Dow UCON™ Oil Soluble Polyalkylene Glycols
A New Type of Group V Base Oil
Presenter: Dr. Yogaraj Nabar
8th International Symposium on Fuels and Lubricants
New Delhi, March 2012
Content
To introduce Oil Soluble PAGs – a new type of Group V base oil and
performance additive
To provide concepts to allow formulators to solve some of their
lubrication challenges
 Traditional Polyalkylene Glycol Technology
 Oil Soluble PAGs (OSPs)
 Physical Properties
 Oil solubility
 Oxidation stability
 Functional benefits of OSPs
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Solvency attributes
Deposit control
Friction behavior
Corrosion inhibition boosters
 Application uses
Dow UCON™ Fluids & Lubricants
PAG manufacturing locations
R&D
USA: Midland (MI)
Europe: Netherlands and Switzerland
Pacific: China
LAA: Brazil
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Global supplier of synthetic base fluids and fully formulated lubricants
Primary chemistry is Polyalkylene Glycol (PAG) – Global leader
Multiple Channels-to-Market but primarily formulators
Innovator – Recent technology introductions: PAG Gas Turbine Fluids, Wind Turbine Oils,
Fire Resistant Hydraulic Fluids, Renewable Base Oils
Recent Innovations in API Group IV and V Base Oils
Polyalphaolefins
High viscosity PAOs manufactured from new catalysis routes
Applications include gear and wind turbine lubricants
Esters
High performance esters from renewable feed stocks
Applications include Bio-hydraulic Fluids
Oil Soluble PAGs
New range of ISO viscosity grade base oils and performance
enhancing additives
Broad range of industrial and automotive formulation options
The Chemical Industry continues to innovate to bring advanced solutions to
emerging market needs
Traditional Polyalkylene Glycol Technology
Typical Synthesis Route to Polyalkylene Glycols
H 2C
O
CH 2
+
H 2C
CH
CH 3
Initiator, ROH
O
Ethylene oxide (EO) Propylene oxide (PO)
• High performance synthetic
lubricants
• Solve problems that mineral
oils can not.
• Synthesized from ethylene
oxide and propylene oxide
• Flexible chemistry –
polymers can be tailor
designed to meet many
requirements
• Extensively researched to
provide energy efficient
solutions
catalyst
CLASSICAL POLYMER STRUCTURES BASED ON EO & PO
Block
Polymerization
Random
Polymerization
Inverse block
Polymerization
....
EO block
Initiator
PO block
Initiator
EO
PO block
EO block
PO
Initiators are typically monols, diols or triols
(for example butanol, propylene glycol, glycerol).
Polymers can be designed to have a wide range of
molecular weights, viscosities and functional
performance
PAG Application Expansion
Historical application development
FUTURE
PAG Expansion
Through
Innovation
Gear oils
Textile oils
Fire resistant
hydraulic
Fluids (HF-C)
Metalworking
Fluids
Refrigeration
oils
Hydraulic
Fluids (HF-D)
Compressor
Fluids
Gas Turbine
Fluids
Quenchants
1960s
1970s
1980s
1990-today
PAG chemistry and functional use
EO/PO
EO/PO
EO/PO
PO
Additive
Viscosity builder
Additive
Lubricity aid
Primary Base oil
Primary Base oil
PAGs from alternative
oxides
PAGs to upgrade
mineral oils
OIL SOLUBLE PAGs
OSPs as performance
enhancing additives for
- Deposit control
- Friction control
- Viscosity builders
- Corrosion inhibitors
- Additive solubility aid
Conventional PAG Attributes
Recognized positive
attributes of PAGs
Good low
temperature
behavior
High
viscosity
indices
Perceived negative
features of some PAGs
Good
deposit
control
Advantages
Hydrolytic
stability
Excellent film
forming
properties
Hygroscopicity
Oil
miscibility
Elastomer
compatibility
Disadvantages
Challenge is to develop PAGs which overcome the perceived disadvantages
but retain the known advantages
Oil solubility of PAG increases for higher C/O ratios
Upgrading Hydrocarbon Oils with Dow UCON™ OSPs
Water soluble and
water insoluble PAGs
Traditional PAGs used
in water based lubes
and as primary base
oils in synthetics
Synthetics
Mineral oils
Oil soluble PAGs
Oil soluble PAGs can
open up the application
envelope and solve
problems with modern
mineral oil lubricants
Mineral oils
Expanding functionality of PAGs using Dow UCON™ OSPs
Traditional uses of PAGs based on
EO and PO derivatives
Primary base oil in formulations
• Compressor and refrigeration oils
• Hydraulic fluids
• Textile lubricants
• Gear & Bearing oils
Additives
• Viscosity builder in water glycol
