US3682823A - Synthetic oils from alpha-olefins - Google Patents

Synthetic oils from alpha-olefins Download PDF

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Publication number
US3682823A
US3682823A US47133A US3682823DA US3682823A US 3682823 A US3682823 A US 3682823A US 47133 A US47133 A US 47133A US 3682823D A US3682823D A US 3682823DA US 3682823 A US3682823 A US 3682823A
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alpha
oil
olefin
oligomers
catalyst
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US47133A
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George Smith
Johannes M Wortel
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Shell USA Inc
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Shell Oil Co
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    • C10M107/02—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation
    • C10M107/10—Hydrocarbon polymers; Hydrocarbon polymers modified by oxidation containing aliphatic monomer having more than 4 carbon atoms
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    • C07—ORGANIC CHEMISTRY
    • C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
    • C07C2/00—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms
    • C07C2/02—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons
    • C07C2/04—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons by oligomerisation of well-defined unsaturated hydrocarbons without ring formation
    • C07C2/06—Preparation of hydrocarbons from hydrocarbons containing a smaller number of carbon atoms by addition between unsaturated hydrocarbons by oligomerisation of well-defined unsaturated hydrocarbons without ring formation of alkenes, i.e. acyclic hydrocarbons having only one carbon-to-carbon double bond
    • C07C2/08—Catalytic processes
    • C07C2/14—Catalytic processes with inorganic acids; with salts or anhydrides of acids
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    • C10M2219/108—Phenothiazine
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    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2010/00—Metal present as such or in compounds
    • C10N2010/02—Groups 1 or 11
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2020/00—Specified physical or chemical properties or characteristics, i.e. function, of component of lubricating compositions
    • C10N2020/01—Physico-chemical properties
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
    • C10N2050/08—Solids
    • C—CHEMISTRY; METALLURGY
    • C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
    • C10N—INDEXING SCHEME ASSOCIATED WITH SUBCLASS C10M RELATING TO LUBRICATING COMPOSITIONS
    • C10N2050/00—Form in which the lubricant is applied to the material being lubricated
    • C10N2050/10—Form in which the lubricant is applied to the material being lubricated semi-solid; greasy

Definitions

  • hydrogenated synthetic lubricating oils of low pour points and high viscosity indices are produced by oligomerizing 0 -0 normal alpha-ole- Patented Aug. 8, 1972 fins with alkali metal tetra-haloalanates as catalysts and subsequently hydrogenating the resulting alpha-olefin oligomers.
  • the hydrogenated synthetic lubricating oils are characterized by low pour points, e.g., pour points at least as low as -60 F., and more often at least as low as R, which pour points are as low as the pour points of the unhydrogenated alpha-olefin oligomers.
  • the hydrogenated lubricating oils are further characterized by a molcular composition consisting of at least 0.7 mole of alicyclic oligomers, e.g., alkyl-substituted naphthenes, per mole of isoparafiinic oligomers.
  • the olefinic reactant-The olefinic reactants useful in the preparation of the synthetic oils are normal alpha-olefins of from 6 to 12 carbon atoms, i.e., l-hexene, l-heptene, l-octene, l-nonene, l-decene, l-undecene and 1- dodecene.
  • a single alpha-olefin or a mixture thereof is suitably employed.
  • synthetic oils of superior properties are obtained with Cg-Cm alpha-olefins or with mixtures of alpha-olefins having an average chain length of about 8 to 10.
  • Suitable mixtures of alpha-olefins are C -C alpha-olefin mixtures obtained by Zieglertype polymerization of ethylene.
  • a particularly preferred alpha-olefin mixture comprises a mixture of 25% mole l-hexene, 25% mole l-octene and 50% mole l-decene.
  • the Catalyst-The alkali metal tetrahaloalanate catalysts have the general formula MAlX, wherein M is an alkali metal of atomic number from 3 to 55, i.e., Li, Na, K, Rb or Cs, and X is a halogen of atomic number from 9 to 53, i.e., F, Cl, Br or I.
