F+L Magazine 2023 Q3

Quarter Three 2023 | Volume 29 Issue 3 MAGAZINE Tesla highlights importance of system approach in fluid design Alternative fuels for heavy-duty off-road applications are ready now No future for conventional internal combustion engine vehicles in China Scan this QR code to subscribe to the digital edition. F+L Magazine Quarter Three 2023 1

March 7-8, 2024 CONFERENCE THEME Towards Carbon Neutrality: Future Opportunities in Fuels and Lubricants CALL FOR PAPERS Where Knowledge Meets Innovation The Call for Papers for F+L Week 2024 is now open. We invite you to showcase your groundbreaking research, technological innovations, sustainability initiatives and industry best practices. Don’t miss this opportunity to shape the future of our dynamic industry. Submit your paper to: Submission deadline: For more information visit: [email protected] November 30, 2023 www.fuelsandlubes.com/fl-week

24 Contents QUARTER THREE 2023 | VOLUME 29 ISSUE 3 14 6 IRENA: The energy transition is “off track” 10 Global car market contracts in 2022, as electric car fleet rise 14 No future for conventional internal combustion engine vehicles in China 18 Closing the efficiency gap: Improving electric drive unit performance F+L Magazine Quarter Three 2023 3

36 Vicky Villena-Denton 20 32 Publisher & Editor-in-Chief Chief Executive Officer Tesla highlights importance Hydrogen: The Swiss Army of system approach in fluid Knife of energy sources Aaron Stone design 36 Assistant Editor 24 Alternative fuels for heavy- Ionut Oproiu duty off-road applications EU Green Claims’ Directive: Magazine Design Cutting through the climate are ready now Glenn Victor Denton jargon Service Delivery Manager 28 Eric N. Marquillero Polyurea greases may offer advantages for electric Sales and Marketing Assistant vehicles Venus Ricardo ISSN 0117 9470 Copyright © 2023 F&L Asia Ltd. Executive Assistant Advertisers’ Index Mary Grace Estacio 2, 40 F&L Asia Ltd. 13 SK Enmove Co., Ltd. 30 GOMA 35 STLE Accounting Assistant 17 IPAC, Inc. 7 The Bahrain Petroleum 27 MOL-LUB Ltd. w w w.fuel sandlubes.com 9 S-Oil Corporation Company B.S.C. (Closed) w w w.linkedin.com /company/f-l-asia 39 SEMA 23 TotalEnergies Lubrifiants 31 Shamrock Oils 15 Vanderbilt Chemicals, LLC twitter.com/fuelsandlubes 25 Xinxiang Richful Lube w w w.facebook.com /fuel sandlubes w w w.youtube.com /user/fuel sandlubesasia Additive Co., Ltd. F&L ASIA LTD. 22/F, 3 Lockhart Road Wanchai, Hong Kong Phone: +852 3183 4143 Fax: +852 3753 5122 Email: [email protected] Annual Subscription Rates: PDF: single user US$100/year; unlimited users US$550/year Digital/on-line: Free F+L Magazine, formerly Fuels & Lubes International, is a quarterly publication that chronicles the latest global trends, issues and developments in the fuels, lubricants and additives industries, with special focus on Asia-Pacific. Its contents are protected by international copyright laws. It is available in both print and digital versions. Unauthorized re- production or distribution by print, electronic or other media is strictly prohibited. F+L Magazine and F&L Asia Ltd., its officers and management, cannot be held liable for any mis- information inadvertently obtained. The opinions expressed by the writers do not reflect the opinion of the management. 4 F+L Magazine Quarter Three 2023

Vicky Villena-Denton EDITORIAL Editor-in-Chief & CEO Where knowledge meets innovation After navigating the turbulent waters of the Covid-19 pandemic we have seen a revival of in-person events. Industry collaboration and knowledge exchange are vital to the advancement of our industry as we look to adapt to the challenges of the energy transition. I would like to reflect on the recently completed F+L Week event, which was held in Kuala Lumpur, Malaysia, in June. The event was an unequivocal success with a strong representation of senior executives, technical, sales and marketing professionals. The conference attracted participants from 18 countries spanning five continents, creating a truly global platform for discourse on Fuels and Lubricants: Navigating the Energy Transition. F+L Week is a fusion of knowledge and innovation. The event has maintained an unwavering commitment to high-quality content, and we were delighted that 96% of respondents in the post-event survey praised the calibre of speakers and the diverse range of topics. I would like to touch on some of the key takeaways from this year’s event. A consistent theme throughout the two-day event was the uncertain future of automotive fuels and lubricants. In the heavy-duty transportation sector there are conflicting views about the likely time frame for decarbonisation. Although, alternative fuels for heavy-duty road applications are ready now, says Hind Abi-Akar, senior advisor to the Electrification and Energy Solutions division at Caterpillar Inc. We feature her F+L Week presentation on page 36. The growth of electric vehicles will significantly impact the future of automotive lubricants. Some lubricants will fall away, however, there will be opportunities in a changing market. In our centrefold, Dr. Wenyang Zhang, senior staff mechanical design engineer, drive system engineering at Tesla, Inc. highlights concerns around an increasing push for ultra-low viscosity fluids in the automotive sector. Speaking at F+L Week, Zhang emphasised the importance of a system approach in fluid design. Conventional internal combustion engines have no chance of survival in China, says Dr. Qingyuan Song, chief engineer of policy and regulatory affairs at Geely Powertrain. During F+L Week, Dr. Song provided details on the development of China’s new energy vehicle (NEV) market and the driving forces behind China’s NEV policy. We review these key drivers on page 14. A 10% efficiency gap exists between the highly operated regions and the peak efficiencies of e-drives. On page 18, we learn from Dr. Shrikant C. Nagpure, cell and battery head at FEV India Pvt Ltd, how to close this efficiency gap and improve electric drive unit performance. In this issue, we also discuss the bewildering array of green claims that are permeating the market. On page 24, we review new regulations looking to address climate jargon, including the European Commission’s proposal for a Directive of the European Parliament and of the Council on Green Claims. The regulation is designed to prevent misleading claims or greenwashing in Europe. F+L Magazine Quarter Three 2023 5

IRENA: The energy transition is “off track” There is growing aware- the goal of the 2015 said. Commitments from that is aligned with the ness of the severe conse- Paris Agreement to limit member countries at 1.5°C climate goal. The quences of climate change temperature increases to the 27th United Nations report delivers a sobering and the urgent need to 1.5°C above pre-industrial Climate Change Confer- message, demonstrating take action to bring down levels. ence (COP 27) in Egypt in our collective ability to our emissions. Weather November 2022 leave an reduce greenhouse gas events such as floods, IRENA is an intergov- emissions gap of about 16 emissions to adhere to a droughts and fires are ernmental organisation gigatonnes (Gt) of carbon 1.5°C (or even 2°C) tem- occurring with increasing that supports countries in dioxide (CO2) in 2050. Most perature rise “hangs in frequency and intensity. their passage to a sustain- climate pledges are yet to the balance.” The current able energy future. The be translated into detailed decade will ultimately Progress has been organisation published its national strategies and determine our success in made towards reducing World Energy Transitions plans, and deployment of limiting global tempera- global emissions and Outlook 2023 in June. The energy transition technol- ture increases. IRENA addressing environmental outlook provides an over- ogies is far short of what called for a significant ac- impacts. Nevertheless, the view of progress on the is required. celeration across energy energy transition is off- energy transition, offers a sectors and technologies. track, says the Interna- vision of the future energy IRENA’s analysis is Failure to address the im- tional Renewable Energy landscape, and identifies based on two key sce- pending climate emergen- Agency (IRENA), which priority areas and actions. narios, a Planned Energy cy will impact vulnerable is based in Abu Dhabi, Scenario (PES) based on populations the hardest, United Arab Emirates. The gap between what government energy plans the agency said. Current pledges and plans has been achieved and and other targets and pol- are insufficient to achieve what is required con- icies, and a 1.5°C Scenario The outlook outlined a tinues to grow, IRENA 6 F+L Magazine Quarter Three 2023

difficult 12 months since dies ever were recorded in cumulative USD150 trillion six performance indicators the 2022 World Energy 2022, the agency said. The is required by 2050, USD47 including the renewables Transitions Outlook was outlook urged policymak- trillion more than in the used to generate electric- published. Enduring im- ers to “strike the correct PES. USD1 trillion of an- ity, and the direct use of pacts of the Covid-19 pan- balance between reactive nual investments in fossil renewables—counting the demic, the Russia-Ukraine measures and proactive fuel-based technologies share of renewable energy war and ongoing economic energy transition strate- need to be redirected in total final energy con- effects have contributed gies.” to the energy transition sumption and the quan- to the worst energy crisis under this scenario, the tity of modern bioenergy. we have experienced in In an I-told-you-so type agency said. Improvements in energy decades. critique, the report also intensity, the electrifica- stated that the impacts of IRENA also highlight- tion of end-use sectors, Understandably, govern- the energy crisis would ed concerns around the production and supply ments have taken actions have been less severe had geographical spread of of clean hydrogen and to mitigate the impact investments in transition energy transition tech- derivative fuels, and the of surging energy prices technologies in the power nology deployments and amount of CO2 captured on both consumers and and heat sectors been investment, which are are also key indicators. businesses. However, too made earlier. limited to a few countries many government actions and regions. 85% of global More can be done to are incompatible with Global investments in renewable energy invest- reduce emissions. It is not the long-term transfor- energy transition tech- ment benefitted less than too late to change course, mation, IRENA said, with nologies reached USD1.3 half of the world's popula- IRENA said. The 1.5°C policies and investments trillion in 2022. To achieve tion, the agency said. scenario requires govern- “not moving in the right a 1.5°C scenario, annu- ments to proactively shape direction.” The highest al investments need to The World Energy a renewables-based en- level of fossil fuel subsi- quadruple, IRENA said. Transition Outlook’s 1.5°C ergy system. The outlook The report estimates a pathway is evaluated using F+L Magazine Quarter Three 2023 7

