Hydraulic Fluid

Market Trends

© 2011 The Lubrizol Corporation

 Hydraulic Fluid Market Data
Global Lubricant Market
36,277 K Metric Tons - Total Global Market
25%

Consumer
Commercial
Industrial
30%

45%

Consumer: Mono and multigrade PCMO, ATFs, Gear Oils, Greases

Commercial: Mono and multigrade HDMO, Tractor Hydraulic Fluid, Gear Oils, Grease
Industrial: Hydraulic, Gear, Turbine, Circulating, Ind. Eng. Oil, Compressor, Grease, MWF, Process Oils

Source: 2011 Kline Lubesnet Database

03-09-11 © 2011 The Lubrizol Corporation HY104-37

 Hydraulic Fluid Market Data
World Industrial Lubricant Consumption
Estimated 2.25 Billion Gallons

Industrial Gear
6.9%
Greases
5.4%
Miscellaneous
Fluid Power
5.0%
65.9%

(Hydraulics,
Metalworking Turbine/R&O,
16.8% Compressor)

01-01-10 © 2011 The Lubrizol Corporation HY104-35

 Hydraulic Fluid Market Data
Global Industrial Lubricant Market

16,310 K Metric Tons - Total Global Industrial Market

40%
5%
5% Asia Pacific
North America
Europe
South America
Africa/Middle East

22%
28%

Source: 2011 Kline Lubesnet Database

03-09-11 © 2011 The Lubrizol Corporation HY104-38

 Hydraulic Fluid Market Data
World Lubricant Consumption

Industrial
35%

Automotive
65%

01-01-10 © 2011 The Lubrizol Corporation HY104-34

 Hydraulic Fluid Applications
End-Uses/Markets Served
Stationary
• Conveyors
• Food production
• Forming Mobile
• Injection molding • Elevators
• Manufacturing • Farm machinery
• Metal fabrication • Heavy construction
• Packaging • Hoist/Crane
• Paper • Logging
• Power generation • Mining
– Hydroelectric • Water transportation
– Gas/steam/combined cycle
turbines
– Wind energy
• Printing
• Textiles

01-01-10 © 2011 The Lubrizol Corporation HY112-20

 Hydraulic Principles
Fluid Functions
• Pressure and power transmission
• Controlled flow
• Minimize wear
• Reduce friction
• Provide cooling—act as heat transfer medium
• Prevent rust and corrosion
• Keep system components free of deposits
• Provide a viscous seal

03-01-06 © 2011 The Lubrizol Corporation HY101-3

 Hydraulic Fluid Market Trends
Fluid Power Trends
It’s a tough world for hydraulic oils
• Hydraulic systems are getting smaller
• Reservoir shapes are often not optimum
• Flow rates are high relative to oil volumes
• Oil residence times can be very short
• Hydraulic systems are designed with higher power densities
• Oil temperatures are higher (> 130°C transients are seen)
• Oil pressures have generally increased
• OEMs agree these trends are leading to more frequent problems
in high performance hydraulic systems

01-01-10 © 2011 The Lubrizol Corporation HY104-4

 Hydraulic Fluid Market Trends
What Do All These Equipment and Operating
Trends Mean to Hydraulic Additives?
• Additives are consumed at a greater rate in providing
protection in these harsher systems
• With less oil in the system and expectations for
longer lifetimes a greater performance reserve is
essential
• Additive quality and careful formulating are more
critical than ever before

01-01-10 © 2011 The Lubrizol Corporation HY104-17

 Hydraulic Fluid Market Trends
Extended Service – Mobile Applications

More opportunity for

performance differentiation
in the mobile end-use
Construction Oil Drain Interval, hrs
Equipment Manufacturer Previous Interval Today’s Interval
Komatsu 2,000 5,000
Hitachi 2,500 4,000
Caterpillar 2,000 4,000
Sumitomo 2,000 5,000
Volvo 2,000 4,000
JCB 1,000 3,000

