WO2020202207A1 - A process for poly alpha olefin synthesis - Google Patents
A process for poly alpha olefin synthesis Download PDFInfo
- Publication number
- WO2020202207A1 WO2020202207A1 PCT/IN2020/050311 IN2020050311W WO2020202207A1 WO 2020202207 A1 WO2020202207 A1 WO 2020202207A1 IN 2020050311 W IN2020050311 W IN 2020050311W WO 2020202207 A1 WO2020202207 A1 WO 2020202207A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- stream
- poly alpha
- range
- alpha olefins
- reaction mixture
- Prior art date
Links
- 229920013639 polyalphaolefin Polymers 0.000 title claims abstract description 164
- 238000000034 method Methods 0.000 title claims abstract description 105
- 230000015572 biosynthetic process Effects 0.000 title description 5
- 238000003786 synthesis reaction Methods 0.000 title description 5
- VSCWAEJMTAWNJL-UHFFFAOYSA-K aluminium trichloride Chemical compound Cl[Al](Cl)Cl VSCWAEJMTAWNJL-UHFFFAOYSA-K 0.000 claims abstract description 76
- 239000011541 reaction mixture Substances 0.000 claims abstract description 69
- 239000003054 catalyst Substances 0.000 claims abstract description 58
- 229910021578 Iron(III) chloride Inorganic materials 0.000 claims abstract description 57
- RBTARNINKXHZNM-UHFFFAOYSA-K iron trichloride Chemical compound Cl[Fe](Cl)Cl RBTARNINKXHZNM-UHFFFAOYSA-K 0.000 claims abstract description 57
- 239000000203 mixture Substances 0.000 claims abstract description 49
- 238000010438 heat treatment Methods 0.000 claims abstract description 41
- 230000002194 synthesizing effect Effects 0.000 claims abstract description 40
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 32
- 239000004711 α-olefin Substances 0.000 claims description 36
- 238000005336 cracking Methods 0.000 claims description 35
- 230000003111 delayed effect Effects 0.000 claims description 31
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 claims description 17
- 239000005864 Sulphur Substances 0.000 claims description 15
- 238000001035 drying Methods 0.000 claims description 9
- 238000001816 cooling Methods 0.000 claims description 8
- 238000001914 filtration Methods 0.000 claims description 8
- 238000000638 solvent extraction Methods 0.000 claims description 8
- 238000007738 vacuum evaporation Methods 0.000 claims description 8
- 239000000539 dimer Substances 0.000 claims description 7
- 239000013638 trimer Substances 0.000 claims description 7
- 239000001993 wax Substances 0.000 description 34
- AFFLGGQVNFXPEV-UHFFFAOYSA-N 1-decene Chemical compound CCCCCCCCC=C AFFLGGQVNFXPEV-UHFFFAOYSA-N 0.000 description 18
- 238000006243 chemical reaction Methods 0.000 description 16
- 150000001336 alkenes Chemical class 0.000 description 14
- 239000000047 product Substances 0.000 description 13
- 238000006384 oligomerization reaction Methods 0.000 description 8
- 229910052799 carbon Inorganic materials 0.000 description 7
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 7
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 6
- 239000000314 lubricant Substances 0.000 description 6
- 239000003921 oil Substances 0.000 description 6
- 238000012986 modification Methods 0.000 description 5
- 230000004048 modification Effects 0.000 description 5
- 238000012545 processing Methods 0.000 description 5
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- 238000009835 boiling Methods 0.000 description 4
- 230000003197 catalytic effect Effects 0.000 description 4
- 239000008367 deionised water Substances 0.000 description 4
- 239000000706 filtrate Substances 0.000 description 4
- 239000000463 material Substances 0.000 description 4
- 239000012044 organic layer Substances 0.000 description 4
- 229910052710 silicon Inorganic materials 0.000 description 4
- 239000010703 silicon Substances 0.000 description 4
- -1 C12 hydrocarbons Chemical class 0.000 description 3
- 229910015400 FeC13 Inorganic materials 0.000 description 3
- 238000005481 NMR spectroscopy Methods 0.000 description 3
- DCTOHCCUXLBQMS-UHFFFAOYSA-N 1-undecene Chemical compound CCCCCCCCCC=C DCTOHCCUXLBQMS-UHFFFAOYSA-N 0.000 description 2
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 239000002841 Lewis acid Substances 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 230000015556 catabolic process Effects 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000004821 distillation Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000009472 formulation Methods 0.000 description 2
- 150000007517 lewis acids Chemical class 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000003208 petroleum Substances 0.000 description 2
- 238000004227 thermal cracking Methods 0.000 description 2
- OXBLVCZKDOZZOJ-UHFFFAOYSA-N 2,3-Dihydrothiophene Chemical compound C1CC=CS1 OXBLVCZKDOZZOJ-UHFFFAOYSA-N 0.000 description 1
- 238000006596 Alder-ene reaction Methods 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000005977 Ethylene Substances 0.000 description 1
- 238000005727 Friedel-Crafts reaction Methods 0.000 description 1
- JIHOFAKIOYGMII-UHFFFAOYSA-I aluminum;iron(2+);pentachloride Chemical compound [Al+3].[Cl-].[Cl-].[Cl-].[Cl-].[Cl-].[Fe+2] JIHOFAKIOYGMII-UHFFFAOYSA-I 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 238000012550 audit Methods 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 239000002199 base oil Substances 0.000 description 1
- 150000007942 carboxylates Chemical class 0.000 description 1
- 238000006555 catalytic reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000010725 compressor oil Substances 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000011143 downstream manufacturing Methods 0.000 description 1
- 230000007717 exclusion Effects 0.000 description 1
- 238000004817 gas chromatography Methods 0.000 description 1
- 239000012208 gear oil Substances 0.000 description 1
- 239000010720 hydraulic oil Substances 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000010348 incorporation Methods 0.000 description 1
- 239000011968 lewis acid catalyst Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- KWKAKUADMBZCLK-UHFFFAOYSA-N methyl heptene Natural products CCCCCCC=C KWKAKUADMBZCLK-UHFFFAOYSA-N 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- TVMXDCGIABBOFY-UHFFFAOYSA-N n-Octanol Natural products CCCCCCCC TVMXDCGIABBOFY-UHFFFAOYSA-N 0.000 description 1
- 230000000269 nucleophilic effect Effects 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 239000003348 petrochemical agent Substances 0.000 description 1
- 238000005120 petroleum cracking Methods 0.000 description 1
- 238000012805 post-processing Methods 0.000 description 1
- 238000007781 pre-processing Methods 0.000 description 1
- 230000035484 reaction time Effects 0.000 description 1
- 229910052938 sodium sulfate Inorganic materials 0.000 description 1
- 235000011152 sodium sulphate Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- 150000003573 thiols Chemical class 0.000 description 1
- 238000005292 vacuum distillation Methods 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G9/00—Thermal non-catalytic cracking, in the absence of hydrogen, of hydrocarbon oils
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J27/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
- B01J27/06—Halogens; Compounds thereof
- B01J27/08—Halides
- B01J27/10—Chlorides
-
- C—CHEMISTRY; METALLURGY
- 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
- C07C2/20—Acids of halogen; Salts thereof ; Complexes thereof with organic compounds
- C07C2/22—Metal halides; Complexes thereof with organic compounds
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G50/00—Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation
- C10G50/02—Production of liquid hydrocarbon mixtures from lower carbon number hydrocarbons, e.g. by oligomerisation of hydrocarbon oils for lubricating purposes