  • alkali metal tetrahaloalanates are: LiAlF KAIF CsAlF LiAlCl NaAlC1 KAlCl RbAlCl LiAlBr NaAlBr CsAlBr LiAlI KAlI and RbAlL
  • suitable alkali metal tetrahaloalanates are those containing more than one halogen such as NaAlCl Br and LiAlBr Cl.
  • Preferred alkali metal tetrahaloalanates are those wherein the alkali metal is lithium, sodium or potassium and the halogen is a middle halogen, i.e., chlorine or bromine. Particularly preferred is lithium tetrachloroalanate.
  • the alkali metal tetrahaloalanate catalysts are prepared by a variety of methods.
  • the alkali metal tetrahaloalanates are prepared by melting together essentially stoichiometric quantities of an alkali metal halide and an aluminum trihalide, e.g., NaCl and AlCl LiBr and AlBr or KCl and AlBr
  • the alkali metal halide and aluminum trihalide, components are formed as a slurry in a liquid organic medium.
  • Suitable organic media include aliphatic hydrocarbons and halohydrocarbons free from unsaturation such as dichloromethane, dibromoethane, hexane, heptane, isooctane, decane, and cyclohexane.
  • the resulting alkali metal tetrahaloalanate catalyst is separated from the solvent, if desired, by conventional techniques, such as filtration and decantation.
  • a slurry of the catalyst in the organic medium is directly employed in the alpha-olefin oligomerization process wherein the presence of a reaction solvent is desired.
  • the amount of oligomerization catalyst employed in the oligomerization process is not critical. Generally, molar ratios of alkali metal tetrahaloalanate to alpha-olefin reactant of from about 1:5 to 1:500 are satisfactory with molar ratios of about 1 :15 to 1:50 being preferred.
  • Reaction conditions The oligomerization process is conducted by contacting in the liquid phase the alphaolefin reactant, the catalyst and a reaction solvent or diluent which is capable of dissolving the alpha-olefin reactant, is liquid at reaction temperature and pressure and is inert to the reactants and product produced therefrom.
  • Suitable diluents include alkanes such as pentane, hexane, heptane, isooetane, and decane; cycloalkanes such as cyclopentane and cyclohexane; and halogenated alkaues such as methyl and ethyl chlorides, methyl and ethyl bromides.
  • Preferred diluents are alkanes of from 5 to 8 carbon atoms, particularly hexane and octane.
  • a portion of the alpha-olefin reactant and the oligomer product suitably serves as reaction diluent.
  • the use of a diluent is generally preferred, however, and when a diluent is utilized amounts up to about four moles of diluent per mole of alpha-olefin are satisfactory.
  • the process is suitably conducted in an inert reaction environment so that the presence of reactive materials such as water and oxygen is desirably avoided. Reaction conditions are therefore substantially anhydrous and substantially oxygenfree.
  • the precise method of establishing alpha-olefin catalyst contact is not critical.
  • the alphaolefin reactant, catalyst and diluent are charged to an autoclave or similar pressure reactor, and the reaction mixture is maintained with agitation at reaction temperature and pressure for the desired reaction period.
  • one reaction component is added to the other component in increments, as by adding the catalyst to the solution of the alpha-olefin and diluent.
  • the process is most efiiciently conductedat elevated temperature and pressure. In general, temperatures varying from about 50 C. to 200 C. are satisfactory with temperatures from about 100 C. to 150 C. being preferred. Suitable reaction pressures are those which serve to maintain the reaction mixture substantially in the liquid phase.
  • Reaction pressures from about 1 atmosphere to about 50 atmospheres in general are satisfactory although autogenous pressure, that is, the pressure generated by the reaction mixture when maintained at reaction temperature in a sealed reaction system is'preferred.
  • the contact time depends in part upon the reaction condition and the particular catalyst employed, but is usually between /2 hour to 20 hours and preferably between 1 hour to 4 hours.
  • the catalyst is recovered from the alpha-olefin oligomeric mixture for re-use.
  • the oligomeric product mixture is generally washed with a caustic solution to destroy any residual catalyst, water washed and then subjected to a flash distillation to recover the diluent.
  • the alpha-olefin oligomeric product is hydrogenated by any more or less conventional procedure.
  • Suitable catalysts include metallic catalysts such as Pt, Pd, or Ni, and metal oxides such as platinum oxide and copper chromite.
