CN112912172A - 高孔隙度的润滑剂调节和修复介质 - Google Patents

高孔隙度的润滑剂调节和修复介质 Download PDF

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CN112912172A
CN112912172A CN201980053742.1A CN201980053742A CN112912172A CN 112912172 A CN112912172 A CN 112912172A CN 201980053742 A CN201980053742 A CN 201980053742A CN 112912172 A CN112912172 A CN 112912172A
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小彼得·T·迪弗雷纳
马修·霍布斯
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Abstract

本发明是一种润滑剂固体处理介质，形状通常为但不限于珠粒，适合通过接触润滑剂来修复和调理润滑剂。所述介质通常是一种聚合树脂，其主要特征是存在非常大的孔隙从而能够吸附和去除细小的润滑剂污染物和分解产物(如小的磷酸酯漆膜、煤烟、焦炭、溶解的金属或其他小的半溶解或不溶解的颗粒)。现有技术的树脂和吸附剂已被证明不能去除对工业设备性能和可靠性有不利影响的细小污染物，如磷酸酯漆膜。所述介质孔隙的平均直径约在
Figure DDA0002942548440000011
Figure DDA0002942548440000012
至
Figure DDA0002942548440000013
之间，更优选地约在
Figure DDA0002942548440000014
至
Figure DDA0002942548440000015
范围内。