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G73/00—Recovery or refining of mineral waxes, e.g. montan wax
- C10G73/02—Recovery of petroleum waxes from hydrocarbon oils; Dewaxing of hydrocarbon oils
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M107/00—Lubricating compositions characterised by the base-material being a macromolecular compound
- 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
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M177/00—Special methods of preparation of lubricating compositions; Chemical modification by after-treatment of components or of the whole of a lubricating composition, not covered by other classes
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2527/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
- C07C2527/06—Halogens; Compounds thereof
- C07C2527/125—Compounds comprising a halogen and scandium, yttrium, aluminium, gallium, indium or thallium
- C07C2527/126—Aluminium chloride
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07C—ACYCLIC OR CARBOCYCLIC COMPOUNDS
- C07C2527/00—Catalysts comprising the elements or compounds of halogens, sulfur, selenium, tellurium, phosphorus or nitrogen; Catalysts comprising carbon compounds
- C07C2527/06—Halogens; Compounds thereof
- C07C2527/128—Compounds comprising a halogen and an iron group metal or a platinum group metal
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10B—DESTRUCTIVE DISTILLATION OF CARBONACEOUS MATERIALS FOR PRODUCTION OF GAS, COKE, TAR, OR SIMILAR MATERIALS
- C10B55/00—Coking mineral oils, bitumen, tar, and the like or mixtures thereof with solid carbonaceous material
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2300/00—Aspects relating to hydrocarbon processing covered by groups C10G1/00 - C10G99/00
- C10G2300/20—Characteristics of the feedstock or the products
- C10G2300/201—Impurities
- C10G2300/202—Heteroatoms content, i.e. S, N, O, P
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10G—CRACKING HYDROCARBON OILS; PRODUCTION OF LIQUID HYDROCARBON MIXTURES, e.g. BY DESTRUCTIVE HYDROGENATION, OLIGOMERISATION, POLYMERISATION; RECOVERY OF HYDROCARBON OILS FROM OIL-SHALE, OIL-SAND, OR GASES; REFINING MIXTURES MAINLY CONSISTING OF HYDROCARBONS; REFORMING OF NAPHTHA; MINERAL WAXES
- C10G2400/00—Products obtained by processes covered by groups C10G9/00 - C10G69/14
- C10G2400/10—Lubricating oil
-
- C—CHEMISTRY; METALLURGY
- C10—PETROLEUM, GAS OR COKE INDUSTRIES; TECHNICAL GASES CONTAINING CARBON MONOXIDE; FUELS; LUBRICANTS; PEAT
- C10M—LUBRICATING COMPOSITIONS; USE OF CHEMICAL SUBSTANCES EITHER ALONE OR AS LUBRICATING INGREDIENTS IN A LUBRICATING COMPOSITION
- C10M2205/00—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions
- C10M2205/02—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers
- C10M2205/028—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers containing aliphatic monomers having more than four carbon atoms
- C10M2205/0285—Organic macromolecular hydrocarbon compounds or fractions, whether or not modified by oxidation as ingredients in lubricant compositions containing acyclic monomers containing aliphatic monomers having more than four carbon atoms used as base material
-
- 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
- C10N2020/02—Viscosity; Viscosity index
-
- 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
- C10N2030/00—Specified physical or chemical properties which is improved by the additive characterising the lubricating composition, e.g. multifunctional additives
- C10N2030/40—Low content or no content compositions
- C10N2030/43—Sulfur free or low sulfur content compositions
-
- 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
- C10N2040/00—Specified use or application for which the lubricating composition is intended
- C10N2040/04—Oil-bath; Gear-boxes; Automatic transmissions; Traction drives
-
- 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
- C10N2040/00—Specified use or application for which the lubricating composition is intended
- C10N2040/08—Hydraulic fluids, e.g. brake-fluids
-
- 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
- C10N2040/00—Specified use or application for which the lubricating composition is intended
- C10N2040/30—Refrigerators lubricants or compressors lubricants
Definitions
- the present disclosure is in the field of lubricants.
- it pertains to process of poly alpha olefin synthesis.
- Frictional failure is cited as one of the most common reason for breakdown of machinery in the industry. For e.g. it is reported that -20% of the total energy produced by tribological contacts is lost due to friction and another 3% is lost due to mechanical wear (Holmberg et al, Friction, 2017, 5(3), 263-284).
- Industrial grade lubricants are typically high molecular weight oils, greases or waxes that have appreciable thermal resistance. Most common greases or waxes are obtained as aby-product of petroleum cracking and related down-stream processes. Of particular importance, are synthetic lubricants such as poly alpha olefins (PAO), which are typically obtained from refined feed streams (olefin or ethylene-rich stream).
- PAO poly alpha olefins
- the instant disclosure relates to a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins.
- a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh)
- Figure 1 depicts the graphical representation of oligomer ratio of commercial PAO grades, in accordance with an implementation of the present subject matter.
- Figure 2 depicts the conversion versus various catalysts comprising FeChiAlCb (having various ratios) at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
- Figure 3 depicts the dimer percentage versus various catalysts comprising FeChiAlCb (having various ratios) in the 1-decene oligomerization reaction at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
- Figure 4 depicts the trimer percentage versus various catalysts comprising FcCFcAlCh (having various ratios) in the 1-decene oligomerization reaction at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
- Figure 5 depicts the tetramer percentage versus various catalysts comprising FeCbiAlCb (having various ratios) in the 1-decene oligomerization reaction at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
- Figure 6 depicts the higher oligomer (greater than tetramer) percentage versus various catalysts comprising FeCbiAlCb (having various ratios) in the 1-decene oligomerization reaction at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
- the articles“a”,“an” and“the” are used to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article.
- the term“delayed coker heavy naphtha stream” refers to naphtha range feed obtained from a coker unit.
- a coker takes the lowest value bottoms material (vacuum resid) and cracks it to the point that all of the resid is eliminated, yielding only lighter fractions and solid carbon.
- Coker naphtha is typically hydrotreated to saturate the relatively high level of olefins and then fed to the reformer for upgrading to reformate.
- the olefin content of said stream is noted to be 20-35%.
- the boiling point range of said stream is in the range of about 75 to about 220 °C.
- wax cracking stream refers to the thermal cracking stream of wax yielding lighter products.
- the boiling point range of said stream is in the range of about 75 to about 220 °C.
- the term“pure linear alpha olefin” refers to purified/refined alpha olefin stream.
- the pure linear alpha olefin stream may comprise 100% 1-decene.
- the pure linear alpha olefin stream comprises an olefin selected from the group consisting of 1-decene, 1 -octane, 1-nonene, 1-undecene, and combinations thereof.
