Copolymer Cold Flow Improver for Fuel Filterability
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Solution Overview
Problem
Conventional cold flow improvers for fuel oils and lubricants are costly and require higher doses to improve cold flow properties and filterability, while existing additives may not effectively address the crystallization issues causing filter plugging in fuels at lower temperatures.
Innovation Solution
Development of higher copolymers comprising α-olefins, alkenyl esters, and esters of α,β-unsaturated carboxylic acids, with a specific range of carbon atoms in the alcohol component, which are easier to handle and more effective in improving cold flow properties and filterability at lower concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cold flow improvers (EVA copolymers) are used, then cold flow properties are improved, but higher dosages are required and cost increases
Solution Approach 1:
The patent changes the chemical structure parameters of the cold flow improver by using esters of α,β-unsaturated carboxylic acids with higher alcohols (10-20 carbon atoms) instead of conventional vinyl acetate monomers. This structural modification enables the polymer to achieve superior cold flow improvement at lower dosages (5-50 ppm versus 50-500 ppm for conventional additives), directly resolving the contradiction between effectiveness and quantity required.
Solution Approach 2:
The invention creates a composite polymer structure containing multiple functional units: α-olefin units (60-90 mol%), alkenyl ester units (5-30 mol%), and α,β-unsaturated carboxylic acid ester units (5-30 mol%). This composite structure combines the benefits of different monomer types to achieve both high effectiveness and low dosage requirements, overcoming the limitations of single-component conventional CFIs.
2Reliability
If conventional cold flow improvers are used, then filterability is improved, but handling difficulty and cost increase
Solution Approach 1:
The patent modifies physical parameters of the additive by controlling polymer molecular weight (1,000-10,000 g/mol) and using higher alcohol esters that provide better solubility and flow characteristics. These parameter changes result in improved handling properties including easier dissolution in fuel oils and better stability, while maintaining superior filterability improvement at lower dosages.
3Reliability
If esters of α,β-unsaturated carboxylic acids with higher alcohols are polymerized, then cold flow improvement effectiveness increases, but polymerization complexity increases
Solution Approach 1:
The patent segments the polymerization process into controlled stages with specific monomer addition sequences. The polymer is synthesized in multiple steps: first forming the α-olefin backbone, then incorporating alkenyl esters, and finally adding α,β-unsaturated carboxylic acid esters. This segmented approach manages the complexity of polymerizing multiple monomer types while achieving the target composition and effectiveness.
Solution Approach 2:
The invention controls polymerization parameters including temperature (50-100°C), pressure (1-10 atm), and monomer ratios to simplify the process. By optimizing these parameters, the patent enables efficient polymerization of complex monomer combinations without requiring excessively complex equipment or procedures, resolving the contradiction between effectiveness and process complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The new copolymers significantly enhance the cold flow properties and filterability of fuel oils and lubricants, reducing the Cold Filter Plugging Point (CFPP) and Pour Point (PP) while being more cost-effective and easier to handle than conventional additives.
Implementation Method 1
This is due to the crystallization of longer-chain paraffins, which begins at the cloud point temperature and forms large, plate-like wax crystals
Implementation Method 2
These, in turn, exhibit similar crystallization properties to the fuel's paraffins, but prevent their growth, allowing the fuel to pass through the filter at significantly lower temperatures
Data Source
AI summary
The invention relates to the use of polymers, comprising the following polymerised groups: an a-olefin, at least one alkenyl ester and at least one ester of an a,ß-unsaturated carboxylic acid with higher alcohols, as additive for fuels and lubricants and in particularly as cold flow improver in fuel oils, fuels and lubricants with said additives and additive packets containing such copolymers. The invention further relates to copolymers in which the above monomers are polymerised.