Description

高孔隙度的润滑剂调节和修复介质
技术领域
本发明涉及一种异常大孔隙的固体介质以用于调节或修复工业润滑剂。
背景技术
本专利申请要求于2018年8月14日提交的美国临时专利申请62/718,638的优先权，并通过引用将其并入本申请。
关键工业设备的有效和可靠运行取决于润滑剂或其他功能液体的使用。但是，工业润滑剂(包括润滑油、液压油、磷酸酯基控制油)在使用过程中会发生降解和污染，从而削弱了它们有效发挥作用的能力。因此，这些润滑剂必须保持在合适的状态，以确保关键设备的可靠运行。如果润滑剂没有维持在合适的状态，则可能导致昂贵的设备故障和停机时间。因此，成功的维护策略必须提供一种识别和解决在使用过程中所产生和累积的有害润滑剂污染物和降解产物的方法。通常使用油分析和各种过滤或调节系统分别监视和维护润滑剂状况。
在润滑剂的使用过程中，污染和降解是不可避免的。不溶性颗粒、水和气体是非水润滑剂中的常见污染物，其对设备性能和可靠性的有害影响为众所周知。润滑剂的降解通过多种途径发生，包括氧化、水解和热分解。降解产生的分解产物通常是酸性的，它们本身可能在润滑剂中难溶或不溶。即使分解产物最初可溶于润滑剂，它们也可能与其他分解产物和污染物发生进一步的反应而产生不溶性颗粒或沉积物，通常称为“漆膜”。无论起源如何，所有这些润滑剂污染物和降解产物都会对设备性能和可靠性产生负面影响。
由于它们会影响设备性能和可靠性，因此通常使用油液分析来监控润滑剂的污染物和降解水平。常用的测试方法包括(但不限于):颗粒计数、水分分析、光谱学、物理性能分析(粘度、密度等)和膜片比色法(MPC)。最后一项测试旨在评估涡轮机润滑油中的“漆膜生成倾向值”。本发明的发明人最近发明了一种改进的MPC方法，该方法可用于评估基于磷酸酯基的合成润滑剂中的“漆膜生成倾向值”。磷酸酯是在各种关键工业应用中普遍使用的控制液。尽管磷酸酯颗粒、水和酸的水平可常规监测以确保设备的性能和可靠性，但迄今为止，它们的“漆膜生成倾向值”在油品分析程序中普遍缺失。众所周知，在涡轮机润滑油中漆膜颗粒或沉积物可能会导致采用磷酸酯控制液的关键工业系统故障和停机而造成损失惨重。
通过油液分析确定有害的润滑剂污染物和降解产物后，必须通过过滤或调节系统对其进行处理以确保关键设备按计划运行。在这方面，现有技术包括干燥系统、静电沉淀/过滤系统、机械过滤系统、吸附剂和使用孔隙度相对有限的固体离子交换介质的处理系统。后者用于从磷酸酯润滑剂中除去酸性降解产物，并且在这方面的用途在Dufresne的美国公开专利申请No.2009/000102B(以下称为“Dufresne所公开的专利申请”)中有所公开。为增加可用于除酸的固体介质的表面积，这些离子交换树脂的孔隙相对较小。使用上述现有技术已多年有效地管理了磷酸酯水、颗粒和酸的水平。然而，这些先前公开的技术不能有效地解决磷酸酯漆膜。随着磷酸酯“漆膜生成倾向值”改进测试的出现和公开，磷酸酯漆膜范畴的问题已变得显而易见，许多昂贵的工业失败的根本原因都与由于磷酸酯降解而产生的细小的漆膜颗粒和沉积物有关。因此，在本发明之前，仍然需要开发润滑剂过滤、处理或调理系统，以能够从磷酸酯润滑剂中除去有害的磷酸酯漆膜，以及从性质大约类似的其他工业润滑剂中除去类似的污染物。
发明内容
为满足上述需要，本发明公开了一种使用离子交换树脂的润滑剂过滤和调节系统，其中至少一些树脂的孔隙大小比现有技术的过滤器和树脂的孔隙显著大(约二十倍)。迄今为止，使用具有异常大孔隙的离子交换树脂是反常识的，因为大孔的体积限制了可用于离子交换/除酸的表面积。所以，根据现有技术，本发明的离子交换树脂是低效的除酸剂。但令人惊讶的是，具有异常大孔隙的离子交换树脂能够从润滑剂中吸附并保留极其细小的颗粒(直径小于4μm)(包括磷酸酯漆膜)。异常大孔隙的离子交换树脂还能吸附并保留通常由热分解润滑剂分解产生的超细烟灰或焦炭颗粒。此外，本发明的大孔隙离子交换树脂可以吸附、保留和去除这些细小的不溶性污染物和分解产物(漆膜、烟灰、焦炭等)，而具有相同间隙尺寸(例如1-4μm)的传统机械过滤介质则不能。因此，大孔隙离子交换树脂不是作为简单的筛孔。这意味者聚合物离子交换树脂介质的三维高孔隙度结构在有效吸附和保留细小的不溶性润滑剂污染物和分解产物中起着重要作用。使用本发明可有效地减轻与润滑剂状况相关的昂贵工业设备故障风险。
具体地，本发明包括一种用于润滑剂修复和调理的异常高孔隙度离子交换树脂。本发明的异常高孔隙度离子交换树脂通常采取珠粒尺寸为300μm-1,500μm的大孔隙聚合物珠粒。在润滑油清洗或使用期间，所述离子交换树脂与润滑油接触。所述离子交换树脂的孔隙比现有技术中已知的离子交换树脂的典型中值孔隙大二十倍(通过水银孔率法测量)。例如，常见的现有技术树脂珠粒的中值孔隙为
Figure BDA0002942548420000021
而本发明的大孔隙离子交换树脂的孔隙中位数为
Figure BDA0002942548420000022
(
Figure BDA0002942548420000023
的二十倍)、
Figure BDA0002942548420000024
(
Figure BDA0002942548420000025
的二十倍)，
Figure BDA0002942548420000026
(
Figure BDA0002942548420000027
的二十倍)、
Figure BDA0002942548420000028
或甚至
Figure BDA0002942548420000029
通常，本发明的孔隙中位数会在
Figure BDA00029425484200000210
Figure BDA00029425484200000211
范围内选择。发明人还相信，与具有比所述范围内的孔隙更小(或者明显更大)的树脂相比，具有中值孔隙在
Figure BDA0002942548420000031
之间的离子交换树脂将提供全新、意想不到的润滑剂污染物和分解产物去除的改善效果。
附图说明
图1为一段轴向流动回路的剖视图；
图2为一段径向流动回路的剖视图；
图3为装有本发明中设有供液体流动入口和出口的介质大容量处理容器的主视图。