- the pure linear alpha olefins are C8 to C12 hydrocarbons.
- catalyst and“catalyst formulation” have been used interchangeably in the present disclosure to define the oil-soluble metal carboxylate formulations that have been employed for thermal cracking process described herein.
- Molar equivalent ratios of metals and organic agents may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited.
- a temperature range of about 50°C to about 100°C should be interpreted to include not only the explicitly recited limits of about 50°C to about 100°C, but also to include sub ranges, such as 55°C to 95°C, 60°C to 80°C, and so forth, as well as individual amounts, including fractional amounts, within the specified ranges, such as 52.2°C, 60.6°C, and 61.3°C, for example.
- the present disclosure is not to be limited in scope by the specific embodiments described herein, which are intended for the purposes of exemplification only. Functionally equivalent products, compositions, and methods are clearly within scope of the disclosure, as described herein.
- the present disclosure furnishes an improved process involving the use of a bimetallic catalyst, which allows the input feed stream to be selectable from the crude and low value petroleum feed streams such as delayed coker heavy naphtha stream and wax cracking stream.
- the catalyst is noted to comprise a combination of AlCb and FcCh.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins.
- a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb)
- AlCb aluminum chloride
- FeCb ferric chloride
- PAO poly alpha olefins
- the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof.
- DCHN delayed coker heavy naphtha
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof.
- DCHN delayed coker heavy naphtha
- PAO poly alpha olefins
- the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream, wax cracking stream and pure linear alpha olefin stream.
- DCHN delayed coker heavy naphtha
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream, wax cracking stream and pure linear alpha olefin stream.
- DCHN delayed coker heavy naphtha
- the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio in the range of 1 :0.1 to 1 :5.
- the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio in the range of 1:0.1 to 1:2.
- the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio of 1:0.17.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream and wax cracking stream and the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio in the range of 1 :0.1 to 1 : 10.
- DCHN delayed coker heavy naphtha
- a process for synthesizing poly alpha olefins as described herein, wherein the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.05 to 1:0.25.
- the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.07 to 1:0.20.
- the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.08 to 1:0.15.
- the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio of 1:0.01.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream and pure linear alpha olefin stream and the delayed coker heavy naphtha stream to the pure linear alpha olefin stream weight ratio is in the range of 1:0.05 to 1:0.25.
- DCHN delayed coker heavy naphtha
- a process for synthesizing poly alpha olefins as described herein, wherein the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1 :0.05 to 1:0.25.
- the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1:0.07 to 1:0.20.
- the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1:0.08 to 1:0.15.
- the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio of 1:0.1.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of wax cracking stream and pure linear alpha olefin stream and the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1:0.05 to 1:0.25.
- the catalyst composition has an AlCb to the FcCl i weight ratio in a range of 1:0.33 to 1:3.
- the catalyst composition has an AlCb to the FcCl i weight ratio in a range of 1:0.36 to 1:2.8.
- the catalyst composition has an AlCb to the FcCl i weight ratio in a range of 1:0.4 to 1:2.5.
- the catalyst composition has an AICI3 to the FcCh weight ratio of 1:0.43.
- the catalyst composition has an AICI3 to the FcCl i weight ratio of 1: 1.
- the catalyst composition has an AICI3 to the FcCl i weight ratio of 1:2.3.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AICI3) and ferric chloride (FcCl i), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the catalyst composition has an AICI3 to the FcCl i weight ratio in a range of 1:0.33 to 1:3.
- AICI3 aluminum chloride
- FcCl i ferric chloride
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AICI3) and ferric chloride (FcCl i), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof and the catalyst composition has an AICI3 to the FcCl i weight ratio in a range of 1:0.33 to 1:3.
- DCHN delayed coker heavy naphtha
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AICI3) and ferric chloride (FcCl i), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream, wax cracking stream and pure linear alpha olefin stream and the catalyst composition has an AICI3 to the FcCl i weight ratio in a range of 1:0.33 to 1:3.
- DCHN delayed coker heavy naphtha
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the delayed coker heavy naptha stream to the wax cracking stream weight ratio is in the range of 1:0.1 to 1: 10 and the catalyst composition has an AlCb to the FcCh weight ratio in a range of 1:0.33 to 1:3.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.05 to 1 :0.25 and the catalyst composition has an AlCb to the FcCh weight ratio in a range of 1:0.33 to 1:3.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FcCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1:0.05 to 1 :0.25 and the catalyst composition has an AlCb to the FcCh weight ratio in a range of 1 :0.33 to 1:3.
- a process for synthesizing poly alpha olefins as described herein, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 100°C for a period in a range of 60 - 100 minutes to obtain the poly alpha olefins.
- heating the reaction mixture is carried out at a temperature in a range of 55°C - 90°C for a period in a range of 60 - 90 minutes to obtain the poly alpha olefins.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FcCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 100°C for a period in a range of 60 - 100 minutes to obtain the poly alpha olefins.
- a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FcCh)
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof heating the reaction mixture is carried out at a temperature in a range of 50°C - 100°C for a period in a range of 60 - 100 minutes to obtain the poly alpha olefins.
- DCHN delayed coker heavy naphtha
- a process for synthesizing poly alpha olefins as described herein, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
- heating the reaction mixture is carried out at a temperature in a range of 55°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
- heating the reaction mixture is carried out at a temperature of 75°C for a period in a range of 62 - 78 minutes to obtain the poly alpha olefins.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
- a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh)
- AlCb aluminum chloride
- FeCh ferric chloride
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
- DCHN delayed coker heavy naphtha
- a process for synthesizing poly alpha olefins as described herein, wherein said process further comprises processes selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof.
- the process is a combination of cooling, solvent extraction, drying, filtration and vacuum evaporation.
- the vacuum distillation is carried out using a rotary evaporator at a temperature below 190 °C.
- drying is carried out using treating poly alpha olefins with anhydrous sodium sulphate.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins
- DCHN delayed coker heavy naphtha
- poly alpha olefins PAO
- the poly alpha olefins has a sulphur content in a range of 10 ppm - 30 ppm.
- the poly alpha olefins has a sulphur content in a range of 10 ppm - 28 ppm.
- the poly alpha olefins has a sulphur content in a range of 10 ppm - 25 ppm.
- PAO poly alpha olefins
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the poly alpha olefins has a sulphur content in a range of 10 ppm - 30 ppm.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof, wherein the poly alpha olefins has a sulphur content in a range of 10 ppm - 30 ppm.
- poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof.
- the poly alpha olefins comprises a combination of dimer, trimer, and tetramer.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof.
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof and has a sulphur content in a range of 10 ppm - 30 ppm.
- a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh)
- AlCb aluminum chloride
- FeCh ferric chloride
- a process for synthesizing poly alpha olefins (PAO) from at least one feed stream comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof, wherein the poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof and has a sulphur content in a range of 10 ppm - 30 ppm.
- a poly alpha olefin obtained by the process for synthesizing poly alpha olefins (PAO) from at least one feed stream, wherein the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins.
