Fischer-Tropsch Poly Alpha Olefin Lubricant Base Stock Process

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Solution Overview

Problem

There is a need for a process to effectively upgrade Fischer-Tropsch products into poly alpha olefins and lubricant base stocks that can maintain high viscosity index and stability under the demanding conditions of modern automotive engines, while also maximizing the yield of higher value hydrocarbon products.

Innovation Solution

A process involving the thermal cracking of Fischer-Tropsch products to produce a C5-C18 fraction, which is then oligomerized using a catalyst such as a Lewis acid, metal oxide, or metallocene compound, followed by fractionation to achieve a product with an average carbon number greater than 24, and subsequent blending with hydroisomerized Fischer-Tropsch wax to create suitable lubricant base stocks.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional mineral oil based lubricants are produced using separative sequence with fractionation under atmospheric pressure and vacuum, then lubricant base stocks can be obtained, but the process cannot meet the viscosity index requirements of modern automotive engines operating at higher temperatures

Engineering Contradiction:

Improveoperating temperatureVSAvoidviscosity index

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent changes the chemical composition parameters by producing poly alpha olefins through oligomerization of alpha olefinic hydrocarbons from Fischer-Tropsch liquids, rather than relying on conventional paraffinic crude fractionation. This chemical transformation enables the lubricant to maintain stable viscosity at high temperatures, directly resolving the contradiction between high operating temperature and adequate viscosity index.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If VI improvers such as polyacrylates are used to achieve high viscosity index values, then viscosity index improves, but the lubricant undergoes degradation under high temperatures and high shear rates

Engineering Contradiction:

Improveviscosity indexVSAvoidchemical stability

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent replaces the use of VI improvers (polyacrylates) with poly alpha olefins produced directly from Fischer-Tropsch liquids. These poly alpha olefins provide the necessary viscosity index without the degradation issues associated with polyacrylate VI improvers, achieving both high viscosity index and chemical stability simultaneously.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Reliability

If Fischer-Tropsch products are upgraded to poly alpha olefins through oligomerization, then high viscosity index lubricants with improved stability are produced, but the process complexity increases compared to conventional separative sequence

Engineering Contradiction:

Improveviscosity index and stabilityVSAvoidprocess complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent segments the Fischer-Tropsch liquid into specific fractions (C5-C18 alpha olefinic hydrocarbon fraction) before oligomerization. This segmentation allows the complex Fischer-Tropsch product to be processed in manageable steps, reducing the overall process complexity while maintaining the ability to produce high viscosity index lubricants with improved stability.

Inventive Principle:

Principle #1Segmentation

4Reliability

If conventional synthetic procedures are used to produce poly alpha olefins, then high viscosity index characteristics are achieved, but the production cost becomes expensive requiring expensive starting materials

Engineering Contradiction:

Improveviscosity index characteristicsVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent uses Fischer-Tropsch liquids as the starting material instead of expensive conventional synthetic feedstocks. Fischer-Tropsch liquids can be produced from various feedstocks including coal, gas, and oil, providing a cost-effective route to poly alpha olefins with high viscosity index characteristics, thereby reducing production costs while maintaining product performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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

This process enhances the production of high viscosity index lubricants with improved stability and yield of higher value hydrocarbons, addressing the limitations of conventional methods in meeting modern engine demands and maximizing carbon value.

Implementation Method 1

thermal cracking of Fischer-Tropsch products to produce a C5-C18 fraction

Methodology Applied

Scientific EffectThermal cracking: Pyrolysis

Implementation Method 2

contacting the C5-C18 fraction with an oligomerization catalyst under conditions to produce an oligomerized product

Methodology Applied

Scientific EffectOligomerization: Chemical Bonding

Data Source

PatentUS8440872B2Process for preparing poly alpha olefins and lubricant basestocks from Fischer-Tropsch liquids

Publication Date: 2013.05.14 MAESTRO ASSOCS

AI summary

A process for preparing poly alpha olefins from a Fisher-Tropsch product. The process comprising the steps of contacting a C5-C18 fraction of an alpha-olefinic hydrocarbon mixture produced from thermal cracking a C16-C40 Fisher-Tropsch product with an oligomerization catalyst under conditions to produce an oligomerized product; and fractionating the oligomerized product to obtain a fractionated product having an average carbon number greater than 30. A process for preparing lubricant base stocks from a Fisher-Tropsch product is also provided.