  • the hydrogenation catalysts are employed as the unsupported materials or as supported materials on carriers such as silica and alumina.
  • Preferred hydrogenation catalysts are nickel catalysts, especially commercial Raney nickel and nickel on kieselguhr.
  • the hydrogenation process is conducted at elevated temperature and pressure. Suitable reaction temperatures vary from 50 C. to 200 C., the optimum temperature depending in part upon the particular catalyst employed. Hydrogen pressures from about 10 atmospheres to about 200 atmospheres are satisfactory but hydrogen pressures. from about 30 to 100 atmospheres are preferred.
  • the alpha-olefin oligomeric product Prior to hydrogenation, the alpha-olefin oligomeric product contains a residual amount of ethylene unsaturation due to the presence of small amounts of highly substituted internal olefins.
  • the synthetic oil product The oligomerization of the alhpa-olefin reactant and the subsequent hydrogenation of the resulting alpha-olefin oligomers produces a synthetic lubricating oil consisting of saturated O -C oligomers, generally dimers, trimers, tetramers, pentamers, hexamers and heptamers.
  • the oligomers are characterized by a unique combination of alicyclic oligomers and isoparaffinic oligomers.
  • the alicyclic oligomers consist essentially of 5 and 6 membered naphthenes substiuted with several isoalkyl side chains.
  • the naphthenic oligomers contain a single naphthenic ring although a small amount, usually about 0.1 to 0.2 mole per mole of total naphthenic oligomers, contain two naphthenic rings.
  • the synthetic lubricating oil consists of at least 0.7 mole of naphthenic oligomers, preferably of at least 0.8 mole, and most preferably the molar ratio of naphthenic oligomers to isoparafiinic oligomers is from about 0.85:1 to 1:1.
  • the average molecular weight of the synthetic lubricating oil is usuallyabout 350 to 700, but preferably is about 450 to 6 00.
  • the hydrogenated synthetic lubricating oil is further characterized by a unique combination of both excellent high temperatures and low temperature properties as refiected particularly in low pour points and high viscosity indices.
  • the viscosity index of the hydrogenated alpha-olefin oligomers is at least 110, and in most 1nstances, is at least 125.
  • the pour points are generally no higher than -60 F. and preferably no higher than --70 F.
  • alphaolefin oligomers produced with a di-tert-butyl peroxide catalyst contains less than 21% naphthenes.
  • the pour points of such alpha-olefin oligomers are increased by as much as 50 F. to F. after hydrogenation.
  • the reaction temperature was C., reaction times ranged from 1.5 hours to 4 hours and n-hexane or noctane was utilized as the reaction solvent.
  • the molar ratio of LiAlCl to alpha-olefin feed was 20:1.
  • Each experiment was conducted by adding the olefin feed to a slurry of the catalyst in the reaction solvent. The catalyst was then removed from the reaction mixture, the oligomeric product mixture was washed once with 2.5% so dium carbonate or sodium hydroxide and twice with water to remove all traces of the catalyst. The solvent and unreacted olefin feed were then removed by rotary evaporation at elevated temperature and reduced pressure to give the oil product. The oil product was then hydrogenated with 5% wt.
  • Example IX Example XI A sample of KAlCl was prepared by heat 50 g of KCl 40 of A Sample of L1A1C14 was Prepared by heatmg g and 80 g. of AlCl in 432 g. of n-octane with vigorous LiCl and 114 g. of AlCl at 200 C. and subsequently cooling and dispersing the resulting LiAlCL; in 400 ml. of n-hexane. The slurry of LiAlCl in n-hexane and a mixture of 360 g. of l-hexene, 480 g. of l-octene and 1200 g.
  • the oligomeric product mixture was then hydrogenated with a commercial 44% wt. Ni-on-kieselguhr catalyst at 200 C. and 1500 p.s.i.g. hydrogen pressure for 8 hours.
  • the n-hexane solvent and unreacted olefins were removed at atmospheric pressure in a wiped-film-evaporator at 100 C.
  • the resulting oil was then topped to remove dimers at reduced pressure (5 mm. of Hg) and a temperature of 240 C. in the same wiped-film-evaporation in a second pass.
