X - All Nadasdi1 - Synthetics Are Not The Same Presentation

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2006 Exxon Mobil Corporation. All rights reserved.

All Synthetic Oils
Are Not The Same

Dr. T. Tim Nadasdi
Dr. Jim T. Carey
Dr. Angela Galiano-Roth

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Introduction
Synthetic lubricating oils have developed a reputation for
working in the most extreme conditions. They have been
associated with superior performance
thermal and oxidative stability
shear stability
low temperature performance
low frictional properties
The evolution of mineral oil processing has recently led to the
introduction of new families of products, marketed as
synthetic lubricants
based on severely hydroprocessed mineral oils
This presentation will provide some insight into:
fundamental characteristics of these newer synthetics compared to
traditional synthetic oils
effects that these base oils have on finished lubricant/grease performance
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API Basestock Classifications
API Basestock Classification
Physical Specifications
Group
VI Sulfur % wt. Saturates % wt
Manufacturing
Process
I 80-120 >0.03 <90
Conventional (solvent
refining)
II 80-120 <0.03 >90
Require
Hydrocracking/dewaxing
III >120 <0.03 >90
Requires severe
Hydrocracking/dewaxing
IV >140 0.00 >90
Chemical Synthesis -
PAO
V
All other synthetics -
esters, polyglycols,
phosphate esters...
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Parameter Group I Group II Group III Group IV
Comparison of Basestock Properties
Oxidation
Stability
Volatility
Additive Solvency of
basestock
Low Temperature
capability
Efficiency / Traction
Relative costs
1 1.1-1.2 1.5 4 to 10
Viscosity range at 40
deg C (in cSt)
Up to 500 Up to 120 Up to 40 Up to 50,000
Direction of arrow indicates improved performance
Generalized Comparison of Base Stock
Properties
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Mineral Oil Molecular Make-Up
Presentation
Symbol
Chemical Advantage in a
Lubricant
Disadvantage in a
Lubricant
Short Chain
Paraffins
High volatility
Low flash Pt.
Medium Chain
Paraffins
Higher VI
Therm. & oxid. stability
Low solvency
Long Chain
Paraffins
High VI
Therm. & oxid. stability
Low solvency
Waxy
Aromatics High solvency
High viscosity
Poor oxid. stability
Low VI
Heteroatomic
Molecules (S, N)
Sometimes oxidative
stability
Can affect other
properties (foam,
Demuls, oxidation)
Saturated Rings Better low temp.
Better solvency
Adds some viscosity
Poor oxidative
stability
A
H
R
Group I oils are a mixture of
many different molecules
with different properties
R
R
R
H
H
H
H
H
A
A
A
A
A
A
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Mineral Oil Group I - Group III Processing
Hydroprocessing
Further
Hydroprocessing
R
R
R
H
H
H
H
H
A
A
A
A
A
A
GP I
R
R
R
R
R
R
R
R
GP II
R
R
R
GP III
Polyalphaolephin (PAO)
Viscosity controlled by molecular design
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Basestock Summary
The processes used to manufacture Group II and
Group III oils limit their viscosity to ~120 and 40 cSt
at 40
o
C, respectively
Group II and Group III base oils require liquid
thickening agents to meet the viscosity
requirements of many industrial applications
PAO oils achieve their high viscosity through
molecular design and do not require liquid thickening
agents for typical industrial applications

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0
50
100
150
200
250
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Year
C
a
p
a
c
i
t
y

(
1
0
0
0

B
B
L
/
d
a
y
)
1990 1991 1992
1993 1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004
Group II
Group I
Total Capacity
86%
14%
29%
71%
51%
49%
North American Base Oil Capacity Change
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Market Changes
1999 ruling by the National Advertising Division of the Better
Business Bureau has expanded the meaning of the word synthetic
relative to lubricants
Synthetic base oil compositions may include a variety of base oils
that have been chemically altered and when formulated properly
deliver the performance standards expected from a synthetic
lubricant
GP II, GP III and white oils may fit the new criteria for synthetics
Increased North American market capacity for GP II & III oils

Practical Result - the meaning of the term synthetic has been
expanded and can no longer be just associated with the performance
strengths and chemistry of GP IV/V stocks.
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Lets Look at 3 Synthetic Gear Oils
All 3 oils are considered synthetic hydrocarbons
The difference in the oils is in the blend of PAO,
Polyisobutylene (PIB) and Group III base stocks
All other additives in the oils are the same
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Three Synthetic Gear Oils
1. The same commercial premium gear oil additive package in all oils
2. The same commercially available ester in all oils
The oils differ ONLY in their base stock composition
Oil A Oil B Oil C
Hydrocarbon Type PAO PAO/PIB GP III/PIB
Viscosity ISO 460 ISO 460 ISO 460
Viscosity Index 164 150 145
PAO 88 51
Polyisobutylene (PIB) 37 37
Group III Oil 51
Gear Oil Additive Package
1
2 2 2
Ester
2
10 10 10
Total 100 100 100
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Test Regiment
Bulk Oil Oxidation Test
- This test is run for 24 hours at 375
o
F. Air is bubbled though the test oil
which contains a metal catalyst. Viscosity increase and TAN are measured.

