14 Analytical Instrumentation
FUTURE TRENDS IN FUELS AND LUBRICANTS TESTING - PREPARE FOR THE CHALLENGES
Future trends in fuels and lubricants testing - prepare for the challenges
The future of fuels and lubricants will be driven by sustainable development goals that includes e-mobility, sustainable biofuels and alternate energy sources. In this emerging landscape, laboratory testing is undergoing a transformation to enable product development and better quality control. The key challenges within these industries will be the development and standardization of test methods for e-lubricants and better precision in lubricity measurement of sustainable fuels.
The future of fuels and lubricants will be driven by sustainable development goals that includes e-mobility, sustainable biofuels and alternate energy sources. In this emerging landscape, laboratory testing is undergoing a transformation to enable product development and better quality control. The key challenges within these industries will be the development and standardization of test methods for e-lubricants and better precision in lubricity measurement of sustainable fuels.
AI enabled tools for accurate and precise fuel AI enabled tools for accurate and precise fuel lubricity measurement
Renewable sources for producing diesel fuel include vegetable oils, waste cooking oils and animal fats among others sources. The second generation of Hydrotreated Vegetable Oils (HVO) have overcome the disadvantages associated with of FAME (fatty acid methyl esters) such as increased NOX emission and poor cold operability. HVOs (EN 15940 standard) are a class of renewable diesel that is close to fossil fuel diesel (EN 590 standard). High frequency reciprocating rig (HFRR), is a test developed in the early nineties which is the global standard for diesel fuels with strict fuel specifications to protect fuel injection system hardware. In the US the ASTM D975 limit is 520 µm, in Europe the EN 590 limit is 460 µm, while the World Wide Fuel Charter recommends a maximum wear scar of 400 µm. HVOs with insufficient lubricity introduced to injection equipment can result in noncompliance with ASTM D975 or EN 590 and hence are blended with anti-wear (AW) additives to comply with lubricity factor specified in D975 and EN 590. HFRR is used to screen AW additives compatible with HVOs and also for quality control of fossil fuel diesel blended with HVOs.
lubricity measurement Renewable sources for producing diesel fuel include vegetable oils, waste cooking oils and animal fats among others sources. The second generation of Hydrotreated Vegetable Oils (HVO) have overcome the disadvantages associated with of FAME (fatty acid methyl esters) such as increased NOX emission and poor cold operability. HVOs (EN 15940 standard) are a class of renewable diesel that is close to fossil fuel diesel (EN 590 standard). High frequency reciprocating rig (HFRR), is a test developed in the early nineties which is the global standard for diesel fuels with strict fuel specifi cations to protect fuel injection system hardware. In the US the ASTM D975 limit is 520 µm, in Europe the EN 590 limit is 460 µm, while the World Wide Fuel Charter recommends a maximum wear scar of 400 µm. HVOs with insuffi cient lubricity introduced to injection equipment can result in noncompliance with ASTM D975 or EN 590 and hence are blended with anti-wear (AW) additives to comply with lubricity factor specifi ed in D975 and EN 590. HFRR is used to screen AW additives compatible with HVOs and also for quality control of fossil fuel diesel blended with HVOs.
HFRR 4.2 (Figure 1) in accordance with ASTM D6079 and ISO 12156 can be used for testing these renewable fuels. It uses a unique salt-free humidity control system that was first introduced in 2020 and requires only distilled water, This is electronically controlled and offers a simpler and environment friendly integrated unit.
HFRR 4.2 (Figure 1) in accordance with ASTM D6079 and ISO 12156 can be used for testing these renewable fuels. It uses a unique salt-free humidity control system that was fi rst introduced in 2020 and requires only distilled water, This is electronically controlled and offers a simpler and environment friendly integrated unit.
Figure 3a Mean wear scar values of intermediate and excellent lubricity fuels measured manually by two operators as well as using AI automated algorithm.
Figure 3a Mean wear scar values of intermediate and excellent lubricity fuels measured manually by two operators as well as using AI automated algorithm.
HFRR 4.2 screens and control quality of next-gen renewable fuels to comply with EN 590 MWSD limit.
Figure 2 HFRR lubricity of HVOs with and without anti-wear additives HFRR 4.2 screens and control quality of next-gen renewable fuels to comply with EN 590 MWSD limit.
Global fuel quality monitoring programs reveal that the HFRR wear scar has values significantly lower than Worldwide Fuel Charter recommendation of 400 microns due to different additive chemistries and concentrations. This range of excellent to intermediate lubricity between 200 to 500 microns has wear scars that do not have well defined shape and boundary due to the underlying tribofilm formation and wear mechanism. Visual observation is widely accepted method to detect and quantify the wear on the HFRR specimens. As a result, precision in measurement can be expected to be poor, something that is well recognized within this community. This can increase the error and test variability as seen in Figure 3a.