- a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh)
- a poly alpha olefin for use as industrial grade lubricant.
- the poly alpha olefin is useful as air compressor oil, gear oil, hydraulic oil and the like.
- the delayed coker heavy naphtha (DCHN) stream was characterized and was found to contain 29% olefin.
- the 1 H NMR was carried out using Joel 500 MHz NMR instrument.
- the simulated distillation (SIMDIS) by gas chromatography is a tool often used in the petrochemical industry to analyze the composition of an oil or gas sample by measuring the boiling point range distribution of the sample components. The same was carried out using AC analytical control systems.
- SIMDIS simulated distillation
- the obtained product (poly alpha olefin) was found to be good characteristics in terms of viscosity (Viscosity at 100 °C: 2.08 and Viscosity index: 148).
- the paraffin wax (representative of wax cracking stream) was subjected to cracking at 390 to 410 °C for a period of 45 minutes to 1 hour.
- the formed olefins were distilled out from the reaction vessel.
- the distilled liquid contains the olefins >50 % in the carbon number of C6 to Cl 5, which was added to a round bottom flask containing magnetic stirrer bar in it.
- AlCh/FcCh (90: 10) (2 mol %) followed by catalytic amount of de-ionized water (200 pL) were added. This flask was quickly set-up with condenser and the reaction was continued at 100 °C (using silicon oil bath) for 6 h.
- reaction was cooled to room temperature and it was transferred into separating funnel which was then quenched with water. The organic layer was collected separately and dried over anhydrous sodium sulfate and then filtered. Collected filtrate was concentrated using rotary evaporator (> 190 °C) to afford desired poly alpha olefin product. Yield: 85 %.
- the obtained product (poly alpha olefin) was found to be good characteristics in terms of viscosity (Viscosity at 40 °C: 6.08; Viscosity at 100 °C: 2.08 and Viscosity index: 166).
- the obtained product (poly alpha olefin) was found to be good characteristics in terms of viscosity (viscosity at 100 oC: 4.8 cst, Viscosity index: 161 and C p : -50 °C).
- Delayed coker naphtha (heavy naphtha) (DCN-HN) (60 mL, 20 mL olefins) along with the wax cracking stream (10 mL, (50 % olefins) 5 ml olefins) was added to a round bottom flask containing magnetic stirrer bar in it.
- AlCh/FcCh (90: 10) ( 1 mol %) followed by catalytic amount of de-ionized water (200 pL) were added.
- This flask was quickly set-up with condenser and the reaction was continued at 100 °C (using silicon oil bath) for 6 hours.
- reaction was cooled to room temperature and it was transferred into separating funnel which was then quenched with water. The organic layer was collected separately and dried over anhydrous sodium sulfate and then filtered. Collected filtrate was concentrated using rotary evaporator (> 190 °C) to afford desired polyalphaolefin product. Yield: 87 %.
- a series of catalysts comprising of the catalyst composition, i.e. AlCb/FeCb in different molar ratios [A1C13, AlC13/FeC13 (0.7:0.3), AlCb/FeCb (0.5:0.5), AlC13/FeC13 (0.3:0.7), FeC13] were chosen for the 1-decene (pure linear alpha olefin stream) oligomerization catalysis.
- the analysis of commercially available PAO is provided in Figure 1, clearly indicating percentage of various oligomers.
- the remarkable near complete conversion of monomers is clearly identifiable in Figure 3.
- the oligomer ratio was found to shift towards higher oligomers upon increasing the Lewis acid strength.
- the catalyst compositions comprising AlCb to the FeCb weight ratio of 0.7:0.3, 0.5:0.5 and 0.3:0.7 (i.e. within the range of 1:0.33 to 1:3) were found to result in an impressive conversion towards higher olefins, especially at relatively low temperatures (even at 50 °C). Furthermore, for a particular catalyst, with increase in temperature, the ratio is shifting towards lower oligomer side. The same may be clearly observable from the results depicted in the Figures 2-6 (wherein conditions used are: 1 mol % of catalyst, 120 min reaction time).
- the process of the present disclosure provides an efficient route for obtaining PAOs from low value crude petroleum streams such as DCHN, wax cracking stream.
- the process also provides an added advantage of ensuring removal of sulphur contamination, thus requiring no additional Sulphur-removal step.
- the process of the present disclosure utilizing a catalyst combination comprising AlCb and FcCh was found to thus found to be both cost and energy efficient.
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Oil, Petroleum & Natural Gas (AREA)
- Chemical Kinetics & Catalysis (AREA)
- General Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Inorganic Chemistry (AREA)
- Materials Engineering (AREA)
- Production Of Liquid Hydrocarbon Mixture For Refining Petroleum (AREA)
- Catalysts (AREA)
Abstract
The present disclosure relates to a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCl3) and ferric chloride (FeCl3), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins.
Description
A PROCESS FOR POLY ALPHA OLEFIN SYNTHESIS
TECHNICAL FIELD
[0001] The present disclosure is in the field of lubricants. In particular, it pertains to process of poly alpha olefin synthesis.
BACKGROUND OF THE INVENTION
[0002] The modem industrial era is heavily reliant on uninterrupted throughput and in this regard, internal quality audits to prevent failures are common place. In most industries, such as petrochemicals, an unforeseen failure or breakdown of machinery can have catastrophic effects. Frictional failure is cited as one of the most common reason for breakdown of machinery in the industry. For e.g. it is reported that -20% of the total energy produced by tribological contacts is lost due to friction and another 3% is lost due to mechanical wear (Holmberg et al, Friction, 2017, 5(3), 263-284).
[0003] Therefore, concentrated efforts are made to ensure smooth running of machinery and in this regard, industrial grade lubricants are known to be of immense importance. Industrial grade lubricants are typically high molecular weight oils, greases or waxes that have appreciable thermal resistance. Most common greases or waxes are obtained as aby-product of petroleum cracking and related down-stream processes. Of particular importance, are synthetic lubricants such as poly alpha olefins (PAO), which are typically obtained from refined feed streams (olefin or ethylene-rich stream).
[0004] Well known synthetic strategies involve the use of lewis acid catalysts for Friedel-crafts alkylation-type synthesis. A number of applications are noted to list modifications of said strategy- US5714661 and US6184429. However, a major drawback of such approaches is noted to be the requirement of post as well as pre-processing of input and output stream. For instance, the input feed stream obtained from cracking processes, is found to be rich in Sulphur, which is found to contaminate the oligomer output stream obtained. Further multiple oligomerization steps may be required to yield PAOs with acceptable viscosity. Additionally, PAO synthesis typically relies on purified or refined feed streams.
[0005] Therefore, considering the importance of PAO’s, energy and cost-effective methodologies to manufacture PAO are of utmost importance. Processes which rely on low- value streams would accordingly be of utmost importance.
SUMMARY OF THE INVENTION
[0006] The instant disclosure relates to a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins.