Worm Gear Test
- This test involves running oils in a worm gear at various loads. It is run for
48hrs during which time the oil temperature and gear box efficiency are
monitored. The used oil is tested for shear stablity (viscosity loss) and wear
metals.
Test Method Relation to Lubricant Performance
Pour Point ASTM D97
In general, lower pour points indicate better low
temperature performance
Brookfield Visc ASTM D5133
Related to flowability and pumpability of oil at lower
temperatures
Bulk Oil Oxidation See Below Estimation of oxidation stability and oil life
Worm Gear Test See Below Shows lubricant performance in a real worm gear box
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Low Temperature Results - Pour Point
Even with PPD concentration optimized for lowest pour point, Oil C
still has a pour point that is 9
o
C higher than PAO or PAO/PIB
blends
Oil A
(PAO)
Oil B
(PAO/PIB)
Oil C
(GP III/PIB)
Oil C
+ PPD
-35
-30
-25
-20
-15
-10
-5
0
1 2 3 4
D
e
g
r
e
e

C
e
l
s
i
u
s
-33
o
C
-24
o
C
-18
o
C
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0
100,000
200,000
300,000
400,000
500,000
600,000
-10 -20 -30
Temperature
o
C
V
i
s
c
o
s
i
t
y

i
n

c
P
Oil A
(PAO)
Oil B
(PAO/PIB)
Oil C
(GP III/PIB)
Low Temperature Results - Brookfield Viscosity
Oil A shows significantly better
flow characteristics at lower
temperatures
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Bulk Oil Oxidation Results
Both TAN and viscosity increase indicate that Oil C
undergoes the highest oxidation
0
5
10
15
20
25
% Change in Viscosity 7 7 23
Change in TAN (mg
KOH/g)
0.4 2.6 3.2
Oil A
(PAO)
Oil B
(PAO/PIB)
Oil C
(GP III/PIB)
V
i
s
c
o
s
i
t
y

C
h
a
n
g
e

(
%
)

T
A
N

C
h
a
n
g
e

(
m
g

K
O
H
/
g
)

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Testing in a Worm Gear Box
Worm Gear
(Steel)
Bearings
(Steel)
Driven Gear
(Cu/Sn alloy)
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Gear Box Efficiency (%)
Oil A (PAO) has an average efficiency benefit of 6% over Oil C (GP III/PIB)
70
71
72
73
74
75
76
77
78
79
80
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Hours
Oil A
(PAO)
Oil B
(PAO/PIB)
Oil C
(GP III/PIB)
E
f
f
i
c
i
e
n
c
y

(
%
)

Worm Gear Test Results
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Sump Temperature (
o
F)
165
170
175
180
185
190
195
200
205
210
215
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Hours
T
e
m
p
e
r
a
t
u
r
e

(
o
F
)

Oil A
(PAO)
Oil B
PAO/PIB)
Oil C
GpIII/PIB)
Oil A Oil B Oil C
Hydrocarbon Type PAO PAO/PIB GpIII/PIB
Viscosity Change - 1.8% - 4.8% - 5.9%
Cu, ppm 70 320 1100
Sn, ppm 25 42 160
Fe, ppm 1 2 8
Used Oil Data
Worm Gear Test Results
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Oil Summary
Group II oils are limited to ~120 cSt and Group III to
~40cSt
Group II and Group III base oils require thickening
agents to meet the viscosity requirements of many
industrial applications
Synthetic industrial lubricants made with Group II/III
oils MAY have different performance properties
than lubricants made with PAO alone
Selection of synthetic lubricants should focus on
product performance, application requirements,
and field experience
All synthetics ARE NOT the same
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Considerations for Greases
Performance differences seen in oils will likely
translate to greases

Need to understand grease lubrication regimes and
determine which type of synthetic oil will perform
best in the intended application

Different types of synthetic oils will likely interact
differently with grease thickeners
Effect on bleed rate?
Effect on shear stability?
Effect on thickener reaction?
Effect on low temperature properties?

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2006 Exxon Mobil Corporation. All rights reserved.

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