stressed the importance drogen meeting 16% and occurred in the power 84% of final consumption of embedding net zero 14%, respectively. sector. In 2022, approxi- in the transportation sector commitments into leg- mately 300 gigawatts (GW) will be satisfied by renew- islation with appropriate Hydrogen is a clean and of renewables were added ables by 2050. Electricity resourcing and implemen- versatile energy carrier globally, with renewables contributes 52% of demand, tation plans. Otherwise, that will play a key role accounting for 83% of followed by hydrogen and they remain purely aspira- in the decarbonisation of new capacity, compared its derivatives (23%) and tional, IRENA said. end-uses and flexibility of to a combined 17% share biofuels (13%). IRENA the power system. How- for fossil fuel and nuclear noted the prominent role A 1.5°C pathway re- ever, traditional hydrogen technologies. Nonethe- of direct electrification in quires the reduction of production methods rely less, annual renewable road and rail transport, 37 gigatonnes (Gt) of CO2 on fossil fuels and can power capacity additions with ammonia and meth- from 2022 levels, with the result in significant green- need to reach an aver- anol playing a central role share of renewable energy house gas emissions. To age of 1,066 GW per year in shipping. Aviation will reaching 77% by 2050 (it achieve the 1.5°C goal, to 2050 under the 1.5°C employ a combination of was 16% in 2020). Changes 94% of hydrogen needs to scenario, with global elec- synthetic fuels and biofuels. in consumption patterns be renewables-based by tricity demand set to triple and improvements in 2050, IRENA said. from that of 2022. IRENA’s 1.5°C Scenar- efficiency will see global io projects demand for energy consumption fall The outlook emphasised clean hydrogen and its by 6% in 2050. that the business case for derivatives will reach 63 renewables is strong. It is exajoules (EJ) by 2050. Electrification and both technically feasible Biofuel's share in primary efficiency were identi- and economically viable energy supply needs to fied as the key drivers to grow the volume and reach 22%, with IRENA of the energy transition, share of renewables. emphasising the need for which will be enabled by However, the analysis strong policy support—in- renewable energy, clean noted several “deeply cluding blending quotas, hydrogen and sustainable entrenched barriers” mandates and subsidies. biomass. To achieve the to faster adoption exist, 1.5°C temperature goal, which are a hangover While the journey towards electrification needs to from a heavy fossil fu- a sustainable and low-car- contribute more than el-reliant system. bon future seems daunt- 50% of total final energy ing, a successful energy consumption by 2050, with Most of the progress transition remains within modern biomass and hy- in the deployment of our grasp. The outlook renewables to date has emphasised the importance of global collaboration on energy, calling for the ap- proach to international co- operation to be “enhanced and redesigned.” 8 F+L Magazine Quarter Three 2023

YOUR SOLUTION S-OIL produces 45MBD of Group I,II,and III base oils with outstanding performance, guaranteeing superior and consistent quality to meet the needs of our customers and evolving markets. S-OIL’s base oils are available globally, directly from Korea as well as from storage tanks in key locations, including US, Europe, Middle East, China, Japan, Brazil and Australia. More information: http://baseoil.s-oil.com [email protected] F+L Magazine Quarter Three 2023 9

Global car market engine (ICE) across all contracts in 2022, as segments—cars, two- and electric car fleet rise three-wheelers, light- and heavy-duty commercial The global car mar- logged record numbers 70% are battery electric vehicles. ket contracted by 3% last year, exceeding 10 vehicles (BEVs). in 2022 relative to 2021, million for the first time The outlook was pub- impacted by supply chain and accounting for 14% According to Global EV lished on April 26, 2023. disruptions, geopolitical of all new cars sold. In Outlook 2023, an annual Headline EV numbers tensions, high energy 2020, just 5% of new car publication by the Interna- paint a strong global and commodity prices, sales were electric. An tional Energy Agency (IEA), picture. The reality is and economic insecurity. exponential rise in EVs has 2022 was another bumper that three key markets Despite a declining overall expanded the electric car year for electric vehicles. dominated electrification car market, electric cars fleet to 26 million. Around EVs are rapidly displacing efforts. China contributed the internal combustion 60% of global electric car sales and now comprises more than half of the ex- isting electric car fleet at 13.8 million. An extension of purchase incentives that were due to expire in 2020 fuelled strong growth in 2022, according to the report. The outlook also noted China has already surpassed its 2025 target for new energy vehicle sales. China aims to achieve a 40% share by 2030, with 50% in key air pollution control regions. Europe holds 30% of the overall global stock and delivered 25% of all electric car sales in 2022. Norway (88%) has the highest market share of electric car sales in Eu- rope, followed by Sweden (54%), the Netherlands (35%) and Germany (31%). The United States is the third largest global mar- ket, achieving 8% share of new car sales in 2022 and a total of almost 800,000 (+55%). The IEA analysis cited a key difference in these three markets. China has achieved higher adop- tion rates through the supply of smaller, more affordable, BEVs— with a sales-weighted average price below USD10,000. 10 F+L Magazine Quarter Three 2023

Conversely, Europe and tric cars and now accounts emission vehicle (ZEV) bus contributed more than the U.S. have focussed for half of the global fleet. and truck sales by 2040. half of registrations of on larger or luxury cars Hyundai Motor Company In 2022, 4.5% of bus sales the vehicle type in 2022. and SUVs—in both the EV is the top fuel cell auto- (66,000) and 1.2% (60,000) The outlook also noted and ICE markets. A higher maker. The global fuel cell of truck sales were elec- the emergence of bat- price offers greater profit electric vehicle (FCEVs) tric. China is by far and tery leasing business margins to manufactur- fleet increased 40% year- away the leader in the models and growth in ers; however, it does not on-year but remains small heavy-duty space—con- manufacturing in India’s facilitate the mass market at 72,000. Approximately tributing 80-85% of global three-wheeler segment. uptake of EVs. 80% of FCEVs are passen- sales in electric buses and Battery swapping is gain- ger cars. medium- to heavy-duty ing momentum through- Affordability is not the trucks. out Asia. Discharged only issue. Sustainability While electrification of battery packs are changed concerns have arisen passenger cars is ram- Two- and three-wheel- rather than plugged into alongside a predilection pant, ambition in electrify- ers offer an affordable a charging station, saving for bigger vehicles. The ing commercial vehicles is mobility option in emerg- drivers time and money. outlook stressed that also growing. Light com- ing and developing Battery swapping for larger SUV batteries mercial vehicle (LCV) sales economies. This market trucks is also emerging. require 75% more critical increased more than 90% segment is the most China has strong policy minerals and produce in 2022, to 310,000 units, electrified and continues support for this and is cur- 70% higher carbon dioxide despite the overall LCV to advance. The out- rently piloting the technol- emissions during mate- market declining by 15%. look highlighted China’s ogy in several cities. rials processing, manu- On current trends, the LCV sharp decline in electric facturing and assembly. market is catching up with two-wheeler sales (-25%) Continued accelera- Although, the IEA did note electric cars, although it in 2022, which it attribut- tion in EVs is expected a rapid increase in the currently stands at just ed to pandemic-related by the IEA with 14 million number of electric car 3.6% of sales. restrictions and their im- electric car sales project- models available in 2022, pact on the supply chain. ed in 2023—18% of total doubling the options avail- Heavy-duty electrifica- Despite the fall in volume, car sales. An increasing able in 2018. tion also surged in 2022 China still accounts for number of electric models alongside pledges from almost 85% of worldwide will hit the market, espe- Outside the three major governments to reduce sales. cially large cars and SUVs. markets, electric car sales public transport emis- This trend is happening are generally low. The sions. Governments from In India, now the world’s alongside a 2% decline in IEA highlighted a ramp up 27 nations have vowed most populous nation, ICE models from 2016- in sales in India, Thailand to achieve 100% zero electric three-wheelers and Indonesia in 2022, with the combined sales of electric cars tripling year-on-year to 80,000. India’s USD3.2 billion incentive programme is encouraging growth in EVs and component manufac- turing, with leading local vehicle manufacturer Tata Motors Limited contrib- uting more than 85% of India’s almost 50,000 BEV sales. Model availabil- ity remains an issue in emerging markets and developing economies, the IEA says. South Korea leads the pack in the development and sale of fuel cell elec- F+L Magazine Quarter Three 2023 11

