Performance Comparison Report

Polyol Esters and PAGs

Performance Comparison Report

Polyol Esters and PAGs
I. SUMMARY
Fire resistant hydraulic fluids are now available that are based on polyalkylene glycol (PAG) technology. These water-free PAG fluids are sometimes referred to as polyether polyols. Quaker has evaluated PAG technology regularly over the last several years most recently by testing a commercially available PAG product. In all cases our conclusion has been that the benefits of PAGs do not outweigh their disadvantages when compared to high quality polyol ester fluids such as QUINTOLUBRIC 822. PAG has several strengths and weaknesses compared to polyol ester products such as QUINTOLUBRIC 822. PAG products, like polyol esters, have excellent lubrication and pump wear characteristics. PAGs have better oxidative stability and are more tolerant of water contamination than polyol esters. In other words, the acid number of PAGs rise more slowly than in polyol esters. On the other hand, PAGs are much more difficult to waste treat than polyol esters. The fire resistancy of PAGs is also more sensitive to fluid aging than with polyol esters. Quaker Chemical has been at the forefront of synthetic, fire resistant hydraulic fluid technology for over twenty years. We have been continuously innovative in bringing new technologies to the field. Our decision not to market a fluid based on PAG technology is based on extensive laboratory testing. This report contains a summary of that data. It is our conclusion that the current PAG technology has too many shortcomings to be a viable alternative to QUINTOLUBRIC 822. In cases where enhanced oxidative stability is required, Quaker routinely offers QUINTOLUBRIC 822-300-CM, a higher performance alternative to normal QUINTOLUBRIC 822-300.

II. BACKGROUND
Quaker Chemical was approached in 1992 by Olin Corporation regarding PAGs. Olin wanted to find a partner to formulate and market hydraulic fluids made with PAGs. Quaker evaluated material from Olin and found it to have excellent thermal and hydrolytic stability but other performance drawbacks and the materials cost led Quaker to decide not to pursue the technology. Quaker had already commercialized Quintolubric 822-300-CM for applications demanding enhanced performance and stability.

III. FIRE RESISTANCE

Factory Mutual Research Corporation approves hydraulic fluids as being less flammable for use near ignition sources. All hydraulic fluids will burn under certain conditions but Factory Mutual approves fluids that will self extinguish when the ignition source is removed. To test for this trait, hydraulic fluid is sprayed through an oil burner nozzle under controlled conditions. A flame is then passed through the resulting hydraulic fluid mist, lighting the fluid on fire. For a fluid to pass the test, the flame must self-extinguish no more than 5 seconds after the ignition source is removed. Several tests are run in sequence and the time for self-extinguishment is recorded for each. Factory Mutual has approved hydraulic fluids based on polyol esters (QUINTOLUBRIC 822-300) as well as PAGs. Quakers laboratory confirmed Factory Mutuals approval by testing Quintolubric 822-300 and a commercially available PAG product. QUINTOLUBRIC 822-300 burned producing a low density, white smoke and self-extinguished passing the spray ignition test. The PAG product burned and generated a moderate density, acrid, white smoke but passed the spray ignition test. These tests were run on fresh, unused fluid. Factory Mutual is developing a new standard fire resistance that classifies fluids into three groups based on increased fire resistance. Under the current draft standard, both QUINTOLUBRIC 822-300 and the commercially available PAG product will be classified as Group 2 or less flammable than mineral oil fluids but may stabilize a spray flame under certain conditions. FIRE RESISTANCE OVER TIME In evaluating the performance of the PAG product, Quaker also tested the product in the Vickers Vane Pump Test (ASTM D-2882) along side Quintolubric 822-300. See Section IV for the results of that testing. While this test was being run, Quaker took samples of the fluids for additional fire resistancy tests. At regular intervals, samples of both products were tested again in the Factory Mutual spray ignition test. After 24 hours in the pump test, the PAG product failed the spray ignition test. The aged sample of Quintolubric 822300 passed the test. Because of the significance of these findings, Quakers laboratory ran this test two more times with fresh fluid samples. Digital images taken during these tests are shown on the next page. Each time the results were the same. Quintolubric 822-300 passed the Factory Mutual test after accelerated aging in the pump test, the PAG product did not. FMRC Spray Ignition Test Fresh Product Aged Product
1

QUINTOLUBRIC 822-300

Commercially Available PAG Product Pass Fail

Pass Pass

Aged 24 hours in Vickers Vane Pump Test (ASTM D-2882)