  • Example X A sample of NaAlCl. was prepared by heating 39 g. of NaCl and 80 g. of A101 in 432 g. of n-octane with vigorous stirring in an autoclave maintained at 150 C. for 1 hour. A mixture of 376 g. of l-hexene, 506 g. of 1- octene and 1202 g. of l-decene was then added continuously over a period of 115 minutes to the autoclave maintained at 150 C. At the end of the 115 minute period, the autoclave was maintained at 150 C. for an additional 20 minutes. The reaction mixture was then cooled, the catalyst slurry removed, the oligomeric product mixture was washed with Water, dried and filtered.
  • n-octene solvent and unreactcd olefin monomers were then removed with a rotary evaporator at 95-100 C. and at a reduced pressure.
  • the resulting oil produce was then hydrogenated with 5% Raney Ni at 1500 p.s.i.g. hydrogen pressure for 8 hours at 150 C.
  • the hydrogenated oil was then topped by distillation to remove dimers at 148 C. (stillhead) and 0.5 mm. of Hg.
  • the unhydrogenated oil and the hydrogenated oil had the properties set forth in Table II under the column designated as Run 2.
  • a mixture of 376 g. of l-hexene, 506 g. of l-octene and 1202 g. of l-decene was then added continuously over a period of minutes to the autoclave maintained at 150 C. At the end of the 90 minute period, the autoclave was maintained at 150 C. for an additional 20 minutes.
  • the reaction mixture was then cooled, the catalyst slurry was removed, the oligomeric product mixture was washed with water and dried.
  • the n-octane solvent and nnreacted olefin monomers were then removed with a rotary evaporator.
  • the resulting oil product was then hydrogenated with 5% Raney Ni at 1500 p.s.i.g. hydrogen ressure for 8 hours at 150 C.
  • the hydrogenated oil was then topped by distillation to remove dimers at 150 C. (stillhead) and 0.5 mm. of Hg.
  • Example XII A mixture of 30.7 g. of di-tert-butyl peroxide and 588 g. of l-decene were heated in an autoclave at 150 C. for 5 hours. The resulting oil product was cooled, distilled to remove unconverted l-decene, and then hydrogenated with 5% wt. Raney Ni at 150 C. for 3 hours at 1500 p.s.i.g. hydrogen. The resulting hydrogenated oil was then topped by distillation to remove dimers at 193 C. (stillhead) and 0.4 mm. of Hg.
  • Example X lII To illustrate the superior thermal and oxidative stability of the hydrogenated lubricating oil of the invention, the unhydrogenated (unsaturated) liquid oil of Example IX, Run 1 and the hydrogenated oil of Example IX, Run 1, (before topping of dimers) were submitted to oxidation by air at 350 F. for 22 hours. The color, acidity and evaporative loss for each oil is provided in Table III.
  • Example XIV The properties of an equal molar blend of the hydrogenated C C and C alpha-olefin oligomers (before topping of dimers) prepared in Examples I, II and HI, respectively, were measured and tabulated below in Table IV under the column designated Blend of Homo-Oligomers. For comparison, the properties of an oligomeric oil produced from a mixed C C and C alpha-olefin feed (Example VII) are also tabulated in Table IV under the column designated Co-oligomers.
  • a hydrogenated high-naphthenic content dimercontaining hydrocarbon synthetic lubricating oil consisting essentially of C to C naphthenic and isoparaflinic oligomers of a C -C normal alpha-olefin, said lubricating oil having all the following properties: a maximum pour point of about F., a minimum viscosity index of about 110 and a molar ratio of naphthenic oligomers to isoparafiinic oligomers of at least 0.7:1.
  • alphaolcfin is a C C alpha-olefin or a mixture of alphaolefins with mean chain length of about 8 to 10.
  • alphaolefins are a mixture of 25% m. l-hexene, 25% m. 1- octene and 50% m. l-decene.