2022. EV models have Photo courtesy of Hyundai Motor Co. grown 30% annually in the same period. The IEA cars exceeded USD425 tery manufacturing capac- than 95% of heavy-duty report called for original billion in 2022. ity to 2030 is “more than trucks produced in China equipment manufactur- sufficient to meet the de- employed LFP cathode ers (OEMs) to offer more Last year, Volkswa- mand implied by govern- chemistries in 2021, ac- affordable, competitively gen announced it would ment pledges.” Projected cording to the report. Over priced electric options phase out combustion car capacity indicates there is 100 gigawatt hours (GWh) outside of China. manufacturing in Europe scope for higher shares of of manufacturing capacity by 2033, two years earlier EV sales moving forward, has also been planned for The IEA has revised up- than originally announced. including a net-zero by (lithium-free) sodium-ion wards its global outlook General Motors (GM) 2050 scenario. batteries. for electric car sales to declared it would grow 2030. A Stated Policies annual capacity for EVs in A 65% increase in China is the leader in Scenario (STEPS), which North America to 1 million automotive lithium-ion battery and EV compo- is based on existing pol- in 2025, and Ford has (Li-ion) battery demand nent trade. Nevertheless, icies and firm objectives, plans to sell more than was observed in 2022. government policymak- projects electric cars will 600,000 EVs annually in Demand for lithium has ing around the world contribute 35% of new car Europe by 2026. China’s outstripped supply over is focused on building sales in 2030, compared BYD, who overtook Tesla the last two years, even resilience in EV supply to less than 25% in the as the global leader in EV considering the 180% chains. In March 2023, the 2021 report. China will sales in 2022, ceased ICE increase in production European Union proposed achieve its targeted 40% production completely in witnessed in the past five the Net-Zero Industry share by 2030 in STEPs, March 2022. The auto- years. The outlook noted Act, a key component whereas the U.S. market maker achieved an 18% the emergence of several of the European Green share will double to 20%. share of electric car sales alternatives to conven- Deal Industrial Plan. The Europe remains consis- in 2022. tional lithium-ion. Lithi- legislation includes a goal tent at 25%. The outlook um-iron-phosphate (LFP) of satisfying 90% of EV anticipates that the EV Battery supply is often chemistries achieved a re- battery demand through fleet will grow by a factor a limiting factor for EVs. cord share in 2022, driven domestic production by of eight or more by the However, the IEA report primarily by China. More 2030. end of the decade and suggests that planned bat- emphasises that the gap between stated policies and individual country targets is closing. An increase in the rate of EV adoption has implications for oil de- mand. Over five million barrels per day will be displaced by EVs by the end of the decade, with 700 Mt CO2-equivalent of avoided emissions. The IEA anticipates peak road transport oil demand will occur around 2025 based on stated policies. Investment in EV tech- nology continues to grow. 50%-70% of capex and R&D budgets of major carmakers is directed into EVs and digital technolo- gies. Spending on electric 12 F+L Magazine Quarter Three 2023

F+L Magazine Quarter Three 2023 13

No future for conventional internal combustion engine vehicles in China The production and sale oil in 2022 at 713 million Powertrain, provided de- look to influence upcom- of electric vehicles (EVs) tonnes, around 80% of tails on the development ing carbon and emissions have exploded in China which has been used in of China’s NEV market regulations, including in recent years and the the transportation sector. and the driving forces be- China VII. East Asian country now At the turn of the century, hind China’s NEV policy. accounts for more than China’s crude oil import During his presenta- half of all new electric dependency was only Song is responsible for tion at F+L Week, from cars sold worldwide. New 27.9%. Today, 71.2% of the technology roadmap a particular OEM stand- energy vehicles (NEVs) of- crude oil is imported. and product planning at point, Song discussed the fer China several environ- Geely Powertrain and has impact of purchase sub- mental benefits including The rapid adoption been tasked with ensuring sidies, tax incentives and a reduction in air pollution of NEVs in China began regulatory compliance the stringent NEV-CAFC and lower greenhouse in 2015 following the for domestic and inter- (New Energy Vehicle-Cor- gas emissions. Diver- introduction of financial national markets. He porate Average Fuel sified powertrains and subsidies nationwide. is active in government Consumption) Dual Credit fuels also enable China to During F+L Week 2023, think-tanks such as the Policy in promoting NEV improve energy security the premier annual China Automotive Tech- growth in China. Central through a reduction in its event for the fuels and nology and Research and municipal govern- reliance on foreign oil. lubricants industries in Center (CATARC), China ment subsidies on the Asia, Dr. Qingyuan Song, Association of Automobile purchase of EVs and plug- China is the number chief engineer of policy & Manufacturers (CAAM) in hybrid electric vehicles one consumer of crude regulatory affairs at Geely and China SAE, as they (PHEV) provided the initial 14 F+L Magazine Quarter Three 2023

driving force, he says. exemption will be halved CAFC Dual Credit Policy ishing the value of NEV Purchase subsidies were and capped at CNY15,000 kicked in, he says. The credits, despite increas- progressively lowered in (USD2,072). This policy policy was implemented ing difficulty in attaining recent years before being applies to battery electric on April 1, 2018, estab- NEV credits. Nonetheless, completely withdrawn at vehicles (BEV), plug-in lishing a points trading voluntary purchases the end of 2022. petrol-electric hybrids system that encouraged a of NEVs are increasing and hydrogen fuel-cell market-oriented trans- rapidly, says Song. NEVs Tax incentives have vehicles. formation of the market. have been widely accept- also motivated the uptake Automakers are required ed by the average Chinese of NEVs. The Vehicle Song shares his insight to sell a certain portion of consumer since 2020, he Purchase Tax in China is on how the Chinese auto NEVs and achieve positive says. Even cities which do 10%. However, NEVs are industry, especially do- results for CAFC. Since not offer favourable pol- exempted from this levy. mestic brands including 2019, most domestic icies on NEV purchases On June 21, China’s Minis- Geely, proactively re- brands have been well and NEV road-rights have try of Finance announced sponded to the changes in prepared and ready for demonstrated strong buy- a further CNY520-billion government policies and high volume production ing interest over the past (USD71.8 billion) package took advantage of the op- of NEVs, due to better couple of years. of tax breaks for NEVs portunities in the growth understanding of govern- over the next four years. of NEVs. The phase-down ment policies and shorter As the voluntary NEV purchases will be and subsequent remov- product development purchase of NEVs gains fully exempted from al of upfront purchase cycles. steam, PHEVs and range the tax in 2024-2025, subsidies was expected extended electric vehicles offering potential sav- to result in a sharp drop A huge supply of NEV (REEV) are emerging as ings of up to CNY30,000 in NEV sales, says Song. credits, due to the ex- the new stars and are (USD4,144) per vehicle. However, sales actually ponential growth in NEV a major driver of NEV In 2026-2027, the tax increased as the NEV- sales, is gradually dimin- growth, says Song. The Reach new heights With our MOLYVAN® Additives MOLYVAN® A MOLYVAN L MOLYVAN FEI PLUS MOLYVAN 3000 MOLYVAN 855 MOLYVAN 822 NT MOLYVAN 807 NT Multifunctional friction modi ers that provide supplemental antioxidant and anti-wear properties to your nished lubricants Vanderbilt Chemicals, LLC 30 Winfield Street, PO Box 5150, Norwalk, CT 06856-5150 • (203) 853-1400 • F: (203) 853-1452 A Wholly Owned Subsidiary of R.T. Vanderbilt Holding Company, Inc. [email protected] • www.vanderbiltchemicals.com F+L Magazine Quarter Three 2023 15 MOLYVAN is a registered trademark of Vanderbilt Chemicals, LLC.

Geely representative cited the range anxiety experi- sions standards increase Conventional ICE several advantages of enced in BEVs. Neverthe- the cost of conventional vehicles have no chance PHEVs and REEVs over less, BEVs seem to be the vehicles. Throughout the of survival in China, says the internal combustion long-term winner, says globe, countries are push- Song. The powertrain will engine (ICE), including Song. These powertrains ing for a zero CO2 emis- lose its cost advantage a favourable upfront offer a cleaner, quieter, sion fleet. For instance, over BEVs after 2025, he purchase price, lower use faster way to travel. Even- the European Union's says. The cost of battery costs and more advanced tually, they will also be “Fit-for-55” regulation material continues to fall, features. The cost ad- cheaper as more rigorous mandates zero tailpipe whereas pollution and vantage of PHEVs versus carbon dioxide (CO2) and carbon emissions by 2035 more stringent global ICEs—and hybrid electric fuel economy standards for both new cars and emissions regulations vehicles (HEV)—will con- come into effect and as vans. China VII emissions mean higher costs for tinue to expand to 2030, raw materials become regulations are anticipat- ICE vehicles. In 2030, the says Song. less expensive. ed to come into effect in expected lower battery 2027. price and low usage cost Of course, PHEVs and As a rule of thumb, will also make BEVs cost REEVs are not subject to more stringent emis- China has pledged to competitive with PHEVs. become carbon neutral by From an OEM standpoint, 2060. To fulfil this am- technology innovations to bitious target, EVs need achieve price and value to account for more than advantages are key to 50% of sales in 2030, 70% meeting the demands of in 2035—with no new tra- both consumers and gov- ditional ICE vehicle sales, ernments, says Song. and 100% of sales in 2045. Dr. Qingyuan Song Photo courtesy of Geely 16 F+L Magazine Quarter Three 2023