QUINTOLUBRIC 822-300 after 24 hours of accelerated use. PASS

0 Seconds

0.5 Seconds

1 Second

PAG product after 24 hours accelerated use: FAIL

0 Seconds

1 Second

2 Seconds

FAILURE POINT 3 Seconds 4 Seconds 5 Seconds

6 Seconds

7 Seconds
4

7.5 Seconds

IV. HYDRAULIC FLUID PERFORMANCE

LUBRICATION AND PUMP WEAR The standard test for lubrication and pump wear properties is ASTM D-2882. In this test, the hydraulic fluid is circulated though a Vickers Vane pump and a pressure relief valve at 2,000 psi and 175F for 100 hours. The ring and vane components of the pump are weighed before and after the test to determine the total weight loss. Less weight loss indicates better lubrication and pump wear characteristics. Twenty milligrams is the maximum weight loss for a product to be considered an excellent anti-wear hydraulic fluid. In recent tests, QUINTOLUBRIC 822-300 showed 4.1mg weight loss after 100 hours. A commercially available PAG product showed 4.8 mg weight loss. Both of these products are considered to have excellent lubrication and pump wear characteristics. Of note during extended testing was the build-up of a dark purple residue in the equipment testing the PAG product. An analysis of the purple sludge suggests it is caused by the degradation of an anti-oxidant additive in the PAG product. No such residue was generated by QUINTOLUBRIC 822-300. Photos of pump stand components after extended testing of a PAG fluid are shown below.

OXIDATIVE STABILITY Two laboratory tests are routinely used to predict the oxidative stability of hydraulic fluids. The first is Federal Test Method Standard 791B. In this test, air is bubbled through the fluid under controlled conditions and in the presence of five different metals. The metals are present to catalyze oxidation. After 7 days, the change in acid number and viscosity of the fluid is measured. The less the change in acid number and viscosity, the greater resistance the fluid has to oxidation. Test results for QUINTOLUBRIC 822-300 and a commercially available PAG product are given below: FEDERAL TEST METHOD 791B Change in Acid Number Change in Viscosity QUINTOLUBRIC 822-300 Commercially Available PAG Product 0% 3%

13% 1%

The second standard oxidation test is ASTM D-2070-91, also known as the Cincinnati Milicron Thermal Stability Test. This test is very similar to the Federal Test Method described above. Results are also expressed as a change in acid number and viscosity. In addition, this test is useful for predicting the amount of sludge generated as the fluid ages. Results of this test are given below: ASTM D-2070-91 QUINTOLUBRIC 822-300 Commercially Available PAG Product 2.5% 1.5% 3.4 mg

Change in Acid Number Change in Viscosity Sludge Generated

13% 10% 3.5 mg

Based on these results, the fluids based on PAGs have better oxidative stability than those based on polyol esters.

FOAM RESISTANCE Since hydraulic fluids circulate through a reservoir, it is important that they not produce excess foam. Foam can lead to fluid level problems and damaging pump cavitation. ASTM D-892 tests the foaming characteristics of hydraulic fluids by bubbling air through a fluid under controlled conditions for 5 minutes and measuring the amount of foam generated immediately and after sitting for 10 minutes. It is most important that any foam generated breaks up within 10 minutes. The test is run in three sequences, first at 75F, then at 200F, then again at 75F. As can be seen in the table below, both QUINTOLUBRIC 822-300 and a commercially available PAG product foam initially but the foam is unstable and breaks up within 10 minutes. Thus, both products are considered to have good foam resistance. ASTM D-892
1

QUINTOLUBRIC 822-300

Commercially Available PAG Product 130/0 20/0 100/0

Sequence I Sequence II Sequence III

1

160/0 190/0 260/0

Results reported as foam height in milliliters. First number is after 5 minutes (foam building); second number is after 10 minutes (foam breaking).

Another test for foam resistance is the ASTM D-3427 Air Release Test. In this test, the time is measured for a fluid to completely release a controlled amount of entrained air. QUINTOLUBRIC 822-300 passes this test in 4 minutes. A commercially available PAG product passes it in 2 minutes. Thus both products have excellent air release characteristics.
6

ELASTOMER COMPATIBILITY A number of elastomers are used to manufacture seals and components for hydraulic systems. Good elastomer compatibility means that the fluid will not degrade the material which can lead to system leaks and performance limitations. Based on laboratory evaluations, the table below shows the elastomers that are compatible with QUINTOLUBRIC 822-300 and a commercially available PAG product. This list is based on elastomers used for dynamic applications such as cylinder rod seals, pump shaft seals and constantly flexing hydraulic hose. Other materials may be compatible for more static applications. QUINTOLUBRIC 822-300 Commercially Available PAG Product Viton (FPM) Neoprene 3 EPR (EPM) Butyl Rubber
2

