be used for refining:

▪ Pre-solution of the base oil in solvent, which improves the crystal formation
▪ Cool down to approx. -30 °C
▪ Filtration of the long chain paraffinics.

l 27
Base Oils
Hydrogenation

▪ Hydrogenation: chemical Reaction with H2

▪ Hydro finishing
▪ Sulphur Removal
▪ Saturation of remaining double bonds

▪ Hydro cracking (➔ HC Base Oils)

▪ Cracking big molecules (aromatics) into smaller ones (paraffins)

➔ Improvement of Colour, Smell, UV-stability tec.

l 28
Base Oils
Synthetic Base Oils

▪ Synthetic Base Oils are the result of a dedicated chemical reaction.

▪ Synthesis process:
Combining defined molecules to form a NEW molecule

▪ base materials for this reaction are also coming from Crude Oil and/or
Gases

▪ Most important groups:

▪ Poly-a-Olefins (PAO) => Oil
▪ synthetic Esters => Ester
▪ Poly-Glycols (PG) => Alcohol
▪ GTL (Gas To Liquid), CTL (Coal to liquid)

l 29
Base Oils
Comparison of the Structures

Purity
Group IV R R

Group III+

Group III R R
R

(Group II)

Group I R R
R
R
R
R
R

0% 10 % 20 % 30 % 40 % 50 % 60 % 70 % 80 % 90 % 100 %
Hydrocarbon types, weight-%

Paraffinic Mono-Naphthenic Multi-ring Naphthene Aromatic

l 30
 Outcome app. 1-2%
Base Oils
Supply chain
From crude… to base oil

Distillation
Mineral
Gp. I/II
Hydration

Solvent Extraction

„Hydro-Crack “
Solvent Dewaxing Gp. III

Hydro Cracking

Synthetic
Synthesis
Gp. IV/(V)
l 31
Base Oils
Types – Processes

Process Product

Destillation / Mineral Base Oil

Hydration Group I + II Group
I + II

Solvent Extraction/
Solvent Dewaxing/ Hydrocrack Base Oil
Group
Hydro Cracking Group III III
Crude Oil

Hydro Cracking/ Synthetic Base Oil

Group
Synthesis Group IV + V IV/ V

Outcome ca. 1 – 2%

l 32
 Base Oils
Classification API/ATIEL

API -Group Classification Saturate Level Sulphur Content Viscosity Index Costs

Mineral Base Oils

Mineral oil 80 < VI < 120

Group I (Solvent Raffinate)
< 90% > 0,03 %
typically < 100
low

Mineral oil
> 90% 80 < VI < 120
Group II (Hydrated Solvent < 0,03 %
typically < 100
low
Raffinate)

Mineral Oil > 90% VI > 120

Group III (Hydrocrack)
< 0,03 %
typically 120 – 135
medium

Synthetic Base Oils

Synthetic VI > 120
Group IV (PAO)
--- 0
typically 120 – 150
high

Synthetic ---
Group V (mainly Ester)
--- 0
typically 120 – 160
very high

Remark: Often a combination of different Base Oil Types is used within one formulation!

l 33
 Base Oil influence on Lubricant performance

Engine cleanliness Oil consumption

Seal compatibility Oil thickening
Process application Deposit formation
Formulation stability
Volatility

Foaming
Air release
Surface
Solvency Emulsification
Activity
Base
Stock

Deposit formation
Wear protection
Oil thickening Oxidation Viscosity
Stability VI Cooling efficiency
Acid formation
Low-temp
Metal corrosion
behave.
l 34 Energy losses
Base Oils
Pros and Cons – Mineral Base Oils

Advantages: Disadvantages:

▪ Established ▪ Only moderate thermal and

▪ Big range of approved elastomers oxidative stability
and paints ▪ Moderate low temperature
▪ Good cost/performance ratio under properties
„normal“ conditions ▪ Gp. I slowly fading
▪ Good additive solubility
▪ Existing oil disposal system
▪ VI ca. 95-100
▪ Availability generally good

l 35
Base Oils
Pros and Cons – PAO

Advantages: Disadvantages:

▪ Increased oxidation and ageing ▪ Inferior solubility of additives and

resistance ageing products
▪ Excellent low temperature ▪ Risk of deposit formation due to
properties poor solubility of ageing products
▪ Good VT properties ▪ PRICE!!!
VI about 150 ▪ Availability!
▪ Disposal can be done like used MO

l 36
Base Oils
Pros and Cons – Synthetic Ester
Advantages:
▪ Very good lubrication
▪ Very low coefficient of friction
▪ High efficiency
▪ Good oxidations/ ageing resistance
▪ Partly excellent low temperature
properties
▪ Good VT properties (VI ~ 120-180)
▪ High solubility (prevention of
deposits)
▪ Miscible with many other lubricant
base oils such as MO, PAO, PAG
l 37
Disadvantages:
▪ Partial tendency to hydrolyse,
depending of ester type
▪ Partial incompatible with NBR-
elastomers (volume swell)
▪ Partly incompatible with
conventional (designed for MO)
paints
▪ Due to the variety → significant
differences in the properties are
possible
▪ Separate disposal necessary
▪ PRICE!!!
Base Oil Quality

Mineral … Semisynthetic … Synthetic … Fully Synthetic…

To make it clear:

▪ Synthetic and fully-synthetic is the same

▪ Synthetic / fully-synthetic → if product is only based on Group IV and/or V
▪ Group III oils are mineral

…if the base oil of a product contents only a part of Group IV / V

→ it is not allowed to call the product „what-ever“-synthetic! (e.g. semi-synthetic)

l 38
Base Oils
Summary

▪ There are two main types of base oils:

▪ Mineral Base Oils which directly base on Crude Oil as a „Natural Product“
▪ Synthetic Base Oils which result from a dedicated chemical reaction
(but also often dependant on fossil resources).

▪ When developing a modern Lubricant the choice of Base Oil is one of

the most important steps right from the start. Base oils can not longer
be seen as simple additive carriers as it might have been in early
times.

▪ It is usual to combine different types of Base Oils within one

formulation to find the best compromise between cost and
performance.

l 39
03 Additives
Types and Classification
Additives
Why are they necessary?

▪ Even by using more and more high quality Base Oils, Additives are
needed to fulfil the requirements of modern lubricants!

▪ What Additives do:

▪ Improvement of desired lubricant properties

▪ Suppression of unwanted lubricant properties

▪ Adding new properties to lubricant

l 42
Additives
Basics
▪ Typical Additive treat rates range from a few parts per million (ppm) up to 30 %
and more.
▪ Not all base oil properties can be influenced by Additives, e.g. thermal stability,
volatility, compressibility, …
▪ Some additives do interact with each other.
▪ synergistic effect,
▪ insoluble deposit formation
▪ Antagonistic effect/reduction of performance.

Careful selection of Additives is therefore required!

▪ Additives can in principal be divided into three groups:

▪ Type A: Surface Protection Additives
▪ Type B: Lubricant Enhancement Additives
▪ Type C: Lubricant Protection Additives

l 43
Type A
Surface Protection Additives

▪ Type A: Surface Protection Additives

Name Code Desired Effect

Detergent/ Keep surfaces free of deposits/

DD
Dispersant Keep insoluble particles dispersed

Extreme Pressure Additive

EP/AW Reduce friction and wear and prevent scoring
Antiwear Additive

Adjust friction level (increase/decrease) between friction

Friction Modifier FM
partners

Corrosion/Rust Inhibitor CI Prevent corrosion of metal parts

l 44
Type B/C
Lubricant Enhancement/Protection Additives

▪ Type B: Lubricant Enhancement Additives

Name Code Desired Effect

VI-Improver VII Reduce the rate of viscosity change with temperature

Pourpoint Depressant PPD Enable Lubricant to flow at low temperatures

Seal Swell Agent -- Swell elastomeric seals

Dye -- Lubricant identification

▪ Type C: Lubricant Protection Additives

Name Code Desired Effect

Antioxidant AO Increase of Oxidation stability

Antifoam Agent AF Avoid Surface Foaming

l 45
Additives
Detergent/ Dispersant

▪ DD are molecules containing an hydrophilic „head“ which is polar and

an oleophilic Tail which is non-polar. The Head adsorbs on solid
particles, the Tails reject each other.
▪ Particles are prevented from agglomeration and kept in dispersion.
▪ Also important for anti-oxidancy and neutralisation behaviour
polar

non-polar

l 46
Additives
Extreme Pressure/ Anti Wear

▪ EP/AW reduce wear as soon as the friction partners get in contact.