With IPAC, Despite the challenges of the past RELIABILITY few years, IPAC has been a steadfast presence and a consistent, reliable is never partner for our customers. We keep in short the lines of communication open, supply. so we’re always within reach. And we’re here to provide the personal service and technical expertise that help you keep your business moving. International Petroleum Products and Additives Company, Inc. 925 556 5530 ipac-inc.com F+L Magazine Quarter Three 2023 17

Closing the efficiency gap: Improving electric drive unit performance Photo courtesy of Nissan Motor Co. Thermal management is the longevity of power vehicles (HEVs) and BEVs. engine. Nagpure outlined critical in the efficient op- electronics components, Thermal management the need for low tempera- eration of battery electric enabling fast charging ture circuits (LT) for the vehicles (BEVs). Argu- and enhancing passenger is more challenging in EVs electric motor and power ably, it is more important comfort. compared to ICE vehicles, electronics, and controlla- in BEVs than in hybrid says Nagpure. An ICE ble connections between and internal combustion Dr. Shrikant C. Nagpure typically includes one LT, the battery, gearbox engine (ICE) vehicles. is an expert in EV sys- high-temperature cooling and A/C circuit. Cabin BEVs generate heat from tems. He is currently Cell circuit (HT) that considers climatisation is compli- multiple sources including and Battery head at FEV oil cooling, transmission cated in EVs by the loss the battery pack, power India Pvt Ltd, a leading cooling and air conditioning of the combustion engine electronics, electric motor engineering and digital (A/C). The presence of a heat source, he says. HEVs and onboard chargers, mobility company. Its par- heat source (the engine) require two cooling circuits yet the compact nature of ent company, FEV Group offers advantages in terms with different ranges and electric vehicle (EV) com- GmbH, is headquartered in of effectively regulating different temperatures— ponents poses challenges Aachen, Germany. During and maintaining cabin an HT circuit for ICE and LT in dissipating the heat ef- the recently completed F+L temperatures. for the electric motor and fectively. Effective thermal Week conference, held in power electronics. This management systems play Kuala Lumpur, Malaysia, BEVs also have re- adds further complexity, an essential role in max- from June 14-16, Nagpure quirements for heating says Nagpure. imising energy efficiency provided an overview of and cooling. However, the and vehicle driving range, thermal management operating temperature of In a BEV, individual aspects for hybrid electric the drivetrain is typically vehicle components have lower than a combustion 18 F+L Magazine Quarter Three 2023

differing needs for heating small but growing applica- showed a quick warming During his address, and cooling. These special tion of dielectric immersion of motor temperature. Nagpure summarised requirements can impact cooling, predominantly in However, a corresponding FEV’s approach to thermal the location of heat ex- large premium cars. The increase in oil sump tem- management and cabin changes, cooling, radiators use of refrigerants for perature was not evident climatisation. and the aerodynamics battery cooling will decline during sudden load. The of the vehicle. There are throughout the current efficiency of the EDU Thermal management many development tasks decade. decreased as the motor development must begin to understand the desired temperature increased in the early concept phase temperature ranges for Development goals in over time. of vehicle development, he the subcomponents—to BEVs not only include the says. Nagpure emphasised ensure they maintain the cooling of components to The use of innovative the importance of simula- temperature for optimal ensure they remain below manufacturing designs tion tools for development efficiency, says Nagpure. critical temperatures, and thermal management and testing. Computed-aid- but also the warming of systems has significantly ed engineering (CAE) tools, The efficiency of electric drivetrain components and improved e-drive per- including one-dimensional drive units (EDU) contin- batteries during cold start formance and efficiency. and three-dimensional ues to improve. However, or cold charging events. Second-generation (Gen computer fluid dynamics, Nagpure outlined a 10% Nagpure noted several 2) EDUs have a high level are essential for thermal efficiency gap between the temperature sensitivities of integration with a 3-in-1 management optimisation, highly operated regions of key BEV components system housing. Gen 2 he says. The process at and the peak efficiencies of determined through labo- EDUs have adopted hybrid FEV follows the standard e-drives. In a typical drive ratory testing. The variable cooling strategies with V-cycle including simula- cycle, the EDU is used results emphasise the dedicated fluids and with tion, function development, within a low/moderate contrasting thermal needs e-motor differentiation. and validation testing. efficient zone, he says. of individual components. In the next generation of EDUs, Nagpure expects Once optimal operating During his F+L Week Lay-shaft transmis- higher power densities and temperatures are known, presentation, Nagpure dis- sion efficiency is lower the possibility of a single specialised lubrication and cussed the key efficiency when the unit is cold. The cooling system. Though, heat transfer fluids are losses in the electric mo- transmission efficiency advanced solutions such as selected. Nagpure empha- tors and gearboxes. Elec- increases with load, says direct oil-cooled inverters sised the importance of un- tric motor losses largely Nagpure. Fewer churning and a split rotor EDU are derstanding the properties consist of energy loss in losses were apparent with not easy to implement, of fluids to determine the the copper windings and higher temperatures and says Nagpure. best fluids for efficiency, but the core, says Nagpure. lower fluid viscosity. Higher also for wear and tear. Copper losses are pre- fluid temperatures lead Dr. Shrikant Nagpure dominant at lower speeds to higher efficiency at all and high torque, whereas loads, he says. iron losses occur mainly at higher speeds. Losses in Electric motor spin loss the gearbox include bear- analysis was undertaken ing, meshing, churning using a demagnetized rotor and seal losses, he says. A at 40°C and 60°C. Higher portion of electrical energy spin losses were recorded loss becomes heat instead at the colder temperatures. of motive energy. However, testing of the electric motor's efficiency For battery thermal during operation indicated management, indirect higher motor temperatures cooling with water-glycol lead to lower motor effi- fluids is the most popular ciency. Nagpure empha- approach to cooling. This sised the significance of method will continue to be cooling in optimising motor the most popular meth- efficiency. od to 2030 and beyond, suggests Nagpure. The Testing of EDU (motor FEV representative noted a and gearbox) efficiency during high-load operation F+L Magazine Quarter Three 2023 19

Photo courtesy of Tesla Tesla highlights importance of system approach in fluid design U.S.-based automaker launched in 2008 followed chanical design engineer, Fremont), China (Shang- Tesla Inc. has been at the by the Model S sedan four drive system engineering hai), and Germany (Berlin). forefront of electric vehicle years later. In 2022, the at Tesla, Inc. Second-quar- The company has invested (EV) technology innovation company delivered 1.3 ter deliveries were report- heavily in its supercharg- since its inception in 2003. million vehicles across ed at 466,140, an 83% jump er network—which is a The Austin, Texas-based a growing portfolio of on the previous year and major differentiator for the company’s strong commit- high-performance, long- comfortably above market company. Currently, Tesla ment to design, perfor- range EVs. Based on deliv- expectations. operates 3,000+ super- mance and sustainability eries in Q1 and Q2, Tesla’s charging stations, which has resonated with a grow- vehicle sales are on track Tesla operates six include a total of 45,000+ ing market of environmen- to grow another 40% to factories that produce EVs, superchargers, in strategic tally conscious consumers. 50% in the current calen- solar and integrated re- locations around the globe. dar year, says Dr. Wenyang newable energy solutions The Roadster sports car, Zhang, senior staff me- across the United States Zhang leads fluid engi- Tesla’s debut model, was (Nevada, Texas, New York, neering, tribology and lu- 20 F+L Magazine Quarter Three 2023