[0007] These and other features, aspects and advantages of the present subject matter will be better understood with reference to the following description and appended claims. This summary is provided to introduce a selection of concepts in a simplified form. This summary is not intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The detailed description is described with reference to the accompanying figures. In the figures, the left-most digit(s) of a reference number identifies the figure in which the reference number first appears. The same numbers are used throughout the drawings to reference like features and components.
[0009] Figure 1 depicts the graphical representation of oligomer ratio of commercial PAO grades, in accordance with an implementation of the present subject matter.
[0010] Figure 2 depicts the conversion versus various catalysts comprising FeChiAlCb (having various ratios) at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
[0011] Figure 3 depicts the dimer percentage versus various catalysts comprising FeChiAlCb (having various ratios) in the 1-decene oligomerization reaction at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
[0012] Figure 4 depicts the trimer percentage versus various catalysts comprising FcCFcAlCh (having various ratios) in the 1-decene oligomerization reaction at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
[0013] Figure 5 depicts the tetramer percentage versus various catalysts comprising FeCbiAlCb (having various ratios) in the 1-decene oligomerization reaction at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
[0014] Figure 6 depicts the higher oligomer (greater than tetramer) percentage versus various catalysts comprising FeCbiAlCb (having various ratios) in the 1-decene oligomerization reaction at 50 °C to 100 °C, in accordance with an implementation of the present subject matter.
DETAILED DESCRIPTION
[0015] Those skilled in the art will be aware that the present disclosure is subject to variations and modifications other than those specifically described. It is to be understood that the present disclosure includes all such variations and modifications. The disclosure also includes all such steps, features, compositions and compounds referred to or indicated in this specification, individually or collectively and any and all combinations of any or more of such steps or features.
Definitions
[0016] For convenience, before further description of the present disclosure, certain terms employed in the specification, and examples are collected here. These definitions should be read in the light of the remainder of the disclosure and understood as by a person of skill in the art. The terms used herein have the meanings recognized and known to those of skill in the art, however, for convenience and completeness, particular terms and their meanings are set forth below.
[0017] The articles“a”,“an” and“the” are used to refer to one or to more than one (i.e., to at least one) of the grammatical object of the article.
[0018] The terms“comprise” and“comprising” are used in the inclusive, open sense, meaning that additional elements may be included. Throughout this specification, unless the context requires otherwise the word“comprise”, and variations, such as“comprises” and“comprising”, will be understood to imply the inclusion of a stated element or step or group of element or steps but not the exclusion of any other element or step or group of element or steps.
[0019] The term“including” is used to mean“including but not limited to”.“Including” and “including but not limited to” are used interchangeably.
[0020] The term“delayed coker heavy naphtha stream” refers to naphtha range feed obtained from a coker unit. A coker takes the lowest value bottoms material (vacuum resid) and cracks it
to the point that all of the resid is eliminated, yielding only lighter fractions and solid carbon. Coker naphtha is typically hydrotreated to saturate the relatively high level of olefins and then fed to the reformer for upgrading to reformate. Typically, the olefin content of said stream is noted to be 20-35%. The boiling point range of said stream is in the range of about 75 to about 220 °C.
[0021] The term“wax cracking stream” refers to the thermal cracking stream of wax yielding lighter products. The boiling point range of said stream is in the range of about 75 to about 220 °C.
[0022] The term“pure linear alpha olefin” refers to purified/refined alpha olefin stream. For instance, the pure linear alpha olefin stream may comprise 100% 1-decene. In another embodiment of the present disclosure, the pure linear alpha olefin stream comprises an olefin selected from the group consisting of 1-decene, 1 -octane, 1-nonene, 1-undecene, and combinations thereof. Typically, the pure linear alpha olefins are C8 to C12 hydrocarbons.
[0023] The terms“catalyst” and“catalyst formulation” have been used interchangeably in the present disclosure to define the oil-soluble metal carboxylate formulations that have been employed for thermal cracking process described herein.
[0024] Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood to one of ordinary skill in the art to which this disclosure belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the disclosure, the preferred methods, and materials are now described. All publications mentioned herein are incorporated herein by reference.
[0025] Molar equivalent ratios of metals and organic agents may be presented herein in a range format. It is to be understood that such range format is used merely for convenience and brevity and should be interpreted flexibly to include not only the numerical values explicitly recited as the limits of the range, but also to include all the individual numerical values or sub-ranges encompassed within that range as if each numerical value and sub-range is explicitly recited. For example, a temperature range of about 50°C to about 100°C should be interpreted to include not only the explicitly recited limits of about 50°C to about 100°C, but also to include sub ranges, such as 55°C to 95°C, 60°C to 80°C, and so forth, as well as individual amounts, including fractional amounts, within the specified ranges, such as 52.2°C, 60.6°C, and 61.3°C, for example.
[0026] The present disclosure is not to be limited in scope by the specific embodiments described herein, which are intended for the purposes of exemplification only. Functionally equivalent products, compositions, and methods are clearly within scope of the disclosure, as described herein.
[0027] With regards to the problems discussed in the background section, the present disclosure furnishes an improved process involving the use of a bimetallic catalyst, which allows the input feed stream to be selectable from the crude and low value petroleum feed streams such as delayed coker heavy naphtha stream and wax cracking stream. Herein, the catalyst is noted to comprise a combination of AlCb and FcCh.
[0028] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins.
[0029] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof.
[0030] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof.
[0031] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream, wax cracking stream and pure linear alpha olefin stream.
[0032] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting
at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream, wax cracking stream and pure linear alpha olefin stream.
[0033] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio in the range of 1:0.1 to 1: 10. In another embodiment of the present disclosure the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio in the range of 1 :0.1 to 1 :5. In yet another embodiment of the present disclosure the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio in the range of 1:0.1 to 1:2. In an alternate embodiment of the present disclosure the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio of 1:0.17.
[0034] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream and wax cracking stream and the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio in the range of 1 :0.1 to 1 : 10.
[0035] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.05 to 1:0.25. In another embodiment of the present disclosure the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.07 to 1:0.20. In yet another embodiment of the present disclosure the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.08 to 1:0.15. In an alternate embodiment of the present disclosure the
combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio of 1:0.01.
[0036] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream and pure linear alpha olefin stream and the delayed coker heavy naphtha stream to the pure linear alpha olefin stream weight ratio is in the range of 1:0.05 to 1:0.25.
[0037] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1 :0.05 to 1:0.25. In another embodiment of the present disclosure the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1:0.07 to 1:0.20. In yet another embodiment of the present disclosure the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1:0.08 to 1:0.15. In an alternate embodiment of the present disclosure the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio of 1:0.1.
[0038] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of wax cracking stream and pure linear alpha olefin stream and the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1:0.05 to 1:0.25.
