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HYDRAULIC FLUIDS

FOR MINING
EQUIPMENTS

Augusto Fernandes
Product Application Specialist

Copyright of Royal Dutch Shell plc


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Hydraulic System Designs
Low Speed Reduced
Power System Operating Energy Hydrostatic
High Torque Environmental
Output Pressure Temperature Efficiency Drives
Motors Impact

Oil Service
Emissions
Life
Controls
Expectation

INCREASED STRESS ON DEMAND FOR


HYDRAULIC FLUID NEWER FLUIDS

Downtime &
Reservoir Finer
Idle at
Size Filtration
Start-up

Trends
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Hydraulic Fluid Selection

Multiple options for selection of


hydraulic fluids.

Selection of hydraulic fluid often a


commodity driven purchase decision.
Consider life-cycle maintenance costs.

Key need to consider application


challenges and demands on lubricant
prior to selection and rationalization
on site.

Trends
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Hydraulic Pump Testing Trends

STRESS ON OIL TBA Bosch Rexroth piston pump (TBD)

Denison HF-0 (T6H20C Hybrid Vane/Piston);


0-250 bar (vane) + 280 bar (piston) /110C
Komatsu Hitachi 35+35 Pump test

Denison HF-2 (T6C vane Pump; Water);


0-250 bar/80C
Bosch Rexroth A2F
207 bar/95C; Vickers 35VQ25 (Vane Pump);
250 bar/0-230 bar/95C Vickers PVH 57 (Piston Pump)

345 bar/75C-100C Denison HF-0 (T5C Vane Pump; P46 Piston Pump)

140 bar/80C General anti-wear Vickers V104C (Vane Pump)

Trends
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Implications for Hydraulic Fluids

As equipment designs and environmental legislations change,


specifications for hydraulic fluids are becoming more demanding.

Recognition of the need for more differentiated performance


specifications driving more differentiated products in all areas.

Hydraulic fluids design is constantly evolving.

Shift in experience of work force.

Implications
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5
Different OEMs Recommend Different Oils
Major manufacturers are split between use of engine oil type fluids and hydraulic type fluids.
Both fluid types can work very well in mobile equipment depending on design and application.
As always, the starting point for fluid selection is the manufacturers recommendation.

Primary Secondary
OEM
Recommendation Recommendation
Komatsu Engine Oil Hydraulic Oil
Caterpillar Engine Oil Hydraulic Oil
Hitachi Hydraulic Oil -
JCB Hydraulic Oil -
Liebherr Engine Oil/ATF -
Terex Engine Oil Hydraulic Oil
Manitou Hydraulic Oil -
Volvo CED Hydraulic Oil -

Implications
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Mobile And Static Systems Impact Operational Severity

Mobile Hydraulic Systems Industrial (Static) Hydraulic Systems

High Pump Capacity/Small Reservoir Large Oil Reservoir

No time for air/water separation Time for air/water separation

High operating pressures Mostly lower operating pressures


Variable operating temperatures Mostly operating under constant
temperatures
Harsh environment Relatively clean environments
Usually pressurised reservoir Reservoir more or less open to air

Hydrostatic drives often present Less likely to have hydrostatic drives

Implications
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Shell Solutions to These Challenges Energy Efficiency
Improving the energy efficiency of hydraulic systems is a major focus for many
OEMs and operators as a way to help reduce operating costs.
Need to develop robust and statistically relevant procedures to evaluate efficiency
benefits through use of hydraulic fluids and control variables.
ASTM D7721-11 Standard Practice for Determining the Effect of Fluid Selection on
Hydraulic System or Component Efficiency (June 2011).
Formation of CCEFP multidisciplinary committee.
Shell has developed computer based modeling techniques and controlled field
based tests to compare the energy efficiency and fuel economy benefits of
different hydraulic fluids.

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Shell Solutions to These Challenges Energy Efficiency
Improving the energy efficiency of hydraulic systems is a major focus for many
OEMs and operators as a way to help reduce operating costs.
Komatsu WH613 Telescopic Handler

Zn-Based Mineral Oil


Better

Zn-Free Synthetic Oil 1

Zn-Free Synthetic Oil 2

Over a working day* Tellus S4 ME 46 gave fuel


savings of 1.5% - 1.9% when compared to a
typical antiwear hydraulic
Tellus S4 ME 46fluid (ISO type HM).
(Run 4)
*working day result5 significant 1.8at 99% confidence level.