bricant-related subjects for deavours to achieve higher termined by fluid viscosity, Dr. Wenyang Zhang all current and future Tesla efficiency without sacrific- says Zhang. Although, the platforms and is responsi- ing durability. Fluids need Tesla representative noted greater efficiency in lower ble for the determination of to maintain sufficient fluid that the breakdown of torque areas, but was less key lubrication parameters film to maintain durability, losses is dependent on the efficient in low-speed high- and designs. achieve lower friction and drive unit design and driver er torque areas, boundary maximise heat transfer behaviour. and mixed lubrication when Speaking at F+L Week in properties—by reducing compared to higher viscos- Kuala Lumpur, Malaysia, working temperature and There is an increasing ity 32 cSt fluid. Analysed on June 14, 2023, Zhang enhancing heat dissipation. push for ultra-low viscosi- alongside the lower viscos- provided an overview of Zhang emphasised the ties in the automotive sec- ity 22 cSt fluid, the Tesla Tesla’s state-of-the-art importance of appropriate tor that allow fluids to flow formulation exhibited high cooling and lubrication of base stock and additive with greater ease. Howev- efficiency in higher torque drive units and the com- selection, balancing and er, Zhang questioned the and lower speed areas, yet pany’s vision for future optimising viscosity, low appropriateness of this lower efficiency in lower development. elastohydrodynamic (EHD) approach. Individual drive torque areas. Rather than a traction and extended fluid unit components can cover singular focus on lower- Unsurprisingly, Tesla’s stability. a wide range of lubrication ing viscosity, we need to every move is monitored conditions. It is extremely optimise for different drive very closely by the mar- Zhang provided a risky to go to lower viscosi- units and drivers, says ket due to the potential breakdown of the energy ty fluids without systematic Zhang. By taking a sys- for it to shape the future efficiency of one of Tes- understanding, simula- tematic approach in fluid of transportation and la’s existing vehicles and tions, and trials, he says. design and computer simu- renewable energy. Tesla’s drive units. ~10% of total lation, with even slightly in- continuous advancements vehicle loss comes from Zhang outlined the creased fluid viscosity, KAF in EV technology, such as the electric motor, whereas results of an efficiency I demonstrated close to 1% longer-range batteries and only ~4% is contributed comparison of various energy efficiency increase faster charging capabil- by the gearbox, he says. fluid viscosities, comparing of the vehicle compared to ities, and innovations in Within the gearbox losses, them to Tesla’s existing the last generation of Tesla autonomous driving tech- ~87% are torque depen- KAF I fluid. The KAF I fluid, which is significant nology have garnered sig- dent with the balance formulation was employed considering only ~4% of the nificant attention. However, from torque-indepen- in the fourth generation of accountable total loss. there is also great interest dent parasitic loss. Fluid Tesla’s drive units in 2022. in Tesla’s efforts from a formulation dominates Testing analysed gearbox Many automakers look tribological standpoint. torque-dependent loss efficiency and evaluated to combine lower fluid and viscosity contributes the performance of KAF I During his presentation, to parasitic loss. Only ~13% to 32 cSt fluid and 22 cSt Zhang highlighted Tesla’s of gearbox losses are de- fluid, as an example. key fluid design consider- ations as the company en- KAF I demonstrated Photo courtesy of Tesla F+L Magazine Quarter Three 2023 21

Photo courtesy of Tesla viscosity with cost-ef- with our additive partners, unit challenges includ- ment, gear life reduction, fective raw materials to including fluid viscosity ing electrically induced scuffing, and NVH (noise, further achieve cooling optimisation and mechani- bearing damage (EIBD) vibration and harshness) efficiency, energy effi- cal design, he says. Based and bearing creep. EIBD is issues. Axial wear can ciency, and to realise an on the early findings of a result of an induced volt- increase clunk due to addi- appropriate build cost. various formulations, Tesla age in the rotor shaft of a tional motion in the shafts. Such an approach does encourages petroleum and motor. Poor protection can There are solutions for not necessarily lower chemical companies to result in heavy frosting bearing creep. However, the overall system cost work on new base oil mole- and fluting. Tesla is inter- Zhang outlined investiga- when you factor in vehicle cules which could further ested in new grounding tions into the impact of fluid lifetime performance, enhance energy efficiency, solutions to mitigate EIBD, formulations to understand maintenance and overall for the next generation he says. if they can provide further energy cost, says Zhang. fluid formulation, KAF II. mitigation. When it comes to solv- A significant amount of ing the complexity of EV Zhang’s presentation radial wear on aluminium lubrication and lubricant also outlined several drive can lead to gear misalign- design, Tesla is open to considering various types Photo courtesy of Tesla and costs of raw mate- rials. It is not the game of fluid cost—but system cost and performance, he says. During his presentation, Zhang outlined upcoming changes to Tesla’s lubrica- tion and cooling designs. We are working on future fluid form optimisation 22 F+L Magazine Quarter Three 2023

Quartz EV-Battery is a range of dielectric fluids specifically designed for lithium battery immersion cooling technology, These fluids o er a high level of cooling performance allowing the cells to accept high charge currents and reduce the risk of thermal runaway propagation of a lithium battery. Thermo-Control Augmented technology is designed to allow the battery to maintain an optimal temperature throughout its usage, ensuring maximum battery e ciency. F+L Magazliunbe riQcuaanrttesr.tTohtraelee2n0e2r3gi2e3s.com

EU Green Claims’ Directive: Cutting through the climate jargon There is a bewildering vide their company with a pressure to communicate Affaire à Tous filed a law- array of “green” claims competitive advantage. the efforts they are mak- suit against the country's from companies around ing to clean up their supply largest energy company the world that profess the However, an expanding chains. But sometimes in the Paris Judicial Court environmentally beneficial number of climate pledg- the rhetoric doesn’t match over what it says are qualities or characteristics es tout vague product the reality and falsely misleading claims around of individual products or attributes with limited promoting environmental its efforts to fight climate their company. Pledges accompanying information measures is becoming a change. such as environmentally to legitimise their claims. considerable legal risk friendly, eco-friendly, Claims can be difficult for organisations. Over In 2021, The Forest green, carbon-neutral, to verify and are often the past couple of years, Litigation Collaborative climate-neutral, biobased, confusing for consum- several non-governmen- lodged a complaint with biodegradable, conscious, ers. In some instances, tal organisations (NGOs) the OECD regarding Drax responsible and net-zero claims are simply “gre- have taken matters into Group plc, a wood-burn- seek to create an impres- enwashing”—deliberately their own hands, forcing ing electricity generator sion of an ethical company misleading or deceptive companies to defend what, in the United Kingdom, doing their utmost to pro- information is provided to they say, are questionable over claims they generate tect our environment. present an environmen- climate pledges in the “carbon-neutral” electric- tally responsible public courtroom. ity. The NGO suggests the Companies have rec- image. Fraudulent claims burning of woody bio- ognised that customers that deceive consumers In France, TotalEner- mass emits more carbon want climate action. Mar- and investors undermine gies’ net-zero marketing emissions per unit of final keting departments have efforts to mitigate climate has come under fire. In energy than burning coal. also learned that putting change. March 2022, Greenpeace Environmental Action their climate credentials France, Friends of the Germany (DUH) is also front-and-centre can pro- There is no doubt that Earth France and Notre acting against BP Europa companies are under 24 F+L Magazine Quarter Three 2023

SE and Shell Deutschland Commission (FTC) recently that protect the interests devices to cheat official GmbH over the advertis- published a proposal on of consumers, the Unfair emissions testing, is ing of certain products as changes to Green Guides Commercial Practices Di- perhaps one of the most carbon or CO2-neutral. for the Use of Environmen- rective 2005/29/EC and the high-profile examples. The outcome of these tal Claims. The update was Consumer Rights Directive During open public con- landmark cases may have presented on December 2011/83/EU. The changes sultation for the EU Green a significant impact on 14, 2022, with the public are broadly in line with the Claims Directive, reli- future climate claims in comment period ending on U.S. proposal. ability of environmental advertising. April 24, 2023— following claims about products was an earlier extension. Oftentimes rulemaking, recognised as the pre- The European Commis- monitoring, enforcement eminent obstacle to more sion conducted a study in Now, the European and remediation occurs sustainable consumption 2020 where it determined Union (EU) is looking to faster in a competitive, behaviour. that 53.3% of environmen- step up its response to self-regulating market tal claims about charac- confusing climate jar- than by government Individual countries teristics of the products gon. After several ear- regulation. When it comes in Europe have differing assessed provided vague, lier postponements, the to sustainability, this does regulations around green misleading and unfounded European Commission not appear to be the case. claims. The directive information. Many juris- published its proposal for The “dieselgate” scandal should provide greater dictions are now beginning a Directive of the Europe- that erupted around eight consistency across the to up their regulatory an Parliament and of the years ago, where the European bloc and ad- game to combat false Council on Green Claims Volkswagen Group misled dress the growing issue of green claims. (The Directive) on March consumers by claiming greenwashing by forcing 22, 2023. The Directive environmentally friendly companies to substantiate As previously reported delivers an amendment features of diesel-pow- their claims. The Europe- in F+L Magazine, the Unit- of two existing directives ered vehicles while fitting an Commission says it will ed States Federal Trade F+L Magazine Quarter Three 2023 25