Requires all-year, multigrade fluid

01-01-10 © 2011 The Lubrizol Corporation HY104-25

 Hydraulic Fluid Formulation
What’s in a Typical Hydraulic Fluid and Why

+ = Hydraulic
Fluid

01-01-10 © 2011 The Lubrizol Corporation HY108-10

 Hydraulic Fluid Testing Concepts
Oxidation Test Life with Group I and II Base Oils

Typical Test Life

Solvent-refined Hydrocracked

Turbine Oil

TOST life, hours 4,000 18,000

RPVOT life, minutes 500 1,800

Hydraulic Oil

TOST live, hours 2,000 6,000

01-01-10 © 2011 The Lubrizol Corporation HY109-10

 Hydraulic Fluid Principles
Base Oil Production and Relative Cost
Percent of Total
Production Relative Cost
Mineral Oils
Traditional solvent extracted, 46 1
Group I
Hydrocracked, Group II 47 1.05
Hydrocracked, Group III 3 1.5
Synthetic Oils
PAO polyalphaolefins, Group IV 2 2.5 to 3
Others, Group V 1.6 5 to 10+

01-01-10 © 2011 The Lubrizol Corporation HY102-18

 Hydraulic Fluid Formulation
Components of Hydraulic Fluid Additive Package

Antioxidant Foam inhibitor

Antiwear agent Pour point
Demulsifier depressant
Detergent Metal deactivator
Dispersant Rust inhibitor
Viscosity modifier

01-01-10 © 2011 The Lubrizol Corporation HY108-12

 Hydraulic Fluid Formulation
Typical Package Constituents

Antiwear

Demulisfier
Antifoam

EP

Rust Inhibitor
Antioxidant
Metal Passivator

01-01-10 © 2011 The Lubrizol Corporation HY108-8

 Hydraulic Fluid Specifications

• OEMs • End-Users
– Denison* – U.S. Steel: 127 and 136
• HF-0 – GM LS-2: LH-03, 04, 06
• HF-1 – Cincinnati Machine: Thermal
• HF-2 Stability*
– Vickers
• Other
• M-2950-S: Mobile
• I-286-S: Industrial
– DIN 51524 German/European
Standard
– Sauer-Danfoss
• Part 1: R&O fluids
– Rexroth • Part 2: Antiwear hydraulic
• Part 3: Multigrade fluids

*Approval letters provided

01-01-10 © 2011 The Lubrizol Corporation HY105-2

 Hydraulic Fluid Specifications
General Specification Tests
• Pump
• Oxidation
• Demulsibility
• Rust
• Hydrolytic stability
• Thermal stability
• Filterability
• Foam
• Wear
• Copper Strip
• Air Release
• VI

01-01-10 © 2011 The Lubrizol Corporation HY105-7

 Hydraulic Fluid Market Trends
General Requirements
• Proper viscosity
• Wear protection
• Oxidation and thermal stability
• Corrosion protection
• Good foam resistant characteristics
• Resistant to air entrainment
• Non-compressible
• Good demulsibility

01-01-10 © 2011 The Lubrizol Corporation HY104-31

 Hydraulic Pump Failure Analysis
Could this have been prevented??

01-01-10 © 2011 The Lubrizol Corporation HY103-27

 Hydraulic Pump Failure Analysis
Major Causes of Premature Failure

Dirt 45%

Misassembly 13%
Other 4%

Corrosion 4%

Misalignment 13% Overload 10%

Insufficient Lube 11%

01-01-10 © 2011 The Lubrizol Corporation HY103-28

 Hydraulics Fluids
Benefits of Properly Formulated Hydraulic Fluid*
• Longer fluid life
• Less equipment downtime
• Lower disposal and labor costs
• Cost savings in the long term
• Peace of mind