Compatible Elastomers

Buna N (NBR) 2 Viton (FPM) Neoprene (moderate)

1 2

Trade name for medium to high nitrile rubber Trade name for fluor-elastomer 3 Ethylene Propylene Rubber

COMPATIBILITY WITH OTHER FLUIDS When converting from one type of hydraulic fluid to another, it is critical that the compatibility of the two fluids be understood. If products are not compatible, special care must be taken in flushing lines and equipment before the new fluid is added. An initial screen for fluid compatibility is made by mixing the two fluids in a laboratory and observing the results. If the two fluids are compatible, they should blend freely and form a clear, homogeneous mixture. If the fluids do not mix and stay in separate layers, they are not compatible. The table on the next page shows the results of mixing QUINTOLUBRIC 822-300 and a commercially available PAG with various types of hydraulic fluids. The results indicate that polyol ester fluids such as QUINTOLUBRIC 822-300 are much more compatible with other fluid types than are PAG based fluids.

QUINTOLUBRIC 822-300 Product mixed with: Mineral Oil Fully Compatible

1

Commercially Available PAG Product Not Compatible Products form two layers Not Compatible Products form two layers Possibly Compatible Products not miscible Not Compatible Precipitate forms Same Fluid

Water Glycol

Not Compatible Products form two layers Fully Compatible

2

Phosphate Ester

Polyol Ester

Same Fluid

PAG

Not Compatible Precipitate forms

1 2

Fire resistancy is compromised by blending polyol esters with mineral oil. QUINTOLUBRIC 822-300 can be blended with phosphate esters that are in good condition.

V. ENVIRONMENTAL CONSIDERATIONS
DEMULSIFICATION Since hydraulic fluids often get into wastewater streams, it is important that they separate easily from the water so that they can be removed. Likewise if water contaminates hydraulic systems, there should be a method for quickly removing the water without draining the entire system. Ideally, hydraulic fluids should float on water so they can be removed with skimmers prior to wastewater treatment and so that excess water can be drained from system reservoirs. ASTM D-1401 measures the ability of a fluid to separate from water. In the test, 40 ml of hydraulic fluid is added to 40 ml of water, the mixture is blended well and then allowed to sit in a cylinder. The mixture should separate into layers: water, oil, and usually an emulsion layer. The greater the separation of oil and water (in other words the smaller the emulsion layer), the easier it is to get the fluid out of wastewater streams. The results of ASTM D-1401 for QUINTOLUBRIC 822-300 and a commercially available PAG fluid are graphed below. As can be seen, QUINTOLUBRIC 822-300 exhibits excellent demulsification with only a slight emulsion layer remaining after 20 minutes. At the end of the test (60 minutes), the fluid and water layers have completely separated. The PAG was still mostly emulsion after the maximum time allowed for the test.

ASTM D-1401 Demulsificaion Test

2 42 Oil 1 37 Emulsion Water 33

45

QUINT 822-300 (after 20 minutes)

Polyether Polyol (after 60 minutes)

CHEMICAL OXYGEN DEMAND Biological oxygen demand (BOD) is a measure of the amount of organic material in a waste stream that can lead to plant and animal growth. This is an important measure of wastewater treatment effectiveness and many facilities have restrictions on the amount of BOD they can release in a given period. Chemical oxygen demand (COD) is a laboratory predictor of BOD that is easier to test for. Samples of QUINTOLUBRIC 822-300 and a commercially available PAG product were sent to a major water treatment company for evaluation of COD before and after water treatment. As can be seen in the table below, Quintolubric 822-300 has a slightly higher COD level prior to any waste treatment but the COD is more readily removed with standard water treatment practices. The water treatment company tested all available water treatment techniques on the two products tested. The best level of COD removal obtained for QUINTOLUBRIC 822-300 was 91%. The best level of COD removal for the PAG product was 57%. Thus, after the best available water treatment techniques, the PAG product has four times the COD of polyol ester based QUINTOLUBRIC 822-300. QUINTOLUBRIC 822-300 Commercially Available PAG Product 12,990

Raw COD (ppm) COD After Treatment Method A Method B Method C Best Case
1

15,000

2,890 (80%) 5,330 (64%) 1,400 (91%) 1,400 (91%)

2

5,680 (57%) 8,040 (39%) 2 na (<10%) 5,680 (57%)

Method was not effective

Fluids tested at 2% by weight in water