provide better protection the commission. Compa- advertising benefits to EU member-states will against unfair practices nies leading the field in consumers that are con- be required to establish and help accelerate the terms of real environmen- sidered common practice independent verification green transition. tal performance should in a relevant market are and enforcement process- come to the fore, they say. forbidden and the use es. Direct penalties for It was initially anticipat- of sustainability labels non-compliance under the ed that the EU would pro- The proposal is de- that are not based on a directive could be up to 4% pose regulation that would signed to prevent mislead- certification scheme or of annual turnover, legal be immediately enforce- ing claims or greenwash- not established by public investigations and the able as law in all member ing, and applies to green authorities is prohibited. potential exclusion from states. Instead, a directive claims whether they imply public procurement for up establishes a goal which a positive environmental Generic environmental to a year. member nations must impact, lesser negative claims in marketing are achieve—with responsibil- impact or no impact. Early banned where they cannot Most see this as a signif- ity falling on the member obsolescence practices, be demonstrated in accor- icant step forward in ad- states to translate it or the premature failure of dance with Regulation (EC) dressing unclear climate into national legislation. goods, and the use of un- 66/2010 (the EU Ecola- jargon and the deliberate Commentators have noted reliable and non-transpar- bel), officially recognised misleading of consumers, that this may cause slight ent sustainability labels eco-labelling schemes in though there has been variances in green claims and information tools are the member states, or oth- criticism of the directive throughout the EU. also targeted. Companies er applicable union laws. in some corners. The with fewer than 10 employ- commission did not stip- The directive will force ees and less than EUR2 Making environmen- ulate a single methodol- companies to substanti- million (USD2.18 million) tal claims about entire ogy to substantiate green ate their environmental turnover are exempt from products when it only claims, despite the recent claims against standard the directive. concerns a specific aspect development of the EU methodologies. Under the of a product are no longer Product and Organisation proposal, companies are Specific requirements permitted and there is a Environmental Footprint obliged to provide more include information on the ban on presenting require- (PEF and PEO) methods information to consumers existence and length of a ments imposed by law on by the Commission's Joint to assist with purchasing producer’s commercial products as a distinctive Research Centre. decisions. The directive guarantee of durability feature. Product compar- is likely to result in fewer, and on the reparability isons are only permitted PEF and PEO are de- more specific claims, says of products. Companies if information is provided signed to help companies around the method of the determine environmental comparison, the products performance based on and suppliers covered. verifiable and comparable The commission expects information. However, the the bans on environmental analysis tools do not yet claims used in market- cover all relevant impact ing to bring significant categories and product benefits to consumers types. Several NGO have while limiting the burden criticised the failure to on traders. impose an EU-wide meth- od—warning that green The directive also claims will not be compa- addresses environmental rable. labelling schemes which it says must be transparent, The directive is currently verified by a third party, undergoing the regular and regularly reviewed. legislative process with EU-level schemes should the European Parlia- be encouraged, and new ment and member-state public schemes that are governments in the EU not developed at an EU Council working to estab- level are not permitted. lish their positions before Restrictions also exist on undertaking joint negotia- private schemes. tions. 26 F+L Magazine Quarter Three 2023

To find the perfect additives we have experimented a lot. So that you don’t have to. • preformulated aluminium complex As Europe’s largest and most flexible grease thickeners that meet the latest manufacturer we also provide: performance requirements to produce high quality industrial greases for general formulation and logistics and food industry applications with NSF support; HX-1, Kosher and Halal approvals laboratory tests; toll blending; • additive components for flexible production. lubricant manufacturers F+L Magazine Quarter Three 2023 27 • selective additives for special applications komadadditive.com

Polyurea greases may offer advantages for electric vehicles Demand for electric Upheaval in the develop- Formed in 1975, El- mulations against quality vehicles (EVs) is already ment and market share of don’s Lubricants is one parameters. strong and the explosive several types of lubricants of the largest production growth of these alternative is inevitable. However, and trading companies The importance of mini- powertrains is expected not all lubricants will be in Greece. The company mum electrical properties to continue. About 70% negatively impacted. An in- manufactures a full range in greases throughout the of the global stock of crease in the demand and of conventional and syn- lubricant lifetime was em- electric cars in 2022 were importance of lubricating thetic lubricants, greases phasised including electric battery electric vehicles greases for electric mo- and special products. conductivity/resistivity and (BEVs), according to Paris, tors is anticipated along- dielectric strength—due France-based Internation- side the EV and hybrid Dodos presented A to proximity to electric al Energy Agency (IEA). vehicle (HV) evolution, says Study on the Performance currents and electromag- BEVs do not require en- Dr. George Dodos, a chem- of Lubricating Greases netic fields. Inadequate gine oil and their growing ical engineer at Eldon’s Lu- for Electric and Hybrid electrical properties can adoption is set to have a bricants in Athens, Greece. Vehicle Applications at the cause electrical discharge significant impact on the Lubricating greases will SAE Powertrains, Fuels damage which can eventu- automotive lubricants continue to be used in & Lubricants Conference ally lead to bearing failures market. The IEA’s Global chassis and wheel-bearing & Exhibition in Krakow, in the form of frosting, flut- EV Outlook 2023 predicts applications but especially Poland, held from Sep- ing and/or micro craters, that oil demand from road in the case of electric mo- tember 6-8, 2022. The says Dodos. The research transport will peak around tor applications, they will technical paper discusses mentioned the influence 2025, based on announced require new design criteria the development trends for of base oil selection on policies from govern- to address the challenges greases in EVs/HVs and electric properties and the ments. posed by EVs. assesses the performance potential adjustment using of a series of grease for- additives. Currently, there 28 F+L Magazine Quarter Three 2023

is no standardised method more than 25%. and leakage tendency Dr. George S. Dodos for measuring the electric The SAE paper outlined (ASTM D1263)—which was properties of greases, he followed by a change in The PAO-based formu- says. several advantages of the consistency—(ASTM lations demonstrated a polyurea greases including D1403) and antiwear reasonably high oxidation The roar of an internal oxidative and shear sta- properties (ASTM D2266). stability, although it is the combustion engine (ICE) bility, low noise charac- Copper corrosion was “considerably elevated” in- will usually mask any teristics, water resistance assessed using a stan- duction period of the polyol minor creaks and rattles and low-temperature dard test method (ASTM ester-based grease that is during vehicle operation. performance. Although, D4048) and an in-house indicative of the potential of With the quieter nature challenges were identified method was developed to this base oil type, says Do- of EVs, noises stemming relating to production and determine noise-damping dos. He also highlighted a from the contact of surfac- a limited compatibility characteristics. Electric possible synergistic effect es can become more ob- with additives and other properties were tested of POE with the polyurea vious. Dodos emphasised thickeners. first via the measurement thickener. Low oxidative the rising importance of conductivity and the resistance was shown of the noise-damping The research assessed breakdown voltage of the in the PAG formulation characteristics of greases. a series of lubricating base oils with subsequent compared to the rest of the Greases also need to be grease formulations based data analysis on the break- polyurea greases. thermally stable under a on polyurea thickener down voltage of the grease wide temperature range, chemistry. The formula- formulations. Leakage could cause with the ability to with- tions excluded additives to premature deterioration of stand sudden and multiple restrict the results to the The results of the study bearings and can contam- thermal shocks and tem- performance of the base confirmed the advan- inate the environment. perature gradients. oil. Greases were formu- tageous performance The research stressed the lated using three kinds of of polyurea thickener strong reputation of poly- Energy savings is anoth- base oils—polyalphaolefin systems in EV applications. urea thickened greases in er key design parameter (PAO), polyalkylene glycol to support higher mileage (PAG) and polyolester Relatively high dropping ranges. The paper not- (POE). Each grease had a point values of above 250 ed EV motor speed can similar ISO viscosity grade degrees Celsius were be two-fold higher than with a slight variance in observed in all samples. conventional high-speed thickener content. For- Dropping point refers thresholds and outlined mulations were finished to the temperature at the role of low viscosity to National Lubricating which the grease loses greases in EV/HEV appli- Grease Institute (NLGI) its structural integrity. cations in reducing bearing Grade 2—a widely used The POE-based polyurea torque for better mileage. lubricating grease consis- greases demonstrated tency. considerably higher drop- Thickener chemis- ping points. tries impart a semi-solid Low-viscosity PAOs consistency to greases. and PAGs are readily Photo courtesy of Eldon's Lubricants A variety of soap and biodegradable. Dodos non-soap thickeners are emphasised the potential available—which include sustainability benefits of lithium complex grease, premium renewable base calcium sulfonate greas- oils, such as tailor-made es and polyurea formu- oleochemical esters, in EV lations. Approximately grease formulations. 5-6% of the global grease market uses polyurea The research reviewed formulations, with its grease performance share expected to grow as against multiple quality polyurea is increasingly parameters including favoured in electric motor dropping point (ASTM applications. In Japan, the D2265), evaporation loss polyurea market share is (ASTM D972), oil sep- already much higher, at aration (ASTM D6184), oxidation (ASTM D8206), F+L Magazine Quarter Three 2023 29