具体实施方式
本发明的离子交换树脂具有非常大尺寸的孔隙，可以吸附在这之前不可能吸附的细小润滑剂污染物和分解产物(磷酸酯漆膜，烟灰，焦炭等)。这些润滑剂污染物和降解产物的尺寸通常小于4μm，因此，难以或不可能通过现有技术中所列的筛式技术去除。通过使用孔隙比所有现有技术中所描述的孔隙大二十倍的离子交换树脂，本发明的树脂可有效去除细小的润滑剂污染物和分解产物。这些有害物质进入本发明相对孔隙较大的离子交换树脂中，然后被吸附并保留下来。在本发明中所使用的常见聚合物树脂有(但不限于):聚苯乙烯(包括交联聚苯乙烯)、聚氨酯、环氧树脂、聚乙烯、乙烯酯、二乙烯基苯或几乎任何类型的丙烯酸树脂，只要它们是通常理解的塑料家族中的聚合物。这些聚合物树脂可以被功能化以形成阴离子或阳离子交换树脂，或聚合物保持未功能化。但是，使用功能化的阴离子或阳离子交换树脂可以增强固体介质从润滑剂中去除其它不利的污染物和分解产物(酸、金属等)的能力。
考虑上述关于“大孔隙”的树脂如何吸附不溶性磷酸酯润滑剂漆膜颗粒等的解释，可见发明人使用异常大孔隙树脂的动机明显。然而，使用这些具有较大孔隙的离子交换树脂是完全违反常识的。由于现有技术所描述的离子交换树脂旨在去除酸性润滑剂分解产物，因此润滑剂处理领域的技术人员将选择具有高交换(除酸)能力的树脂。具有许多较小孔隙的离子交换树脂具有较大的表面积，因而固有地提供较高的除酸能力。基于常识，润滑剂处理领域的技术人员将选择具有较小孔隙和较大表面积的离子交换树脂以最大化处理介质去除漆膜的吸附能力以。本发明人采用与上述既定的常识完全相反的方法，本发明通过大幅度增加离子交换树脂的中值孔隙，并因此以压倒性的方式减少了离子交换树脂的表面积。尽管如此，这种反常且显著增加(大约20倍)的离子交换树脂孔隙导致了新颖而出人意料的改进结果，从而可以解决至今为止未被重视也未解决的细小润滑剂污染物和分解产物(漆膜、烟灰、焦炭等)的问题。
本发明的关键在于以牺牲介质的除酸能力为代价来去除在此之前难以或不可能去除的细小润滑剂污染物和分解产物(漆膜、烟灰、焦炭等)。然而，现有技术除酸的必要性依然很重要。幸好，可以将本发明的孔隙较大的离子交换树脂与孔隙较小且随之除酸能力较大的其他离子交换树脂组合。本发明的离子交换树脂与现有技术中比较常规的树脂的组合可以通过混合或分层两种或更多种类型的离子交换树脂珠粒来实现。可将约20％(质量百分比)本发明的“大孔隙”离子交换树脂与约80％(质量百分比)的传统除酸离子交换树脂组合；也可各自取约50％进行混合或分层。在理解了本发明和现有技术的离子交换树脂不同的工作机理之后(如本文和Dufresne公开的专利申请中所述)，比例的选择与除酸需求有关，这主要是因为传统除酸介质用量的减少会伴随化学计量上整个离子交换树脂混合物的除酸能力的降低。至于本发明的离子交换树脂，包含约20％或更多本发明的离子交换树脂在经验上已被证明是足够的，因为本发明树脂的较大孔隙具有异常大且可吸附大量的细小润滑剂污染物和分解产物的空隙空间。在无需考虑酸的体系中，可直接使用本发明的异常离子交换树脂而不必与现有技术的除酸树脂混合。
因此，显然，本发明的核心在于洞悉如何使用具有相对较大(约20倍)孔隙的离子交换树脂来吸附细小的润滑剂污染物和分解产物，包括磷酸酯漆膜(尽管迄今为止尚未进行常规监控，然而带来了可避免的设备故障和停机时间以及过早的润滑剂寿命)。
参考图1，其为一段管10的剖视图，图中展示了常见润滑剂系统中设有滤芯12的清洁回路。所述滤芯12是设有两个滤网14的管的一部分，通常是带孔的筛或网，分别位于本发明中固体介质的多个多孔珠16上游处和下游处。为进行说明放大图中的多孔珠，因此未按比例显示。所述滤网14中的孔或网眼需小于所述多孔珠16的最小尺寸以将所述多孔珠16保持位于所述滤芯12内。可通过螺纹紧固件或具有完整结构的等效手段，包括压合、环氧树脂密封、焊接，机械密封或任何其他结构方式，使得所述滤芯12可拆出以更换所述多孔珠16。可选地，可以在沿液体流动的任何位置中添加一个或多个传统的微粒过滤器(图未示)。可以将该段管10放置在润滑剂系统中任何方便的位置，优选地，放置在易于维护的位置(以更换固体介质)。虽然图1中未示，但采用“肾环”形的次级过滤系统或作为初级过滤系统的一部分也是有益的，特别是对于润滑剂的修复。图2所示为用于径向流动的一个实施例，其具有与图1类似的滤芯22、滤网24、多孔珠26、入口管20和出口管28。图3所示为用于大容量处理中一个实施例的主视图，其中容器30装有本发明的多孔珠36，所述多孔珠36可通过舱口32装入到容器中，液体通过管31流入并通过管33流出。所述容器包含可选的圆顶盖舱口32，其可以用作添加或取出本发明的多孔珠的备用进入点。再次说明，所有图中的多孔珠均未按比例绘制。
涡轮润滑剂的应用通常可以包含400至20,000加仑的润滑油，甚至更少或更多，以及根据本发明按比例增加或减少的相关介质。所需介质的数量也随待处理润滑剂的作用而变化。可被本发明调理或修复的油类型(具有或不具有如图1-3所示的特定结构)为石油基和合成润滑剂以及绝缘液，其被分类为API组I，II，III，IV或V。如本领域技术人员所知，基于磷酸酯基的控制油属于API组V中的非烃基合成润滑剂。因此，本发明适用于各种介质数量和液体系统，并且本领域技术人员能够容易地从本说明书中学习使用所公开的具有相对较大孔隙的介质，而无需进行过多的实验，即可确定所需多孔介质的数量以及更换频率。如上所述，酯基合成润滑剂的常见具体实施例可以包括但不限于两个直径分别为6英寸且长度为18英寸的滤芯，所述滤芯装有本发明的多孔珠(如100％本发明的多孔珠，或50％本发明的多孔珠和50％的除酸介质珠或其他介质珠，或上述实施例中20％的本发明的多孔珠和80％除酸介质珠或其他介质珠)来处理约400加仑的润滑剂。另一个常见的碳氢化合物涡轮润滑油的具体实施例可包括但不限于两个填充树脂的滤芯，每个直径为1英尺、长度为20英寸，来处理大约6000加仑的润滑油。注意，在上面的例子中，酯基合成润滑剂具体实施例中每单位体积所用的树脂比碳氢基润滑剂的多三倍。
尽管上面已经具体描述了本发明，但本发明仅限制于所附权利要求书中阐述的保护范围之内。

