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Engine Oil Requirements from an OEM Point of View
- Prevention of Diesel Turbocharger Compressor Deposit -
4th – 5th April, 2017 in Stuttgart UNITI Mineral Oil Technology Congress
Satoshi Hirano
TOYOTA MOTOR CORPORATION Paul Decker-Brentano
TOYOTA Motorsport GmbH
4th - 5th April, 2017 UNITI Mineral Oil Technology Congress 2017 in Stuttgart 1
Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
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Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
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1. Background
• Turbocharger is a requisite element for modern diesel engines to meet ;
– Stringent emission regulations
– Engine performance requirements such as fuel economy, power output
• Turbocharger cannot get away from simple physics
– PV = nRT
– Increasing engine performance requires higher outlet pressure and results in higher outlet temperature
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1. Background
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NOx
PM DPF
SCR
DI + NA DI + TC
DI +TC + Common Rail EGR
Fig. 1 Trade-Off between NOx and PM, and Improvements by Engine/After-treatment Hardware
Turbocharger is an essential device to meet emission regulations.
1. Background
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After-Treatment
Mu
ffle
r
Compressor Turbine
Exhaust Intake D-Throttle
Blow-By Intercooler
Air Cleaner
Temperature (T1) Pressure (P1)
Temperature (T3) Pressure (P3)
Fig. 2 Diesel Engine with Turbocharger
1. Background
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Turbine Side Compressor Side
Fig. 3 Cross Section of Turbocharger
Recover Exhaust Gas Energy and Utilize it to compress Intake Air
PV = nRT
When the inlet air is compressed,
its temperature goes up.
Higher Temp
1. Background
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Fig. 4 Comparison of Typical Torque Curves and Turbocharger Map
Turbocharger Map
Pre
ssu
re R
atio
Air Flow Rate Engine Speed
Torq
ue
/L
Engine Torque Curve
Boosted by Turbocharger
1. Background
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Torq
ue
Engine Speed
Fig. 5 Engine Operation and Compressor Outlet Temperature (T3)
Compressor Outlet Temp. (T3) Drivability Fuel Economy
Maximum Power Output
Turbocharger Efficiency
Turbine Housing Water Cooling Jacket
Bearing Housing
Compressor Housing Variable Nozzle
1. Background
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Fig. 6 Deposit Formation in Turbocharger Compressor
Intake Air +
Ventilation Gas with Oil Mist
Concerned Areas for Deposit Formation
Diffuser
Diffuser
Scroll
Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
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2. Mechanism of Diesel TCC Deposit
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Fig. 7 IR Analysis and Elemental Analysis of New Oil and Deposit
a.u. = arbitrary units
2000 10001500[cm-1]
New oil
Deposits
Tra
nsm
itta
nce
[a
.u.]
Oxidation degradation
components: 1710 cm-1
S
Ca
Zn
P
MoNew oil
S
Ca
Zn
P
Mo
Fe, Cu, Si etc. Deposits
Similar Composition
No Oxidation
Simply Concentration of Oil + Soot
2. Mechanism of Diesel TCC Deposit
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GC
Sig
nal
300 400 500 600 700 800
Boiling Temp.(oC) by GC Distillation
New Engine Oil
Evaporated portion
Extracted Oil Portion from Deposit
Fig. 8 Distillation Characteristics by GC Distillation Analysis (ASTM D6352)
Adjustment of scale
High temperature and high flow speed In the compressor
Compressor Diffuser Surface
2. Mechanism of Diesel TCC Deposit
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Small particle of soot-containing engine oil from crankcase ventilation
Evaporation
Concentrated and thickened
Fig. 9 Mechanism of Deposit Formation
It was confirmed that the concentration of sooted oil by evaporation is the major mechanism of deposit formation in the turbocharger compressor. (SAE 2013-01-2500)
Attaches on surface
Deposit formation
2. Mechanism of Diesel TCC Deposit
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Less Residual Base Oil by Evaporation
Thickening Effects
Base Oil Volatility Engine Oil Formulation Factors
Fig. 10 Cause Effect Diagram of Turbocharger Compressor Deposit
Soot Accumulation in Engine Oil
Compressor Outlet Temperature (T3)
Engine Operation Factors
Solidification of Oil Mist Particle
Viscous Components in Engine Oil*
* Not confirmed yet
2. Mechanism of Diesel TCC Deposit
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T3 T
em
pe
ratu
re
Soot Concentration
No Deposit
Deposit
T3 T
em
pe
ratu
re
GC Distillation (496oC)
No Deposit
Deposit
Soo
t C
on
cen
trat
ion
GC Distillation (496oC)
No Deposit
Deposit
Fig. 11 Trade-Off Diagrams of Three Major Deposit Factors
Oil Soot Concentration
T3 Temperature
Engine Oil Volatility
Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
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3. Test Engine and Test Conditions