leakage tendency, which is observed during testing, noise damping charac- tric strength of the base why they are often used in which Dodos notes is teristics, Dodos noted the oil, says Dodos. automotive wheel bear- typical for polyurea thick- PAO and PAG greases ings. Grease formulated eners. provided relatively quieter In a continuation of this with PAOs displayed the operation of leakage project, the cold flow prop- least mass separation, Efficient wear prevention tendency equipment com- erties of these three poly- whereas the POE formula- properties were demon- pared to the POE-based urea grease formulations tion had a higher tendency strated in the four-ball formulation. are investigated, since to overflow from the bulk wear test for all formu- this is also an important grease. However, Dodos lations, even considering The POE and PAG base parameter for EV appli- noted that all results are the absence of additives in oils possessed a high- cations. The preliminary within the repeatability of the designs. The exper- er dielectric strength results obtained by DIN the method. iment also verified that compared to PAO base oil, 51805, a test method that the selected base oils did which was comparable to tests the flow of greas- Base oil evaporation not negatively affect the a typical transformer oil. es at low temperatures, can impact grease life in corrosiveness of the final The analysis indicated that show that at -30oC the flow rolling bearings. Despite formulated grease and the selected base oils are pressure of all greases is the low viscosity of the none were characterised all appropriate for greases satisfactory, being below base oils, evaporation loss as corrosive to copper. requiring medium-volume the threshold of 1000 mbar. at 100 degrees Celsius was The pro-oxidant activity of resistivity as they are nei- At lower temperatures, found to be lower than copper was also evaluated, ther purely conductive or the presence of PAO or 0.5% in all cases. Oil sep- showing that all formula- insulating materials. PAG appears to be more aration tests measure the tions are efficient against beneficial. A more detailed inclination of the lubricat- the catalytic activity, with Results from the grease report of this work will be ing grease to separate at PAO and PAG greases electric properties slightly available later this year. high or low temperatures being the least affected. contradict the base oil during storage or normal results. The PAO- and The development of operation. A satisfactory While no statistical POE- based greases specific specifications and oil release tendency was significance was found offered similar dielectric standardised test methods between the greases on strength that could meet within the grease industry the requirements for an is critical, particularly elevated behaviour in this when it comes to the elec- parameter, says Dodos. tric protocols of greases However, the breakdown for EV applications. Collab- voltage of the PAG-based oration between original grease was substantially equipment manufacturers lower and regularly below (OEMs) and the grease the detection threshold of industry is essential to 10 kV. Further investigation ensure formulations that of this finding is recom- meet the evolving de- mended, as the behaviour mands of a rapidly growing is at odds with the dielec- EV market. 30 F+L Magazine Quarter Three 2023

We are on a mission to find new colleagues! Are you one of them? • Join an International Trading Company with 15+ years of expertise and reputation. • During your training, you will be fully supported by our global team. Bring your experience, as you are, and we’ll teach you the rest. • We guarantee competitive salary, flexible working, extensive travel, and an amazing team in which to grow! shamrockoils.com Shamrock Oils CYPRUS I UAE E [email protected] Your one stop shop in the Lubricants Industry F+L Magazine Quarter Three 2023 31

Photo courtesy of BMW Hydrogen: The Swiss Army Knife of energy sources A whole suite of technol- zero emissions by 2050. transportation, heating, always be the best option ogies is needed to de- Hydrogen contains no car- electricity generation and for the job, she says. carbonise the planet and bon and is one of the few industry. Angel Wileman, achieve the goals of the large, long-term energy manager of Thermofluids Wileman delivered the 2015 Paris Accord. Hydro- storage options. at Southwest Research keynote address on the gen is the most abundant Institute (SwRI) and a future of hydrogen entitled molecule in the world and Today, hydrogen is self-proclaimed hydrogen Hydrogen is Here. Are we is emerging as an import- commonly used as a enthusiast, characterises ready? during the STLE ant energy solution. The catalyst in oil refining, hydrogen as the Swiss Annual Meeting in Long chemical element will ammonia and methanol Army Knife of energy Beach, California, U.S.A., aid individual countries production. It has broad sources. It can do every- from May 21-25, 2023. in their bid to achieve net future applications as a thing, although it might not Wileman joined Southwest clean energy source in Research Institute in San 32 F+L Magazine Quarter Three 2023

Antonio, Texas, U.S.A., successful advancements The hydrogen hubs aim Angel Wileman in 2011 and is focused on in battery technology— to overcome the difficulty researching alternative which solved many energy of transporting hydrogen are attempting to design energy and trying to un- storage challenges, and with the creation of cen- equipment that can handle derstand water resources the perfection of hydrau- tres for generating and us- extremely high pressure. and hydrogen. lic fracturing enabling ing hydrogen in the same Efforts to advance sealing access to vast natural gas location. Applications to mechanisms and other Hydrogen emerged resources. The United develop the hubs closed technologies to make in the transportation States went from not on April 7, 2023, with compression more reli- sphere as early as 2005, having enough natural gas requests received from able are ongoing. with BMW undertaking to so much that it began throughout the country— limited production of the exporting it. primarily around ports SwRI designed a linear BMW Hydrogen 7 from and industrial regions. motor reciprocating 2005-2007. The German The pendulum is compressor (LMRC) to automobile manufactur- swinging back to hydro- Wileman noted that compress hydrogen as er’s revolutionary vehi- gen again, says Wileman. the current approach to a fuel source in hydro- cle burned hydrogen in The significant ramp-up develop hydrogen does not gen-powered cars. LMRC the internal combustion in funding of hydrogen follow a typical pattern of applies dynamic seals that engine (ICE). At the time, can be seen by comparing supply and demand. The are hermetically sealed significant government the U.S. Department of government is investing in to prevent leakage and al- funding was available, Energy’s (DOE) investment generation, end-use appli- lows increased compres- fuelling research efforts of USD280 million with cations and infrastructure. sion efficiency. Wileman in material science and last year’s announcement This means that the entire anticipates greater re- energy storage. of around USD8 billion for spectrum of hydrogen is search into understanding hydrogen technology and “ripe for research,” she the interaction of hydro- Almost as soon as it infrastructure as part of says. The real demand gen with materials, wear arrived, the hype around the Bipartisan Infrastruc- driver is the need to patterns and lubricant hydrogen was gone again. ture Law signed by U.S. decarbonise the economy, requirements. “It sort of faded into President Joseph Biden. she says. oblivion,” says Wileman. Most of the funding is Vehicles powered by The thermal fluids system directed into a regional The clean combustion hydrogen still require engineer attributed the network of “hydrogen of hydrogen offers many significant lubrication. near disappearance of hubs.” benefits, but there are However, Wileman noted hydrogen research to major technical chal- that hydrogen is an lenges that need to be extremely dry fuel and addressed. Hydrogen is a can cause problems with very energy-dense fuel by friction and wear. The weight, but not by volume, small molecules can also and therefore needs to be easily permeate materials. stored at extremely high A further obstacle is that pressures of up to 10,000 lubricants do not mix well pounds per square inch with the by-product of hy- (psi), or 700 bar. This is a drogen combustion, water, serious challenge, says and further research is Wileman. The physical required in this area, she characteristics also make says. it difficult to move around. Almost four times as Hydrogen is an explo- much power is required to sive material and concern shift hydrogen via pipe- lines, she says. Hydrogen “does not play nicely with materi- als,” says Wileman, with components sometimes cracking in the presence of hydrogen. Researchers F+L Magazine Quarter Three 2023 33

around safety is prevalent Photo courtesy of SwRI es, according to Paris, market by 2030, as of April during hydrogen combus- France-based Internation- 2023 there were only 60 tion. Wileman emphasised The first initiative, an- al Energy Agency (IEA). public hydrogen refuelling the need to watch for nounced on June 7, 2021, stations in the entire Unit- auto-ignition or pre-igni- aims to reduce the cost of Trying to clean up this ed States—59 in California tion and outlined the role of clean hydrogen by 80% by process is a key challenge and one in Hawaii. computational modelling the end of the decade and for the industry, says Wile- in deploying hydrogen on a to accelerate demand. man. Methane pyrolysis is Funding is important large scale—to understand a promising new approach for advancing technology, the potential impacts of Green hydrogen is that involves the thermal but what really changes accidental explosion. produced by running an breakdown of methane behaviour is regulation, electrical current across into hydrogen gas and says Wileman. The SwRI Cost is a significant bar- water to split it into H2 and solid carbon that can be representative believes rier to the uptake of clean O2. Hydrogen can also be used to make things like two recent regulations hydrogen. The DOE has produced via fossil fuels carbon fibre. Investiga- from the California Air established the Energy with natural gas using tions into how to scale up Resources Board (CARB) Earthshots Initiative to steam methane reforming this process are ongoing, will have a notable impact deliver more abundant, and from coal gasification she says. on hydrogen advancement affordable and reliable and oil. Currently, less in the U.S— the In-Use clean energy solutions. than 1% of global hydrogen It is generally acknowl- Locomotive Rule, passed production comes from edged that hydrogen will on April 27, 2023, and the renewable energy sourc- be an important part Advanced Clean Fleets of our decarbonisation rule, which was passed a journey. However, ques- day later. tions remain about exactly what role it will play. It is The In-Use Locomo- not a silver bullet, says tive Rule aims to reduce Wileman. The reality is emissions from all switch, it will play a supporting passenger, industrial and role, with a smaller overall freight line haul locomo- impact than behaviour tives, whereas the Ad- change and reductions in vanced Clean Fleets Rule demand, she says. puts an end to combustion truck sales in California in The DOE hydrogen road- 2036. Heavy-duty trucks map indicates that 90% of account for 6% of the traf- hydrogen use in 2021 was fic on California roads but refining related (ammonia, a quarter of greenhouse metals and chemicals). gas emissions. Trains are However, there is a slow worse. One train produces transition to making syn- more nitrous oxide and thetic fuels and upgrading diesel particulate than biomass. The SwRI repre- 400 heavy-duty trucks, sentative also highlighted according to CARB. immediate plans to blend up to 20% hydrogen into Despite its application in natural gas pipelines in California, the new regula- some areas of California. tion will have a significant knock-on impact for the Wileman believes the rest of the U.S. Currently, best applications for hy- 40% of imported goods drogen are in the hard-to- arrive in California and abate heavy-duty trans- are distributed to the rest portation and long-term of the U.S. Decarbonised energy storage sectors. trade routes from Los While some forecasts Angeles will start to filter suggest hydrogen fuel throughout the entire cell electric vehicles will country. become a USD40 billion 34 F+L Magazine Quarter Three 2023