[0039] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the catalyst composition has an AlCb to the FcCl i weight ratio in a range of 1:0.33 to 1:3. In another embodiment of the present disclosure the catalyst composition has an AlCb to the FcCl i weight ratio in a range of 1:0.36
to 1:2.8. In yet another embodiment of the present disclosure the catalyst composition has an AlCb to the FcCl i weight ratio in a range of 1:0.4 to 1:2.5. In an alternate embodiment of the present disclosure the catalyst composition has an AICI3 to the FcCh weight ratio of 1:0.43. In an alternate embodiment of the present disclosure the catalyst composition has an AICI3 to the FcCl i weight ratio of 1: 1. In an alternate embodiment of the present disclosure the catalyst composition has an AICI3 to the FcCl i weight ratio of 1:2.3.
[0040] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AICI3) and ferric chloride (FcCl i), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the catalyst composition has an AICI3 to the FcCl i weight ratio in a range of 1:0.33 to 1:3.
[0041] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AICI3) and ferric chloride (FcCl i), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof and the catalyst composition has an AICI3 to the FcCl i weight ratio in a range of 1:0.33 to 1:3.
[0042] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AICI3) and ferric chloride (FcCl i), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream, wax cracking stream and pure linear alpha olefin stream and the catalyst composition has an AICI3 to the FcCl i weight ratio in a range of 1:0.33 to 1:3.
[0043] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum
chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the delayed coker heavy naptha stream to the wax cracking stream weight ratio is in the range of 1:0.1 to 1: 10 and the catalyst composition has an AlCb to the FcCh weight ratio in a range of 1:0.33 to 1:3.
[0044] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCb), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.05 to 1 :0.25 and the catalyst composition has an AlCb to the FcCh weight ratio in a range of 1:0.33 to 1:3.
[0045] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FcCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1:0.05 to 1 :0.25 and the catalyst composition has an AlCb to the FcCh weight ratio in a range of 1 :0.33 to 1:3.
[0046] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 100°C for a period in a range of 60 - 100 minutes to obtain the poly alpha olefins. In another embodiment of the present disclosure heating the reaction mixture is carried out at a temperature in a range of 55°C - 90°C for a period in a range of 60 - 90 minutes to obtain the poly alpha olefins.
[0047] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FcCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein heating the reaction
mixture is carried out at a temperature in a range of 50°C - 100°C for a period in a range of 60 - 100 minutes to obtain the poly alpha olefins.
[0048] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof heating the reaction mixture is carried out at a temperature in a range of 50°C - 100°C for a period in a range of 60 - 100 minutes to obtain the poly alpha olefins.
[0049] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins. In another embodiment of the present disclosure heating the reaction mixture is carried out at a temperature in a range of 55°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins. In another embodiment of the present disclosure heating the reaction mixture is carried out at a temperature of 75°C for a period in a range of 62 - 78 minutes to obtain the poly alpha olefins.
[0050] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
[0051] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the at least one feed
stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
[0052] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein said process further comprises processes selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof. In another embodiment of the present disclosure the process is a combination of cooling, solvent extraction, drying, filtration and vacuum evaporation. In another embodiment of the present disclosure the vacuum distillation is carried out using a rotary evaporator at a temperature below 190 °C. In yet another embodiment of the present disclosure drying is carried out using treating poly alpha olefins with anhydrous sodium sulphate.
[0053] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof.
[0054] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
[0055] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting
at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
[0056] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the poly alpha olefins has a sulphur content in a range of 10 ppm - 30 ppm. In another embodiment of the present disclosure the poly alpha olefins has a sulphur content in a range of 10 ppm - 28 ppm. In another embodiment of the present disclosure the poly alpha olefins has a sulphur content in a range of 10 ppm - 25 ppm.
[0057] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the at least one feed stream has a sulphur content in the range of 100 ppm to 2% of total weight.
[0058] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the poly alpha olefins has a sulphur content in a range of 10 ppm - 30 ppm.
[0059] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation,
and combinations thereof, wherein the poly alpha olefins has a sulphur content in a range of 10 ppm - 30 ppm.
[0060] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) as described herein, wherein the poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof. In another embodiment of the present disclosure the poly alpha olefins comprises a combination of dimer, trimer, and tetramer.
[0061] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof.
[0062] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins, wherein the poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof and has a sulphur content in a range of 10 ppm - 30 ppm.
[0063] In an embodiment of the present disclosure, there is provided a process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; (b) heating the reaction mixture to obtain the poly alpha olefins; and (c) processing by a process selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof, wherein the poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof and has a sulphur content in a range of 10 ppm - 30 ppm.
[0064] In an embodiment of the present disclosure, there is provided a poly alpha olefin obtained by the process for synthesizing poly alpha olefins (PAO) from at least one feed stream, wherein the process comprising: (a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water
to obtain a reaction mixture; and (b) heating the reaction mixture to obtain the poly alpha olefins.
[0065] In an embodiment of the present disclosure, there is provided a poly alpha olefin for use as industrial grade lubricant. In another embodiment of the present disclosure, the poly alpha olefin is useful as air compressor oil, gear oil, hydraulic oil and the like.
[0066] Although the subject matter has been described in considerable details with reference to certain preferred embodiments thereof, other embodiments are possible.
EXAMPLES
[0067] The following examples are given by way of illustration of the present disclosure and should not be construed to limit the scope of the present disclosure. It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are intended to provide further explanation of the claimed subject matter.
Materials and methods
[0068] The delayed coker heavy naphtha (DCHN) stream was characterized and was found to contain 29% olefin. The 1 H NMR analysis if DCHN revealed distinct alpha olefins peaks. The analysis is provided hereinbelow in Table 1-
[0069] The 1 H NMR was carried out using Joel 500 MHz NMR instrument. The simulated distillation (SIMDIS) by gas chromatography is a tool often used in the petrochemical industry to analyze the composition of an oil or gas sample by measuring the boiling point range distribution of the sample components. The same was carried out using AC analytical control systems.
Example 1
[0070] DCHN (1000 mL) was added to a round bottom flask containing overhead stirrer in it. To this flask, AlCL/FeCL (90: 10) (15 g) followed by catalytic amount of de-ionized water (500 pL) were added. This flask was quickly set-up with condenser and the reaction was continued at 100 °C (using silicon oil bath) for 6 hours. After the reaction stopped, reaction was cooled to room temperature and it was transferred into separating funnel which was then quenched with water. The organic layer was collected separately and dried over anhydrous sodium sulfate and then filtered. Collected filtrate was concentrated using rotary evaporator (>190 °C) to afford desired poly alpha olefin product. Yield: 300 mL.
[0071] The obtained product (poly alpha olefin) was found to be good characteristics in terms of viscosity (Viscosity at 100 °C: 2.08 and Viscosity index: 148).
Example 2
[0072] The paraffin wax (representative of wax cracking stream) was subjected to cracking at 390 to 410 °C for a period of 45 minutes to 1 hour. The formed olefins were distilled out from the reaction vessel. The distilled liquid contains the olefins >50 % in the carbon number of C6 to Cl 5, which was added to a round bottom flask containing magnetic stirrer bar in it. To this flask, AlCh/FcCh (90: 10) (2 mol %) followed by catalytic amount of de-ionized water (200 pL) were added. This flask was quickly set-up with condenser and the reaction was continued at 100 °C (using silicon oil bath) for 6 h. After the reaction stopped, reaction was cooled to room temperature and it was transferred into separating funnel which was then quenched with water. The organic layer was collected separately and dried over anhydrous sodium sulfate and then filtered. Collected filtrate was concentrated using rotary evaporator (> 190 °C) to afford desired poly alpha olefin product. Yield: 85 %.