*Formulated with a premium hydraulic package at the prescribed treat rate

01-01-10 © 2011 The Lubrizol Corporation HY116-6

Industrial Gear Oil

© 2011 The Lubrizol Corporation

 Applications
Major End Use Industries % of Total
Primary steel 21
Mining 21
Manufacturing 20
Metal fabrication
Chemical industry
Machinery
Electrical equipment
Energy production 10
Construction 9
Agriculture 9
Off-highway 7
Other 3
100
01-01-10 © 2011 The Lubrizol Corporation GI106-3
 Applications

• Enclosed and open gear drives

• Reducers
• Industrial machinery
• Mobile equipment
• Gears - spur, straight, spiral, bevel, helical, worm and others
• Multiple reduction gear drives
• Mill pinions and bearings
• Roll-table gears and bearings
• Screw-down screw and nut
• Rock drills
• Trucks and automobile axles

01-01-10 © 2011 The Lubrizol Corporation GI106-2

 Fundamentals of Industrial Gear Oils
Requirements
• Load bearing properties
• Friction reducing properties
• Oxidative and thermal stability
• Rust and corrosion protection
• Ability to separate water
• Resistance to foaming
• Freedom from toxicity
• Cleanliness during fluid life

01-01-10 © 2011 The Lubrizol Corporation GI104-3

 Industrial Gear Oil
Performance Pyramid
Performance Level Gear Oil Performance

Cleanliness
Top Tier Improved demulsibility
Thermal Retention of performance
Stability under high thermal stress

Heavy duty
Standard AMGA 9005-E02 EP protection
DIN 51517 Part 3

Gear
Basic US Steel 224 Protection

01-01-10 © 2011 The Lubrizol Corporation GI104-46

 Market Data
US Market Breakdown

Performance Tier Estimated Share Performance Description

Cleanliness
Top Tier 10% Plus thermal stability
Plus thermal durability
DIN 51517 Part 3
Standard 60%
AGMA 9005-EO2

Minimum 30% U.S. Steel 224

01-01-10 © 2011 The Lubrizol Corporation GI102-5

 Specifications
Baseline Performance of Industrial Gears
FZG spur gear test 11th stage minimum
Timken OK load 60 lb minimum
Four ball EP 250 kg weld point minimum
45 kg load wear index minimum
Four ball wear 0.35 mm scar diameter maximum

Copper strip corrosion ASTM 1b maximum

Turbine oil rust test Pass

Wheeling steel demulsibility 80 ml free water minimum

2.0% water-in-oil maximum
1.0 ml emulsion maximum
Gear oil oxidation viscosity increase 6.0% maximum
ASTM foam 10 ml stable foam maximum

01-01-10 © 2011 The Lubrizol Corporation GI101-2

 Fundamentals of Industrial Gears
Viscosity Classification

ISO Grade AGMA Grade Type SUS at 100°F cSt at 40°C

46 1 R&O 193-235 41.4-50.6
68 2 R & O; EP 284-347 61.2-74.8
100 3 R & O; EP 417-510 90.0-110
150 4 R & O; EP 626-765 135-165
220 5 R & O; EP 918-1122 198-242
320 6 R & O; EP 1335-1632 288-352
460 7 EP; Comp* 1919-2346 414-506
680 8 EP; Comp* 2837-3467 612-748
1000 8A Comp* 4171-5098 900-1100

* Compounded with Fatty Oil

01-01-10 © 2011 The Lubrizol Corporation GI104-30
 Industrial Gear Oils - Market Trends
Changes in Industrial Gearboxes

Changes in •More power

Industrial Gearboxes •Reduction in weight and size
•Lower oil volume
Lubricant Attributes •Reliability … durability
Oil property retention •Lower cost to produce
Oxidative, viscosity, thermal •New materials & surface finishing
stability
Improved lubrication
Micropitting resistance
Bearing protection
Improved performance
Demulsibility •Higher teeth & bearing loadings
Seal performance •Increased gearbox temperatures