• Test Engine – Toyota 1KD-FTV – Inline-4, 2,982 cc – Max Torque = 305Nm @ 3,600rpm (w modified ECU for test) – Max Output = 118KW @ 3,600rpm (w modified ECU for test)
• Test Cycle (Steady State) – Duration = 100hrs – Engine Speed = 3,600rpm – Engine Torque = 290Nm – Turbocharger Compressor Outlet Temperature = 190oC – Soot at EOT = 3.5 +/- 0.5% (CEC L-82-97 (UV))
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3. Test Engine and Test Conditions
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Fig. 12 1KD-FTV Engine Bench at ISP
Engine Bench Build Up Intake Air Conditioner
3. Test Engine and Test Conditions
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Compressor Turbine
Exhaust Intake D-Throttle
Blow-By Intercooler
Temperature (T1) Pressure (P1)
Temperature (T3) Pressure (P3)
Facility Exhaust System
Inlet Air Conditioner
Fig. 13 1KD-FTV Engine Bench at ISP
Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
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4. Reference Engine Oils
• Reference Engine Oil Selection – Chosen from Commercial Products from the European Market
with known Performance Claims – ACEA Sequences, OEM In-house Specifications
• Low Reference Engine Oil – ACEA C2 – SAE 0W-30
• High Reference Engine Oil – ACEA C3, API SM/SL – BMW LL-04, dexos2, MB229.31/229.51/229.52, VW502 00/505 00/505 01 – SAE 5W-30
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Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
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5. Test Results and Discussion
• Test Matrix
– Ran 4 High Reference Oil tests and 3 Low Reference Oil tests with randomized test order
– The same engine hardware was used for all tests
– Turbocharger was replaced with new one for every test
– The turbocharger unit was disassembled and rated by visual cleanliness rating
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5. Test Results and Discussion
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High Reference Oil Test
Low Reference Oil Test
Low Reference Oil Test
Low Reference Oil Test
High Reference Oil Test
High Reference Oil Test
High Reference Oil Test
Fig. 14 Test Sequence
5. Test Results and Discussion
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Fig. 15 Turbocharger Deposit Rating Areas
5. Test Results and Discussion
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Fig. 16 Turbocharger Deposit Rating Scale
5. Test Results and Discussion
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Fig. 17 Turbocharger Deposit Examples
5. Test Results and Discussion
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Fig. 18 Average Oil Consumption
5. Test Results and Discussion
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Fig. 19 Soot Concentration at the EOT Used Oil
5. Test Results and Discussion
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Fig. 20 Turbocharger Deposit Ratings
Average S. Deviation
Average (1+2) 8.4 1.2
Average (1+2+3+4) 5.5 1.9
Average 1+2+0.5*(3+4) 6.5 1.4
Average S. Deviation
Average (1+2) 66.1 5.9
Average (1+2+3+4) 61.5 6.4
Average 1+2+0.5*(3+4) 63.0 6.1
5. Test Results and Discussion
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Fig. 21 Soot Concentration and Deposit Rating
Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
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6. Summary
• The mechanism of the turbocharger compressor deposit was proposed based on the deposit analysis and prove-out tests. (see details in SAE 2013-01-2500)
– Engine oil volatility, soot concentration, and turbocharger compressor outlet temperature are 3 key factors.
– Viscous components in engine oils may have the similar impact for oil thickening.
• Based on the mechanism, the preventative engine test for protecting turbocharger was developed.
– Anticipating more demands on improving over-all engine performance by increasing the boost by turbocharger.
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6. Summary
• High and Low Reference Oils were chosen from commercially available products in the European market.
– High Reference : ACEA C3 + OEM specs, SAE 5W-30
– Low Reference : ACEA C2, SAE 0W-30
• The test procedure could discriminate high and low reference oils with repeatable results.
• This test will provide good tool to formulate better engine oils suitable for future diesel engines at improved performance level.
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Agenda
1. Background
2. Mechanism of Diesel Turbocharger Compressor Deposit
3. Test Engine and Test Conditions
4. Reference Engine Oils
5. Test Results and Discussion
6. Summary
7. Acknowledgements
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7. Acknowledgements
ISP Salzbergen GmbH & Co. KG
Dr. Tono Nasch
Managing Director
Mr. Michael Schulz
Manager Engine and Vehicle Testing
Mr. Johannes Villinger
Project Engineer, Engine Testing
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Thank you for kind your attention !
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