A co-branded event STLE Tribology Frontiers Conference Learn about the technical, environmental and social issues impacting tribology research in the 21st Century. Conference Highlights: • Daily keynote presentations • Invited “Spotlight” talks by noted principal investigators • Artificial intelligence (AI) and machine learning in tribology session • Graduate, undergraduate and early career researcher poster competition • “Beyond the Cutting Edge” special symposium (organized by the editors of Tribology Letters) STLE Tribology & Lubrication for E-Mobility Conference Explore the latest technical challenges and opportunities impacting the future of electric vehicle technology. Conference Highlights: • Expert-led presentations from leading companies and organizations with an interest in e-mobility • Panel discussions on state-of-the-art developments in electric vehicle technology and lubrication • Networking opportunities Sponsorship Opportunities: Ensure your company has a presence at one or both of these cutting-edge conferences! Separate sponsorship activities and combination packages are available to demonstrate support and garner huge exposure. Contact STLE national sales manager Tracy VanEe at (847) 430-6767 or at [email protected] for details. For more information and program updates, visit www.stle.org/joint. Society of Tribologists and Lubrication Engineers 840 Busse Highway, Park Ridge, Illinois 60068 (USA) P: (847) 825-5536 | F: (847) 825-1456 | www.stle.org | [email protected] Follow us on: F+L Magazine Quarter Three 2023 35

Alternative fuels for Fueling heavy-duty heavy-duty off-road off-road vehicles is a far applications are ready now more complex exercise than powering personal transportation. Unlike on the road, heavy-duty off- road vehicles don’t “cruise” and fuel at the site. They are engaged in rugged applications, often with strong vibrations, heavy loads and high torques. The vehicles must contend with dirt and contamina- tion, and durability and reliability are of utmost importance. Transitioning these vehicles to more sustainable, alternative fu- els pose many challenges for engine designers. Hind Abi-Akar is senior advisor to the Electrifica- tion and Energy Solutions division at Caterpillar Inc., the world's largest man- ufacturer of construction equipment based in Irving, Texas, U.S.A.. Abi-Akar holds a PhD in Materials Science based on elec- trochemistry and sur- face science. During F+L Week 2023, held in Kuala Lumpur, Malaysia from June 14-16, Abi-Akar dis- cussed Fueling Heavy Duty Applications for Energy Transition. In her presen- tation, Abi-Akar outlined several key engine design considerations relating to alternative fuels. We focus on the [fuel] availability, says Abi-Akar. Equipment can operate in incredibly remote areas, making transportation of fuels to the work site difficult. If alternative fuels have low energy not only does this mean carrying more fuel, but it also impacts work time. Fueling and maintenance 36 F+L Magazine Quarter Three 2023

such as filter changes Dr. Hind Abi-Akar ammonia, methanol and particular low carbon are rigorously scheduled. hydrogen autoignition tem- fuel, but in most regions “Downtime is costly,” says alternative fuels on service peratures are much higher, alternative fuel volumes Abi-Akar. intervals also need to be potentially requiring spark are low or non-existent. considered, she says. ignition. This is a major Capacity is growing, but Various low carbon fuel change, says Abi-Akar. constraints can impact options were discussed. There are several the price, says Abi-Akar. The factors that impact important factors relating Flame characteristics Currently subsidies are the selection of these fuels to the combustion of new are also noteworthy. Sig- important for the final cost were highlighted. Energy fuels, including the auto- nificant differences exist of alternative fuels. Costs, content of the fuels was ignition temperature and between H2 and ammonia and supply impact the total one key factor. The storage its relativity to diesel fuels. for example. Hydrogen is cost of ownership. This volumes of renewable die- Changes to autoignition fast burning compared to is a big consideration for sel, or hydrotreated vege- dictate whether a com- diesel fuel, which means Caterpillar and heavy-duty table oil (HVO), and biodies- pression ignition engine is it can exceed pressure machines’ customers, she el are relatively similar. appropriate or if the engine limits, says Abi-Akar. On says. HVO’s storage volume is design needs to employ the other hand, ammonia is 1.04 times the equivalent of spark ignition— which slower burning, favouring During her presentation, diesel energy and biodiesel is not common in diesel lower engine speeds. This, Abi-Akar discussed a vari- is 1.1 times. However, meth- engines. Dimethyl ether however, can result in un- ety of low-carbon intensity anol requires 2.3 times (DME), a synthetically pro- burnt fuel—a challenge in a fuel options. Biodiesel and the storage volume. This duced alternative to diesel combustion environment. HVO can be implemented is a huge consideration, fuel, has a similar autoigni- at any time and are misci- says Abi-Akar. Hydrogen tion to diesel fuel, whereas There are conflicting ble with diesel at any blend (H2) requires 10 times views around the likely level. Caterpillar has been the volume—at very high time frame for decarbonis- using biodiesel since the pressures—and requires a ing the heavy-duty sector. late 1990s, although she different level of expertise “In our experience, some concedes it requires more for handling. The ability of these fuels are ready management and handling to transport and store a now,” says Abi-Akar. “We than HVO. Caterpillar has particular alternative fuel encourage our custom- certain models that allow dictate its use in the appro- ers to use them,” she blends of up to B100, which priate application. says. However, there are tend to be in the lower concerns about fuel supply. regulated engine models. Abi-Akar also high- In some areas, there can If aftertreatment is used, lighted the importance of be plentiful supply of a materials compatibility of alternative fuels, which can influence component design—such as elasto- mers, hoses and engine components. Maintenance is critical in fluid tech- nology and the impact of F+L Magazine Quarter Three 2023 37

then blends are limited to Methanol allows liquid couple established power Abi-Akar also underlined B20, she says. Abi-Akar storage in standard con- sources with new technol- customers’ concerns about also noted the potential ditions and offers similar ogies, including electric the impact of alternative role of synthetics. E-die- handling to gasoline. It and hybrid powertrains fuel use on equipment sel is an excellent drop-in is also relatively ener- and the use of electric warranties. The Caterpillar solution that can operate at gy dense, compared to drive transmissions with representative reassured any blend level up to 100%. hydrogen and batteries, power components. The participants that the use of with multiple paths to equipment manufacturer consumables, including fu- Results of testing on renewable production. is integrating renewable els, do not void warranties. HVO using the Caterpillar Methanol is widely avail- energy sources into elec- However, Caterpillar, and 3MWe genset were dis- able today as a commodity tric power systems, with in general OEMs, warrant cussed. A slight reduction chemical and can offer a Abi-Akar noting the role of workmanship and materi- in full power and transient low environmental impact small-scale independent als and not issues resulting response was observed due to its biodegradability. power grids (microgrids) from the use of consum- compared to diesel fuel. However, existing feed- to bring solutions to the ables, she says. HVO demonstrated half the stock is natural gas or coal, customer. smoke opacity on tran- requiring a shift to biomass Finally, Caterpillar sients, and similar nitrogen and excess renewable detailed efforts to replace oxide (NOx) levels, with a electricity moving forward. established power sourc- slight reduction at lower Abi-Akar outlined various es with batteries, stored loads. NOx emissions can fuel injection strategies to electrical energy, fuel cells vary depending on the load, allow use of methanol in and renewable hydrogen says Abi-Akar. heavy duty engines. fuel. However, Abi-Akar emphasised that there is Abi-Akar also outlined As part of its commit- not one single solution. Caterpillar’s expanding H2 ment to sustainability, A variety of solutions and capabilities. Using dynamic Caterpillar is investing in a lower carbon intensity gas blending technology, range of advanced power fuels are needed based Caterpillar engines can technology options, says on differing applications, burn a wide range of fuels/ Abi-Akar. An increasing regions, and availability. H2 blends. The G3516H en- use of low-carbon intensity There will be challenges in gine is currently available fuel and hydrogen blends is infrastructure, distribution as a 100% hydrogen-ca- being used in existing field and customer education, pable demonstrator. The assets to make them more she says, calling on various company is focused on efficient and fuel flexible. stakeholders for high level quickly expanding its H2 There are also efforts to of collaboration. capabilities, she says. 38 F+L Magazine Quarter Three 2023

WHERE CONNECTIONS ARE BUILT AOLACCSTVTNSEOOGEAWBSM!ECRAORENSGVHI3ESN1OTT—EWIORNN.ECCAOEROVNLTMYEERF/MO•RRBLEATESGHRVEIESBG3EAT,SSE,T2NRP0ERV2AICD3EA F+L Magazine Quarter Three 2023 39

Personalised advertising solutions for every business Every business is unique. From cutting-edge startups to Contact us today to discuss established enterprises, each has its own identity, goals, your advertising goals! and target audience. So why would you settle for a cookie- cutter advertising approach? At F&L Asia Ltd we pride ourselves on crafting personalised advertising solutions that cater to your specific needs, enabling your business to unlock its true potential. PRINT DIGITAL EMAIL PODCAST EVENTS Reach your target audience with precision and impact.