Industrial gearbox changes are key drivers for improved industrial gear oils

01-01-10 © 2011 The Lubrizol Corporation GI102-2

 Industrial Gear Oil

• Gear Lubricant Categories

– Automotive
– Industrial
• Distinction between the two
– Types of gears they lubricate
– Environment they are exposed to

01-01-10 © 2011 The Lubrizol Corporation GI104-41

 Industrial Gear Oil
Automotive Gear Oils
• Lubricate
– Spiral-bevel gears in on and off-highway truck axles
– Hypoid gears in vehicles include trucks and passenger cars
• Demand high levels of Extreme Pressure (EP) protection
– Require a treat rate ~ 4 times higher than industrial gear oils

01-01-10 © 2011 The Lubrizol Corporation GI104-42

 Industrial Gear Oil

• Work under diverse conditions and applications.

• Steel-on-steel gear sets
– Lubricant is required to function in
• Steel mills, in the presence of large quantities of water
• Mines and quarries, high contamination environments
• Must sustain high loads, speeds, operating temperatures

01-01-10 © 2011 The Lubrizol Corporation GI104-43

 Industrial Gear Oil

• Primary industrial gear oil formulation

– Sulfur-phosphorous: provide load bearing protection
• Versatility allows for close matching of performance characteristics
to base oil types which takes into account:
– Worldwide sourcing of crude oil
– Changing refining methods
• Factors that contribute to industrial gear oil performance:
– Additive solubility
– Demulsibility
– Oxidation and thermal stability
– Storage stability
– Foam prevention
– Extreme pressure protection
– Corrosion protection
01-01-10 © 2011 The Lubrizol Corporation GI104-45
 Industrial Gear Oil
Superior Demulsibility (Water Shedding)
• Industrial gearboxes often
suffer water ingress
• This can seriously impact the
quality of lubrication
• An effective modern oil must
retain it’s ability to separate
this water in service
• The water must be shed
quickly (but also at different
temperatures)
ASTM D1401 test
The right additive technology is required to offer high demulsibility

01-01-10 © 2011 The Lubrizol Corporation GI104-50

 Industrial Gear Oil
Thermal Stability vs. Durability
• Thermal Stability
– The ability of a fluid to resist decomposition at high
temperatures. The necessity comes from heavier loads and
smaller gearbox designs that elevate temperatures and
pressures.
• Durability
– Pushing a fluid beyond standard limits. Lubrizol will stress a
fluid through standard testing then use the “end of test” fluid
to run another test to show durability and retention of
performance.

01-01-10 © 2011 The Lubrizol Corporation GI104-51

 Industrial Gear Oil
Thermally Stable IGO – Cleanliness

Conventional Chemistry Thermally Stable Chemistry

Industrial Gear Oil Oxidation Test 312 hours @ 121°C

Thermally stable chemistry is critical in high temp applications

01-01-10 © 2011 The Lubrizol Corporation GI104-52

 Industrial Gear Oil
Thermally Stable IGO – Cleanliness

1.8% wt 2.0% wt Competitive Additive

Additive Additive 2.0% wt

Thermally stable chemistry can be offered with the right additive technology
01-01-10 © 2011 The Lubrizol Corporation GI104-53
 Fundamentals of Industrial Gears
Gear Wear and Failure
• Most gear failures are due to
– Misalignment
– Abrasives
– Contamination
– Lack of lubrication
– Improper lubricant

01-01-10 © 2011 The Lubrizol Corporation GI104-18

 For more information on Hydraulics & Industrial Gear Oils
please use your trial K2M subscription.

To login to the K2M learning environment go to:

http://www.lubrizolk2m.net/login/login.htm

Once you login, click the link to your standard subscription.

Under the Industrial category you will find the following courses:

Operation of an Hydraulic System

Contamination Leads to Hydraulic Problems
Fluid Recommendations for Hydraulic Pumps
Hydraulic Fluid Compatibility
Preventing Failure with Correct Gear Oil Selection

© 2011 The Lubrizol Corporation