[0073] The obtained product (poly alpha olefin) was found to be good characteristics in terms of viscosity (Viscosity at 40 °C: 6.08; Viscosity at 100 °C: 2.08 and Viscosity index: 166).
Example 3
[0074] DCHN (300 mL, 90 ml olefins) along with the 1-decene (pure linear alpha olefin; 30 mL, 25 % olefin feed) was added to a round bottom flask containing magnetic stirrer bar in it. To this flask, AlCh/FcCh (50:50) (1 mol %) followed by catalytic amount of de-ionized water (200 pL) were added. This flask was quickly set-up with condenser and the reaction was continued at 100 °C (using silicon oil bath) for 6 hours. After the reaction stopped, reaction
was cooled to room temperature and it was transferred into separating funnel which was then quenched with water. The organic layer was collected separately and dried over anhydrous sodium sulfate and then filtered. Collected filtrate was concentrated using rotary evaporator (>190 °C) to afford desired poly alpha olefin product. Yield: 85 %.
[0075] The obtained product (poly alpha olefin) was found to be good characteristics in terms of viscosity (viscosity at 100 oC: 4.8 cst, Viscosity index: 161 and Cp: -50 °C).
Example 4
[0076] Delayed coker naphtha (heavy naphtha) (DCN-HN) (60 mL, 20 mL olefins) along with the wax cracking stream (10 mL, (50 % olefins) 5 ml olefins) was added to a round bottom flask containing magnetic stirrer bar in it. To this flask, AlCh/FcCh (90: 10) ( 1 mol %) followed by catalytic amount of de-ionized water (200 pL) were added. This flask was quickly set-up with condenser and the reaction was continued at 100 °C (using silicon oil bath) for 6 hours. After the reaction stopped, reaction was cooled to room temperature and it was transferred into separating funnel which was then quenched with water. The organic layer was collected separately and dried over anhydrous sodium sulfate and then filtered. Collected filtrate was concentrated using rotary evaporator (> 190 °C) to afford desired polyalphaolefin product. Yield: 87 %.
[0077] The obtained product (poly alpha olefin) was found to be good characteristics in terms of viscosity (2 cst at 100 °C grade, Viscosity index: 167 and Cp: -54).
[0078] Overall the examples 1-4 were noted to provide good viscosity index, wherein cut off of 130 was established. Therefore, a viscosity index of 167, as shown by example 4 was indeed impressive. Furthermore, based on requirement, the viscosity was identified to be tunable, i.e. the same could be increased with an addition of 1-decene.
Example 5
[0079] A series of catalysts comprising of the catalyst composition, i.e. AlCb/FeCb in different molar ratios [A1C13, AlC13/FeC13 (0.7:0.3), AlCb/FeCb (0.5:0.5), AlC13/FeC13 (0.3:0.7), FeC13] were chosen for the 1-decene (pure linear alpha olefin stream) oligomerization catalysis. The analysis of commercially available PAO is provided in Figure 1, clearly indicating percentage of various oligomers. Herein, the remarkable near complete conversion of monomers is clearly identifiable in Figure 3. The oligomer ratio was found to shift towards higher oligomers upon increasing the Lewis acid strength. In this regard, the catalyst
compositions comprising AlCb to the FeCb weight ratio of 0.7:0.3, 0.5:0.5 and 0.3:0.7 (i.e. within the range of 1:0.33 to 1:3) were found to result in an impressive conversion towards higher olefins, especially at relatively low temperatures (even at 50 °C). Furthermore, for a particular catalyst, with increase in temperature, the ratio is shifting towards lower oligomer side. The same may be clearly observable from the results depicted in the Figures 2-6 (wherein conditions used are: 1 mol % of catalyst, 120 min reaction time).
[0080] It was surprisingly noted that the catalyst combination of iron chloride- aluminium chloride yielded the PAO (2 cst grade) lubricants without the necessity of distillation of high boiling oligomer products. Furthermore, it was found that the feedstock can be separated easily from the product and the remaining residue can be used for PAO (2 cst grade) base oil. Therefore, with a variation in the Lewis acid strength, it was possible to obtain different grades of low viscosity PAO base stocks (refer Figures 2-6).
[0081] Effect of Sulphur compounds in oligomerization reaction: It was hypothesized that sulphur impurities get impregnated into the PAO matrix. In the presence of nucleophilic thiol or FbS compounds, the carbonium ion formed in the oligomerization reaction can be trapped by Sulphur compounds to form the alpha olefin oligomers containing Sulphur in their backbone. Or thiol-ene reaction with the alkene above 75 °C can also lead to PAO with sulphur compounds. The presence of the catalyst composition of the present disclosure was found to successfully trap sulphur contaminants, thus preventing their incorporation into PAOs. The results of same are enlisted the Table 2 below-
SCD data: Table 2
[0082] Further it was noted that the process was equally effective when using wax cracking stream (refer Table 3 above), wherein the PAO was found to have < 20 ppm content of Sulphur compound.
Advantages of the present disclosure
[0083] The process of the present disclosure provides an efficient route for obtaining PAOs from low value crude petroleum streams such as DCHN, wax cracking stream. The process also provides an added advantage of ensuring removal of sulphur contamination, thus requiring no additional Sulphur-removal step. The process of the present disclosure utilizing a catalyst combination comprising AlCb and FcCh was found to thus found to be both cost and energy efficient.
[0084] Although the subject matter has been described in considerable details with reference to certain examples and embodiments, this description is not meant to be construed in a limiting sense. Various modifications of the disclosed embodiments, as well as alternate embodiments of the subject matter, will become apparent to persons skilled in the art upon reference to the description of the subject matter. It is therefore contemplated that such modifications can be made without departing from the present subject matter as defined.
Claims
I/We Claim:
1) A process for synthesizing poly alpha olefins (PAO) from at least one feed stream, the process comprising:
(a) contacting at least one feed stream, a catalyst composition comprising a combination of aluminum chloride (AlCb) and ferric chloride (FeCh), and water to obtain a reaction mixture; and
(b) heating the reaction mixture to obtain the poly alpha olefins.
2) The process as claimed in claim 1, wherein the at least one feed stream is selected from a group consisting of delayed coker heavy naphtha (DCHN) stream, wax cracking stream, pure linear alpha olefin stream, and combinations thereof.
3) The process as claimed in claim 1, wherein the at least one feed stream is a combination of delayed coker heavy naphtha (DCHN) stream, wax cracking stream and pure linear alpha olefin stream.
4) The process as claimed in claim 2, wherein the combination of delayed coker heavy naphtha stream and the wax cracking stream has a weight ratio in the range of 1:0.1 to 1:10.
5) The process as claimed in claim 2, wherein the combination of delayed coker heavy naphtha stream and the pure linear alpha olefin stream has a weight ratio in a range of 1:0.05 to 1:0.25.