hydrodynamic boundary

▪ EP/AW usually are carrying Phosphor (P) and Sulphur (S) forming
protection films on the metal surface under the influence of pressure
and high temperatures.
R R R R
R R
+

S S S+S S S

polar metal surface

l 47 Physisorption Chemisorption Separation and
reaction of S
Additives
Friction Modifier

▪ FM start to work at even lower temperatures. They are sometimes

called “mild AW Additives”.

▪ They also form surface layers but in the opposite to EP/AW Additives
the mechanism behind is Physisorption which makes them removable
by shear e.g.

non-polar
Buffer
polar Shear

l 48
Additives
Corrosion Inhibitor

▪ CI are also highly surface active and can be parted into two groups:
▪ Anti Rust Inhibitors for Iron-like Metals
▪ Passivators for yellow metals (like Copper)

CH3 CH3 CH3 CH3 CH3

-
SO 3
-
SO 3
-
SO 3 SO 3
- -
SO 3

polar metal surface

Physisorption
l 49
Additives
VI Improver

▪ VII are long chain polymers which are getting more and more soluble
with higher temperatures. The better they are solved the wider they
get, which means an apparent increase of the lubricant’s viscosity.

Low Temperature High

Low Solubility High
Low Viscosity High
l 50
Additives
Pourpoint Depresent (PPD)

▪ Pourpoint: Minimum Temperature where the lubricant can still be

poured
▪ PP is an indicator relevant for handling and storage
▪ PP is NOT an indicator for cold temperature properties
▪ Light oils form large soft crystals – Heavy oils form harder
microcrystalline waxes
▪ PPDs are tailor-made long chain polymers
▪ prevent large interlocking needle like masses from agglomeration and
▪ promote formation of smaller (more rounded free-moving) crystals

l 51
Additives
Antioxidant

▪ Oxidation (aging of the lubricant by the influence of oxygen) leads to

▪ discoloration
▪ viscosity increase
▪ sludge formation
▪ acidification which again is a booster for corrosion.

▪ Antioxidants may not prevent the oxidation of the lubricant completely,

but significantly slow it down.

l 52
Additives
Anti Foam Agent (Defoamer)

▪ Typical AF are modified, tailor made Silicon Oils or other chemistries.

They are highly efficient and treat at
some few ppm.
▪ AF are surface active substances. Their droplets
adhere on the surface oft the air bubbles which
makes them collapse and brings the foam
down (reduces surface tension).

Foam

Defoamer
l 53
 Challenges of formulating a lubricant

Let’s get ready to rumble! Additives inter-/counteract!

Anti Foam Air Release

Friction Modifier
Metal Deactivator
EP/ AW
Corrosion Inh. Anti Oxidant

Metal Surface
Additives
Summary

▪ To meet the requirements of modern high tech lubricants the usage of

a plenitude of special Additives is needed.

▪ Additives have to improve desired properties and prevent from

unwanted effects of the lubricant.

▪ Most of the additives are surface active and therefore compete on the
friction partner surface. Some additives can interact with each other
(sometimes synergistic/negative effect).

▪ Careful selection of Additives is therefore required which means to find

the best compromise.

l 55
Summary

Additives
Base Oil

Key is balancing the additives in combination with the base oil

l 56
composition!
Value Chain
From Crude Oil to a High-End Lubricant

What is a modern High-End Lubricant and which value chain is created?

R&D and
Crude Oil Base Oil Additive
Technical Approval

Production/ Filling/ QM-System Service

l 57 Logistics
04 Suggestions – Discussion – Questions
Feedback
Thank you very much for your
Attention!