Claims (11)

1.一种用于调节或修复润滑剂的聚合物树脂介质，大量聚合物树脂包含多个孔隙，其特征在于：所述孔隙的平均直径通过水银孔率法测量为
Figure FDA0002942548410000011
至
Figure FDA0002942548410000012
之间。
2.根据权利要求1所述的聚合物树脂介质，其特征在于：所述孔隙的平均直径通过水银孔率法测定为
Figure FDA0002942548410000013
至
Figure FDA0002942548410000014
之间。
3.根据权利要求1所述的聚合物树脂介质，其特征在于：所述聚合物树脂包括聚苯乙烯、交联聚苯乙烯、聚氨酯、环氧树脂、聚乙烯基、乙烯基酯、二乙烯基苯或丙烯酸类材料。
4.根据权利要求1所述的聚合物树脂介质，其特征在于：所述孔隙的平均直径通过水银孔率法测定为
Figure FDA0002942548410000015
至
Figure FDA0002942548410000016
之间。
5.根据权利要求1所述的聚合物树脂介质，其特征在于：所述聚合物树脂的形状为珠粒。
6.根据权利要求5所述的聚合物树脂介质，其特征在于：所述珠粒的平均直径大约在100μm-2,000μm之间。
7.根据权利要求6所述的聚合物树脂介质，其特征在于：所述珠粒适合与其他介质珠粒混合、掺合或分层以处理润滑油。
8.一种清洁大量润滑剂的方法，包括：使大量遍布孔隙的聚合物介质接触全部或部分待清洁润滑剂，其特征在于：通过所述孔隙吸附小于4μm的不溶性和半可溶性的润滑剂污染物和分解产物，所述孔隙平均直径通过水银孔率法测定为
Figure FDA0002942548410000017
至
Figure FDA0002942548410000018
之间。
9.根据权利要求8所述的方法，其特征在于：所述聚合物介质的形状为珠粒。
10.根据权利要求8所述的方法，其特征在于：所述聚合物介质包括聚苯乙烯、交联聚苯乙烯、聚氨酯、环氧树脂、聚乙烯基、乙烯基酯、二乙烯基苯或丙烯酸。
11.根据权利要求8所述的方法，其特征在于：磷酸酯基润滑剂的MPC漆膜生成倾向值可以显著提高到<20.0的值。
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