OILS & LUBRICANTS
SulNOx has developed a hydrocarbon fuels conditioning and emulsifying process which enables more efficient fuel combustion
reduced by over 50 % and PM2.5 by over 60 %. “ It reduces the contamination of engine oil , thus potentially preserving the life of the engine . Reduces fouling of ignition , diesel filters and fuelling components along with reduced engine parts corrosion , reduced failure of lubricating films . Significantly reducing the load on the Exhaust Gas Recirculation ( EGR ) system . Longer turbo life and increased time periods between routine engine maintenance .”
The company told IM that these combined benefits mean expected reduced maintenance costs of up to 10 % are achievable and depending on the size and maintenance costs of the mining fleet this should also be factored into any combined calculations .
A better way to reduce DPF clogging
In a recent article , Shawn Whitacre , Senior Staff Engineer at Chevron Lubricants , discussed in some detail diesel particulate filters ( DPFs ). They are unquestionably efficient and effective at doing what they are supposed to do , namely reducing harmful emissions from heavy duty diesel engines . However , the buildup of noncombustible ash in DPFs clogs the filters , impairing their performance and reducing their efficiency . “ Left unchecked for too long , DPF
Operators can slow down DPF ash accumulation with a conventional , 1 % ash CK-4 oil simply by reducing oil consumption in the engine clogging can also impair engine performance and diminish fuel economy . That is why they require periodic cleaning , which is a maintenance headache for fleet operators . First , it is a costly and laborious process , usually involving a chemical treatment to break down the ash and special equipment to blow it out of the filter . What ’ s worse , it requires taking a truck out of service for as much as a day , meaning downtime and lost revenue .”
The main causes of ash formation in DPFs are the metallic additives in heavy duty engine oils , whose formulations typically include calcium , magnesium , zinc , phosphorus , molybdenum and boron . “ To help minimise the accumulation of ash and the resulting maintenance requirements ( and costs ), Chevron developed the first diesel oil based on a new , patented ultra-low ash ( ULA ) technology . Delo ® 600 ADF is formulated with a novel additive package that has proven in exhaustive testing to be just as effective at wear protection , oxidation stability and oil life extension as conventional additives . More significantly , ULA technology reduces the ash content in the oil from the API-mandated maximum of 1 % ( considered ‘ low ash ’) to just 0.4 %. This 60 % reduction in ash content dramatically slows the buildup of ash in the DPF , meaning longer and more predictable maintenance intervals , while delivering a fuel economy benefit as well .”
Whitacre says it has been suggested that operators can slow down DPF ash accumulation with a conventional , 1 % ash CK-4 oil simply by reducing oil consumption in the engine . “ One can see the logic in this argument – the less oil consumed , the less unburned ash flowing out through the exhaust aftertreatment system . And reducing oil consumption without compromising lubrication and protection is always a desirable goal .”
But as a practical matter , how do you actually control oil consumption ? “ It ’ s not as though there is a dial on the dashboard that you can turn up and down to regulate the flow of oil . This logic relies entirely on the ability of an oil to inhibit piston deposit formation in the power cylinder , which is the main driver of increased oil consumption over the life of an engine . In other words , the rate of oil consumption depends largely on the properties of the oil being used , and is otherwise out of the operator ’ s control .”
But he says on the other hand , the selection of an ultra-low ash oil is very much within the operator ’ s control and effectively guarantees minimal ash accumulation , making it a much easier and more predictable solution . “ By the way , our testing of Delo 600 ADF found that it also exhibits remarkably good piston deposit control – so it will help limit oil consumption along with the specific and unique additional benefit of limiting ash buildup in the DPF .”
How much of a difference can a ULA oil make over the long haul ? The most commonly used metric for oil consumption is miles traveled per quart of oil consumed . That figure is bound to vary widely from one engine to another , and oil consumption generally scales in proportion to fuel consumption . If an engine is working harder and burns more fuel , it will simultaneously consume more oil .
“ Let ’ s assume , however , an average oil consumption rate of 4,000 miles per quart . It might be much less in an older engine and far more in a brand new engine , but that is a good starting point . After 400,000 miles , the engine will have consumed 100 quarts or 25 gallons of oil that pushes unburned ash through the exhaust system and into the DPF . Now consider whether all that oil has a 1 % or a 0.4 % sulfur ash content . Simple math tells us that an ultralow ash oil is going to produce a fraction of the ash accumulation of a low-ash CK-4 oil .”
He concludes : “ Certainly the lubrication industry as a whole has made tremendous progress in ash reduction over the past decade . The CK-4 standard represented a huge leap over previous generations . Now , the introduction of ULA technology is a game-changing breakthrough , achieved without compromising any of the protective benefits you expect from a CK-4 oil . Simply stated , if you really want to minimise DPF ash accumulation and avoid unpredictable maintenance and downtime , then you are better off with an oil specifically designed for that purpose . And at the time of this posting , there is only one on the market .”
HollyFrontier on the hidden impact of engine idling
Gord Susinski , Senior Technical Adviser at HollyFrontier Lubricants & Specialties , which includes the Petro-Canada Lubricants brand – told IM about the significant negative effects of idling in mining and the role of oils to mitigate problems .
“ Heavy-duty equipment in the mining industry operates in some of the world ’ s most extreme environments and weather conditions . In an
44 International Mining | JULY 2021