Lower coefficient of friction 4 1.9

with specially formulated Test phase


number
3 1.2

synthetic hydraulic fluid 2 1.0

1 1.4

-1.5 -0.5 0.5 1.5 2.5 3.5 4.5 5.5


Copyright of Royal Dutch Shell plcLeadership
9 Fuel saving (% consumption vs. Tellus S2 M 46)
Shell Tellus S4 ME 68 Hagglunds Motors Energy Efficiency
Barrick Gold, a large mining company in Western Australia,
have been conducting a trial of Tellus S4 ME 68 (formerly
Tellus EE) in a conveyor system powered by Hagglunds
hydraulic motors.
Careful measurement of energy consumption before and after
converting to Tellus S4 ME 68 has demonstrated an energy
saving of 5.3% relative to Tellus S2 M 68.

Better

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Shell Solutions to These Challenges Tackling Low
Residence Times
Compliance with emission
regulations on off-highway vehicles ISO VG 46 Hydraulic Fluids
requires additional treatment
devices space becomes a factor
reduce hydraulic reservoir sizing to

Better
fit space remaining.
Reservoir size decreasing from a 4:1
or 3:1 ratio of sump size to flow rate
to now less than 1:1 very low oil
residence time in tank.
Lubricants with improved air release
performance allow for improved * Compared to requirements included in DIN 51 525 HLP specification

system design and minimizes


effective compressibility.

Leadership
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Shell Solutions to These Challenges Temperature
Operating Window
High equipment availability, including
reduced time for start-up is a major driver for
mobile equipment operators.
Equipment operated and exposed to wide
temperature swings during winter or
overnight can be exposed to major stresses
upon start-up.
Pump cavitation as a result of very high fluid
viscosity at start-up can significantly reduce
pump life.
Hydraulic fluids possessing excellent low
temperature fluidity, a high viscosity index
and being shear stable help in protecting
pumps at low start-up temperatures.
Leadership
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Pump Efficiency
Shell Tellus S4 ME displays excellent
shear stability and resistance to
thinning in service.
high viscosity index without the use

Efficiency
of Viscosity Index Improver
Additives Optimum
Operating Range

Thinner fluid at high temperatures


causes:
Viscosity
High wear rates of pump parts
High leakage
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16

Better
System failure
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Loss of Reliability Viscosity Loss (%)
12
Shell Tellus
Shell TellusS4 EE
ME
10

Loss of Productivity 8
Oil A
Oil B

6
Increased Costs 4

2
Leadership
0
Copyright of Royal Dutch Shell plc Shell Tellus
Shell S4EE
Tellus ME Oil A Oil B ISO VG 46 Fluids
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Hydraulic Fluid Consumption
Blown hydraulic hoses and leaking seals on
hydraulic cylinders are major contributors to high
hydraulic oil consumption on mobile equipment:
Increases oil consumption.
can reduce pump/system efficiency.
Non-availability of equipment and unplanned
downtime.
safety hazard.
environmental hazard.
Smart hoses like Eaton Life Sense
hydraulic hose condition monitoring system:
A hose-condition sensor continuously
monitors hose conditions via electrical
measurement technology-sends alert to
user.
Leadership
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17
Minimizing Environmental Impact
Specifications and Ecolabeling.
Utilization of renewable raw materials.
Significant fines from EPA for discharges to the
environment.
Positive steps for license to operate for companies.
Consideration for ore handling ship loaders and
unloaders.

Implications
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Shell Solutions to These Challenges Biodegradable
Lubricants

Synthetic ester based biodegradable hydraulic


fluid designed with a measured bio-based content
of over 80% m/m (ASTM D 6866) exceeding USA
Federal Procurement requirement for bio-based
hydraulic fluids (USDA Bio-preferred program limit
of 44%)
Low ecotoxicity towards marine and plant life
Performance
low temperature fluidity for low temperature start-
up wider temperature operating window
Shell Naturelle
Anti-wear characteristics exceeding mineral oil Hydraulic Fluid HF-E 32
limits imposed by OEMs
Cam ring at the end of the
Compatibility with yellow metals, seals, hoses test the original
machining marks are still
Resistance to deposit formation with long fluid life clearly visible
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