hydraulic fluids
• Lubricity aid in water miscible
MWFs
Use of OSPs
Expansion of formulators options
Primary base oil in formulations
• Compressor/refrigeration oils
• Hydraulic fluids
• Gear & Bearing Oils
• Engine/transmission Oils
Co-base oil
• Upgrade Group I-III mineral oils
• Upgrade PAOs
Additives
• Deposit control additive
• Friction modifier
• Viscosity builder in mineral oils
PAG Polymer Design Principles
Dow UCON™ OSPs – Typical Physical Properties
Polymers derived from downstream derivatives of butylene oxide
KV40
cSt
KV100
cSt
Viscosity
Index
CCS
viscosity
at -20oC
mPa.s
ASTM
D445
ASTM
D445
ASTM
D2270
ASTM
D5293
ASTM
D97
ASTM
D92
ASTM
D611-01
OSP-18
18
4
123
n/d
-41
204
n/d
OSP-32
32
6.5
146
1750
-57
216
<-30
OSP-46
46
8.5
164
2900
-57
210
<-30
OSP-68
68
12
171
5400
-53
218
<-30
OSP-150
150
23
186
17100
-37
228
<-30
OSP-220
220
32
196
29100
-34
226
-22
OSP-320
320
36
163
n/d
-37
230
n/d
OSP-460
460
52
177
n/d
-35
235
n/d
OSP-680
680
77
196
n/d
-30
243
n/d
Pour
Point
°C
Flash
Point, °C
Aniline
Point, °C
Attributes of Dow UCON™ OSPs & Traditional PAGs
Viscosity index
100
Oil miscibility
80
Pour points
60
Elastomer compatibility
40
Biodegradability
20
New OSPs
0
Traditional PAGs
Deposit control
Antiwear
Oxidation stability
Hydrolytic stability
Hygroscopicity
Arbitrary scale but higher values preferred
PAG polymer design space is significant
Changes in polymer chemistry can target improvements in functional performance
Synthetic and hydrocarbon oil incompatibility is in the past!
Solubility of Dow UCON™ OSPs at up to 10% in hydrocarbon oils
Group I Mineral Oils
Group II and III Mineral Oils
High
Solubility
Solubility
High
Soluble
Low
18
Not
Soluble
Soluble
Soluble
Low
32
46
68
150
220
320 460 680
18 32
46
68
150 220
320
460
Group IV PAO – Low viscosity
High
Solubility is good in other
base oils such as
 Diesters
 Polyol esters
 Vegetable oils
 PAGs (PO homo-polymers)
Solubility
Not
soluble
Soluble
Soluble
Low
18
32
46
68 150 220 320
460
680
680
Base oil solvency power
Typical chemical components in hydrocarbon base oils
Isoparaffins
Naphthenes
N-paraffins
Aromatics
Polar *
compounds
Group I
Less polarity
and solvency
Group II
Group III
Group IV
* e.g. sulphur compounds
Group III and IV base oils
• Higher iso-paraffinic content
• Low or no aromatic content
• Provide more challenges in formulating with modern
performance boosting additives due to lower solubility
Comparison of Aniline Points
Typical values - Aniline points using ASTM D611-01
140
120
Aniline point, oC
100
Additive technologies
used to boost solvency
in hydrocarbon oils
80
60
40
20
OSP
0
GpI
GpII
GpIII
PAO
Naphthenic Alk. Napth
Ester
-20
-40
Dow UCON™ OSPs can provide formulators another option for
adding back some solvency power to Group II, III and IV base oils
Deposit Control Benefits of PAGs – Field Experience
Mineral oil
PAG synthetic
Thousands of rotary screw air compressors
and other turbo-machinery use conventional
PAG technology
oxidation
Oxidation of PAGs
produces small polar
by-products. These
are soluble in PAGs
PAG Gas Turbine Fluid
Problems with deposit formation in some
gas turbines are being solved today using
conventional PAG technology
Mineral oil degradation byproducts are polar and often not
soluble in the base oil
Conceptually – Dow UCON™
OSPs as components of
mineral oils may improve
deposit control and extend fluid
life
Deposit Control Study – Concentration effect of UCON™ OSPs
Group I Mineral Oil
Group I Mineral oil + OSP-46 (10%)
Deposit
free
Deposit
formation
0
14d
50d
0
Group I Mineral Oil + OSP-46 (5%)
14d
50d
Group I Mineral Oil + OSP-46 (1%)
Deposit
free
0
14d
0
50d
Modified ASTM D2893B at 120oC
Minor
deposit
14d
50d
Deposit Control Study – OSP versus Esters and Alkylated Naphthalenes
Group I Mineral Oil
Group I Mineral oil + OSP-46 (10%)
Deposit
free
Deposit
formation
0
14d
50d
14d
0
Group I Mineral Oil + Synthetic Ester (10%)
50d
Group I Mineral Oil + Alkylated Naphthalene (10%)
Deposit
formation
Deposit
formation
0
13d
41d
0
13d
41d
Traction Performance as Base Oils
LESS FRICTION
Energy Efficiency
+
Reduced Wear
+
Longer fluid Life
Friction Performance of Dow UCON™ OSPs as Additives in PAO
Mini-traction machine, steel ball on steel disc, temperature 80oC, speed 15 mm/sec,
Slide roll ratio = 10%, Pressure = 0.9GPa
0.4
0.35
Friction Coefficient
0.3
PAO
0.25
PAO + 10% OSP
0.2
PAO + 8% OSP
