Crosslinked Polymer Dewaxing Aid for Faster Wax Filtration
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Solution Overview
Problem
Existing dewaxing processes face challenges with wax crystals blocking filters during filtration, leading to increased filtration time and oil trapped in wax cakes, necessitating a dewaxing aid that accelerates wax crystal formation for faster separation.
Innovation Solution
A crosslinked polymer composed of alkyl acrylate, vinyl aromatic hydrocarbon, crosslinker, and initiator is developed, with a molecular weight range of 5000-15000, to enhance nucleation and adsorption processes, facilitating efficient wax crystal formation and filtration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If conventional dewaxing aids are used, then dewaxing process can be carried out, but filtration time increases due to wax crystal blocking filters
Solution Approach 1:
The patent changes the molecular parameters of the dewaxing aid by specifying a narrow molecular weight range (5000-15000) and controlled degree of crosslinking (0.1-2.5 wt%). This parameter optimization ensures the polymer forms a appropriate network structure that promotes rapid wax crystal formation and growth, preventing filter blocking while maintaining high separation efficiency
Solution Approach 2:
The invention uses a composite polymer structure combining linear chains with crosslinked networks. The linear portions provide flexibility and solubility, while the crosslinked regions (formed by 0.1-2.5 wt% crosslinking agent) create nucleation sites that accelerate wax crystal formation. This composite structure resolves the contradiction by enabling both fast crystal formation and good filtration properties
2Productivity
If dewaxing aid accelerates wax crystal formation, then filtration time reduces, but oil content in wax cake increases
Solution Approach 1:
The patent applies local quality by creating specific zones within the wax crystal structure. The crosslinked polymer segments locally concentrate at crystal nuclei and grow outward, forming a hierarchical structure where the polymer-rich core promotes rapid growth while the polymer-depleted outer regions maintain good oil-wax separation. This local differentiation resolves the contradiction between fast formation and low oil content
3Reliability
If polymer molecular weight is increased, then nucleation capability improves, but viscosity increases affecting processability
Solution Approach 1:
The patent employs dynamic balance by selecting an optimal molecular weight range (5000-15000) that provides sufficient nucleation capability while maintaining adequate chain flexibility. The controlled crosslinking (0.1-2.5 wt%) further modulates the polymer dynamics, creating a network that is rigid enough for effective nucleation but flexible enough for easy dissolution and processing. This dynamic optimization resolves the contradiction between nucleation reliability and manufacturing ease
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 crosslinked polymer significantly reduces filtration time and improves the separation of wax from oil, resulting in faster and more efficient dewaxing processes.
Implementation Method 1
it is essential to prepare a dewaxing aid which can fasten the wax crystal formation
Implementation Method 2
A crosslinked polymer... to enhance nucleation and adsorption processes, facilitating efficient wax crystal formation and filtration
Data Source
AI summary
The present disclosure discloses a crosslinked polymer for dewaxing the lubricating oils, the polymer derived from (a) 70-77 weight percentage of at least one alkyl acrylate; (b) 23-28 weight percentage of at least one vinyl aromatic hydrocarbon; (c) 0.1-2.5 weight percentage of at least one crosslinker; and (d) 0.75-2.5 weight percentage of at least one initiator and wherein the polymer has a number average molecular weight in the range of 5000-15000. The present disclosure discloses a convenient process for preparing the crosslinked polymer. The present disclosure further reveals a method for dewaxing the lubricating oil.