  • a process of producing a fully saturated high-naphthenic content hydrocarbon synthetic lubricating oil consisting essentially of naphthenic and iso paraflinic C -C oligomers with a molar ratio of naphthenic oligomers to isoparaflinic oligomers of at least 0.7 1, having a viscosity index of at least and a maximum pour point of about -60 F. which comprises:
  • alpha-olefin is a C -C alpha-olefin or a mixture of alpha-olefins with mean chain length of about 8 to 10.

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  • Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
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Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3925217A (en) * 1974-03-28 1975-12-09 Monsanto Co Lubricants for rolling contact bearings
US3957898A (en) * 1973-03-12 1976-05-18 Snam Progetti S.P.A. Synthetic lubricating oils from thermal cracking or polymers having very high viscosity
US4031020A (en) * 1974-05-31 1977-06-21 Nippon Oil Company, Ltd. Central system fluid composition
US4032591A (en) * 1975-11-24 1977-06-28 Gulf Research & Development Company Preparation of alpha-olefin oligomer synthetic lubricant
US4032471A (en) * 1975-01-27 1977-06-28 Eastman Kodak Company Process for preparing yttrium oxide and rare earth metal oxide phosphors
US7396970B1 (en) * 2000-11-03 2008-07-08 Chevron Phillips Chemical Company Lp Monitoring and control of processes for making 1-hexene
WO2015171482A1 (en) 2014-05-08 2015-11-12 Ineos Usa, Llc Drilling fluid and process of making the same
WO2019212674A2 (en) 2018-04-25 2019-11-07 Ineos Oligomers Usa Llc Synthetic fluids with improved biodegradability

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CA1113707A (en) * 1978-03-09 1981-12-08 Uniroyal, Inc. Use of synthetic hydrocarbon fluids in transformers
US4261841A (en) * 1979-12-18 1981-04-14 Phillips Petroleum Company Lubricating composition comprising hydrogenated oligomers of 1,3-diolefins and a calcium petroleum sulfonate
FR2501224A1 (fr) * 1981-03-03 1982-09-10 Nyco Sa Nouveau fluide hydraulique a base de polymeres isoparaffiniques
US4992183A (en) * 1987-04-01 1991-02-12 Ethyl Corporation Multigrade hydrogenated decene-1 oligomer engine oils
US6093861A (en) * 1993-01-25 2000-07-25 Muntz; Pieter Jan Dirk Lubricating oil composition
JP5436022B2 (ja) * 2009-04-23 2014-03-05 昭和シェル石油株式会社 潤滑油
US20120156052A1 (en) * 2010-12-20 2012-06-21 General Electric Company Ice release systems
US10676689B2 (en) 2017-12-29 2020-06-09 Exxonmobil Research And Engineering Company Grease compositions for low temperature operation

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3957898A (en) * 1973-03-12 1976-05-18 Snam Progetti S.P.A. Synthetic lubricating oils from thermal cracking or polymers having very high viscosity
US3925217A (en) * 1974-03-28 1975-12-09 Monsanto Co Lubricants for rolling contact bearings
US4031020A (en) * 1974-05-31 1977-06-21 Nippon Oil Company, Ltd. Central system fluid composition
US4032471A (en) * 1975-01-27 1977-06-28 Eastman Kodak Company Process for preparing yttrium oxide and rare earth metal oxide phosphors
US4032591A (en) * 1975-11-24 1977-06-28 Gulf Research & Development Company Preparation of alpha-olefin oligomer synthetic lubricant
US7396970B1 (en) * 2000-11-03 2008-07-08 Chevron Phillips Chemical Company Lp Monitoring and control of processes for making 1-hexene
US20080275282A1 (en) * 2000-11-03 2008-11-06 Chevron Phillips Chemical Company Lp Monitoring and control of processes for making 1-hexene
US7754932B2 (en) 2000-11-03 2010-07-13 Chevron Phillips Chemical Company Lp Monitoring and control of processes for making 1-hexene
WO2015171482A1 (en) 2014-05-08 2015-11-12 Ineos Usa, Llc Drilling fluid and process of making the same
RU2708426C2 (ru) * 2014-05-08 2019-12-06 Инеос Юса, Ллс Буровые растворы и способ их получения
WO2019212674A2 (en) 2018-04-25 2019-11-07 Ineos Oligomers Usa Llc Synthetic fluids with improved biodegradability

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