6) The process as claimed in claim 2, wherein the combination of wax cracking stream and the pure linear alpha olefin stream has a weight ratio in the range of 1 :0.05 to 1 :0.25.
7) The process as claimed in claim 1, wherein the catalyst composition has an AlCb to the FcCl i weight ratio in a range of 1:0.33 to 1:3.
8) The process as claimed in claim 1, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 100°C for a period in a range of 60 - 100 minutes to obtain the poly alpha olefins.
9) The process as claimed in claim 8, wherein heating the reaction mixture is carried out at a temperature in a range of 50°C - 80°C for a period in a range of 60 - 80 minutes to obtain the poly alpha olefins.
10) The process as claimed in claim 1, wherein said process further comprises processes selected from a group consisting of cooling, solvent extraction, drying, filtering, vacuum evaporation, and combinations thereof.
11) The process as claimed in claim 1, wherein the poly alpha olefins has a sulphur content in a range of 10 ppm - 30 ppm.
12) The process as claimed in claim 1, wherein the poly alpha olefins comprises dimer, trimer, tetramer, and combinations thereof.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
IN201921013519 | 2019-04-03 | ||
IN201921013519 | 2019-04-03 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2020202207A1 true WO2020202207A1 (en) | 2020-10-08 |
Family
ID=70617183
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/IN2020/050311 WO2020202207A1 (en) | 2019-04-03 | 2020-03-31 | A process for poly alpha olefin synthesis |
Country Status (1)
Country | Link |
---|---|
WO (1) | WO2020202207A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN116651506A (en) * | 2023-03-27 | 2023-08-29 | 中国石油大学(华东) | Oil-soluble molybdenum-based catalyst, and preparation method and application thereof |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB479632A (en) * | 1936-02-11 | 1938-02-09 | Bataafsche Petroleum | A process for the polymerisation of unsaturated compounds |
GB1308211A (en) * | 1969-08-01 | 1973-02-21 | Chisso Corp | Catalyst and process for polymerizing olefins |
US5714661A (en) | 1996-05-31 | 1998-02-03 | Tuli; Deepak Kumar | Process for the preparation of synthetic lubricant base stocks |
US6184429B1 (en) | 1997-11-19 | 2001-02-06 | The Indian Oil Corporation Ltd. | Oligomerization of alpha-olefins |
US20110004038A1 (en) * | 2009-07-06 | 2011-01-06 | Chevron U.S.A., Inc. | Process to make base oil from thermally cracked waxy feed using ionic liquid catalyst |
US20170203286A1 (en) * | 2014-07-10 | 2017-07-20 | Reliance Industries Limited | Ionic liquid, adduct and methods thereof |
-
2020
- 2020-03-31 WO PCT/IN2020/050311 patent/WO2020202207A1/en active Application Filing
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB479632A (en) * | 1936-02-11 | 1938-02-09 | Bataafsche Petroleum | A process for the polymerisation of unsaturated compounds |
GB1308211A (en) * | 1969-08-01 | 1973-02-21 | Chisso Corp | Catalyst and process for polymerizing olefins |
US5714661A (en) | 1996-05-31 | 1998-02-03 | Tuli; Deepak Kumar | Process for the preparation of synthetic lubricant base stocks |
US6184429B1 (en) | 1997-11-19 | 2001-02-06 | The Indian Oil Corporation Ltd. | Oligomerization of alpha-olefins |
US20110004038A1 (en) * | 2009-07-06 | 2011-01-06 | Chevron U.S.A., Inc. | Process to make base oil from thermally cracked waxy feed using ionic liquid catalyst |
US20170203286A1 (en) * | 2014-07-10 | 2017-07-20 | Reliance Industries Limited | Ionic liquid, adduct and methods thereof |
Non-Patent Citations (1)
Title |
---|
HOLMBERG ET AL., FRICTION, vol. 5, no. 3, 2017, pages 263 - 284 |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
CN116651506A (en) * | 2023-03-27 | 2023-08-29 | 中国石油大学(华东) | Oil-soluble molybdenum-based catalyst, and preparation method and application thereof |
CN116651506B (en) * | 2023-03-27 | 2024-06-07 | 中国石油大学(华东) | Oil-soluble molybdenum-based catalyst, and preparation method and application thereof |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
JP5800449B2 (en) | Lubricating oil base oil, method for producing the same, and lubricating oil composition | |
JP5726397B2 (en) | Lubricating oil base oil, method for producing the same, and lubricating oil composition | |
JP2010090251A (en) | Lubricant base oil, method for producing the same, and lubricating oil composition | |
WO2009119505A1 (en) | Lubricant base oil, method for production thereof, and lubricant oil composition | |
EP3652281A1 (en) | Base oils and methods of making the same | |
CN101688147A (en) | Electrical insulating oil compositions and preparation thereof | |
JP2015227471A (en) | Base oil for lubrication oil, method for producing the same and lubrication oil composition | |
CN109022027B (en) | Method for producing poly alpha-olefin from Fischer-Tropsch synthesis light oil and poly alpha-olefin obtained by method | |
EP3538628B1 (en) | Synthetic oligomer compositions and methods of manufacture | |
US4013736A (en) | Synthesis of low viscosity low pour point hydrocarbon lubricating oils | |
WO2020202207A1 (en) | A process for poly alpha olefin synthesis | |
EP1301580A4 (en) | Compositions of group ii and/or group iii base oils and alkylated fused and/or polyfused aromatic compounds | |
CN105829268A (en) | Method for making polyolefins using aluminum halide catalyzed oligomerization of olefins | |
JPS5837642B2 (en) | electrical insulation oil | |
US4062791A (en) | Electrical insulating oil | |
CN107949626B (en) | Method for producing polyalphaolefins using ionic liquid catalyzed olefin oligomerization | |
JP5390743B2 (en) | Heat treated oil composition | |
WO2014167332A1 (en) | Oligomerisation process | |
JP2010090254A (en) | Lubricant base oil, method for producing the same, and lubricating oil composition | |
JP2015127427A (en) | Lubricant base oil and manufacturing method thereof and lubricant composition | |
JPS606044B2 (en) | Electrical insulation oil composition | |
JPH11185530A (en) | Electric insulation oil | |
JP5913174B2 (en) | Lubricating oil base oil production method, lubricating oil base oil, and lubricating oil composition | |
EP0497024B1 (en) | Non-carcinogenic light lubricants and a process for producing same | |
Tanashev et al. | DEVELOPMENT OF TECHNOLOGY FOR SELECTIVE PURIFICATION OF OIL DISTILLATES FROM PARAFFIN BASE OILS |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
121 | Ep: the epo has been informed by wipo that ep was designated in this application |
Ref document number: 20724958 Country of ref document: EP Kind code of ref document: A1 |
|
NENP | Non-entry into the national phase |
Ref country code: DE |
|
122 | Ep: pct application non-entry in european phase |
Ref document number: 20724958 Country of ref document: EP Kind code of ref document: A1 |