Global fuel quality monitoring programs reveal that the HFRR wear scar has values signifi cantly lower than Worldwide Fuel Charter recommendation of 400 microns due to different additive chemistries and concentrations. This range of excellent to intermediate lubricity between 200 to 500 microns has wear scars that do not have well defi ned shape and boundary due to the underlying tribofi lm formation and wear mechanism. Visual observation is widely accepted method to detect and quantify the wear on the HFRR specimens. As a result, precision in measurement can be expected to be poor, something that is well recognized within this community. This can increase the error and test variability as seen in Figure 3a.
precision of 26 μm). The wear scar measurement were done using our advanced artificial intelligence (AI) algorithm that automates this process.
2 | P ag e Figure 1 Automated HFRR 4.2 powered by AI wear scar measurement. Insert shows the test geometry. Figure 1 Automated HFRR 4.2 powered by AI wear scar measurement. Insert shows the test geometry.
ision of 26 μm). The wear scar measurement were done using our advanced artificial intelligence (AI) algorithm automates this process.
The ball wear scar diameter (MWSD) was measured according to fuel lubricity test standards like ISO 12156-1 or ASTM D6079 to check HVOs compliance with EN 590 or D975. Ten samples of HVOs without AW additives and ten samples of HVOs with AW additives were tested. As shown in Figure 2, the average of ball MWSD for HVOs without AW additives was 618 μm (N = 10, precision of 33 μm) and for the HVOs with AW additives it was 399 μm (N = 10,
The ball wear scar diameter (MWSD) was measured according to fuel lubricity test standards like ISO 12156-1 or ASTM D6079 to check HVOs compliance with EN 590 or D975. Ten samples of HVOs without AW additives and ten samples of HVOs with AW additives were tested. As shown in Figure 2, the average of ball MWSD for HVOs without AW additives was 618 μm (N = 10, precision of 33 μm) and for the HVOs with AW additives it was 399 μm (N = 10, precision of 26 μm). The wear scar measurement were done using our advanced artifi cial intelligence (AI) algorithm that automates this process.
1 | P ag e
Figure 3b AI algorithm that automatically detect the edge of the scar and measures the mean wear scar diameter on the ball.
Figure 3b AI algorithm that automatically detect the edge of the scar and measures the mean wear scar diameter on the ball.
AI based algorithms with image segmentation techniques can consistently and precisely detect the edg and predict wear scar diameter eliminating operator variability in reporting data from fuels. Such become indispensable for the fuel and lubricant industry to accurately quantify ultralow wear susta the future.
AI based algorithms with image segmentation techniques can consistently and precisely detect the edges of the scars and predict wear scar diameter eliminating operator variability in reporting data from fuels. Such AI tools will become indispensable for the fuel and lubricant industry to accurately quantify ultralow wear sustainable fuels of the future.
Conventional test methods may not be adequate Conventional test methods may not be adequate for electric vehicle lubricants Figure 2 HFRR lubricity of HVOs with and without anti-wear additives
The automotive industry has undergone a revolutionary shift with the rise of electric vehicles (EVs) in sustainable transportation. EVs require specialized formulations for electric motors, gear systems, and transition to electric mobility demands cutting-edge lubricants with enhanced thermal stability, con anti-wear properties to address challenges like higher temperatures and increased power density. T adapting to these needs to ensure optimal efficiency and durability in EVs especially balancing the l lubricants with durable anti-wear additives.
for electric vehicle lubricants The automotive industry has undergone a revolutionary shift with the rise of electric vehicles (EVs) in the pursuit of sustainable transportation. EVs require specialized formulations for electric motors, gear systems, and bearings. The transition to electric mobility demands cutting-edge lubricants with enhanced thermal stability, conductivity, and anti-wear properties to address challenges like higher temperatures and increased power density. The industry is adapting to these needs to ensure optimal effi ciency and durability in EVs especially balancing the lower viscosity lubricants with durable anti-wear additives.
Standard testing methods may fall short in accurately gauging the performance of lubricants in electric vehicles. In this study, we evaluated the anti-wear, extreme pressure and viscosity loss of two different EV fl uids according to widely used ASTM and CEC test standards. These e-lubricants were tested on four ball tester, FBT 3.0 with KRL attachment (Figure 4)
Figure 2 HFRR lubricity of HVOs with and without anti-wear additives R 4.2 screens and control quality of next-gen renewable fuels to comply with EN 590 MWSD limit. PIN ANNUAL BUYERS’ GUIDE 2025
Standard testing methods may fall short in accurately gauging the performance of lubricants in elect this study, we evaluated the anti-wear, extreme pressure and viscosity loss of two different EV fluid widely used ASTM and CEC test standards. These e-lubricants were tested on four ball tester, FBT attachment (Figure 4)
bal fuel quality monitoring programs reveal that the HFRR wear scar has values significantly lower than ldwide Fuel Charter recommendation of 400 microns due to different additive chemistries and concentrations.
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