PAO + 5% OSP
0.15
PAO + 8% Polyol ester
0.1
0.05
0
0
200
400
600
800
1000
1200
1400
1600
1800
2000
Time (s)
Polyalphaolefin is a PAO-8 base oil (un-additized)
Dow UCON™ OSPs may offer another choice to esters and other surface
active additives
Dow UCON™ OSPs and Application Expansion
Opportunities to expanding the functionality of PAGs using OSPs
Conventional
PAGs (EO & PO)
Primary Base Oil Component in Synthetics
Compressors
Industrial Gears
Hydraulic Fluids
Greases
Transmission fluids
Metal deformation
Performance Additive for Hydrocarbon Oils
Deposit control additive
Friction modifier
Viscosity builder
Additive solubiliser
Corrosion inhibitor booster
UCON™ OSPs
UCON™ OSP Recommended Applications & Uses
Base Oil Uses
Additive Uses
Concepts for UCON™ OSPs for Hydraulic Fluids
Hydrocarbon based
Anti-wear Hydraulic Fluids
• OSPs to upgrade current technology
• Treat levels 1-20%
• Inherent film forming properties of
OSPs to deliver improved wear rates
• Deposit control to minimize varnish
formation and filter and servo valve
blockages
Fire Resistant Hydraulic Fluids
• OSPs have much lower heats of
combustion than mineral oils (oxygen
rich polymers)
• Significantly more hydrolytically stable
than conventional esters
• Provide excellent deposit control
• Offer a high level of biodegradability
Concepts for Dow UCON™ OSPs for
Gas and Air Compressors
Compressor types
Function of OSPs
Centrifugal
Rotary screw
Reciprocating
Primary base oil or additive in hydrocarbon oils
Deposit control
Heat removal – higher high capacities
Photo of turbine
Concepts for UCON™ OSPs for Gas Turbine Fluids
Utilize OSPs as a component additive or co-base oil in Group II and III mineral
oils
 Improve deposit control
 Reduce risk of varnish formation
 Reduce risk of equipment failure or turbine shut down
Concepts for UCON™ OSPs in Gear and Transmission Fluids
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Improved friction control through excellent film forming behavior of OSPs
Better energy efficiency
Good deposit control
Extended lubricant and equipment life
Concepts for UCON™ OSPs in
Wind Turbine Lubricants
 PAGs (OSPs) can generate much thicker EHD films than mineral
oils and PAOs under higher contact pressures
- 10-25% thicker EHD films at 60-100oC
- Predicted to yield longer gear life
 PAGs have higher heat capacities than hydrocarbon oils
- Potentially lower oxidation rates
Concepts for UCON™ OSPs for Greases
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Recent research observations
Excellent friction control
High dropping points – significant increase in number of cycles
Reduced thickener concentration in blend preparations (e.g. Li
complex)
Formulation flexibility (excellent additive solvating power)
Concepts for UCON™ OSPs in Engine Oils
Formulation Component of Engine Oil
 Friction control and film forming behavior (fuel economy benefit)
 Deposit control and engine cleanliness (reduced wear)
 Heat capacity improvement (improved oxidation stability)
Concepts for UCON™ OSPs for Metalworking Fluids
Oxygen rich polymers providing
surface activity and film forming
behavior
Metal Deformation & Metal Cutting
 Lubricity (AW/EP) booster for neat hydrocarbon oils
 Metal deformation applications (stamping, drawing,
rolling etc) and metal removal (cutting, drilling)
 Detergent additive – to maintain machine cleanliness
and prevent swarf build-up (validated by customers
in machine trials).
Value Proposition - UCONTM OSP Technology
Cleanliness
• Very high solvency power
• Excellent thermal stability
1
Energy Efficiency
• Reduced friction
• Very high Viscosity Index
2
Upgrade
conventional
Hydrocarbon
Oils
3
by
4
Adding Dow
UCONTM OSP
co-base oils
from 1% to 40%
Reduced Wear
• Cleaner operation
• Reduced friction
• Additive compatibility
Environmentally Friendly
• Biodegradable grades (OECDf >70% degradation)
• Pending H1 food grade status OSP 68 and up
Increased Fluid Life
• Excellent thermal and oxidative stability
• High thermal transfer capabilities
• Excellent hydrolytic stability
5
How to Follow-Up?

Email: OSP@dow.com

Contact our Team Directly



Mayur Garg – DGM, Commercial

+91-22-67832366

mgarg@dow.com
Sandeep Nikam – Application Development Manager

+91-22-61820411

nikam@dow.com
Visit our website at http://www.dow.com/ucon/osp/
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