High Viscosity Group II Base Stock via Radical Coupling
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Solution Overview
Problem
Conventional methods for producing high viscosity lubricant base stocks, such as solvent processing and catalytic processing, face challenges in reducing sulfur and nitrogen content while maintaining viscosity, with catalytic processing limiting viscosities to around 10 cSt at 100°C and being costly for specialty polymeric materials.
Innovation Solution
A base stock composition is formed by radical coupling of a feedstock with a viscosity index of 50 to 120, using a peroxide catalyst to achieve a coupled effluent with a kinematic viscosity of at least 14 cSt, sulfur content of 0.03 wt% or less, and aromatics content of 10 wt% or less, followed by fractionation to achieve desired molecular weights and viscosities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If hydrotreating and hydrocracking processes are used for heteroatom removal, then sulfur and nitrogen content is reduced, but viscosity is significantly reduced
Solution Approach 1:
The patent applies preliminary heteroatom removal through hydroprocessing before the coupling reaction. By removing sulfur and nitrogen early in the process, the subsequent coupling reaction can build high molecular weight polymers without the viscosity-reducing side effects of heteroatoms, achieving both low heteroatom content and high viscosity
Solution Approach 2:
The patent changes the molecular weight parameters through coupling reactions, combining lower molecular weight intermediates into higher molecular weight base stocks. This parameter change increases viscosity while the preliminary heteroatom removal ensures the final product maintains low sulfur and nitrogen content
2Ease of manufacture
If catalytic processing is used for base stock production, then lower viscosity base stocks are produced, but the ability to make high viscosity base stocks is limited
Solution Approach 1:
The patent merges catalytic processing with coupling reactions in a sequential process. The catalytic processing first creates clean, low-viscosity intermediates with removed heteroatoms, then coupling reactions merge these intermediates into high molecular weight polymers, combining the advantages of both methods to achieve high viscosity with low heteroatom content
Solution Approach 2:
The patent uses parameter changes in molecular weight through controlled coupling reactions. By adjusting coupling conditions and feedstock selection, the process can produce base stocks across a wide viscosity range, overcoming the viscosity limitation of conventional catalytic processing
3Temperature
If solvent processing is used for high viscosity base stock production, then high viscosity base stocks are produced, but heteroatom removal is less effective
Solution Approach 1:
The patent applies preliminary heteroatom removal through hydroprocessing before the coupling reaction. By removing sulfur and nitrogen early in the process, the subsequent coupling reaction can build high molecular weight polymers without the viscosity-reducing side effects of heteroatoms, achieving both low heteroatom content and high viscosity
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 method produces Group II base stocks with viscosities greater than conventional limits, retaining desirable properties of low molecular weight base stocks while increasing viscosity, and can be used to formulate high-quality lubricants with improved low-temperature performance and oxidation stability.
Implementation Method 1
A base stock composition is formed by radical coupling of a feedstock with a viscosity index of 50 to 120, using a peroxide catalyst to achieve a coupled effluent with a kinematic viscosity of at least 14 cSt
Implementation Method 2
followed by fractionating the coupled effluent to achieve desired molecular weights and viscosities
Data Source
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AI summary
Methods are provided for producing Group II base stocks having high viscosity and also having one or more properties indicative of a high quality base stock. The resulting Group II base stocks can have a viscosity at 100°C and/or a viscosity at 40°C that is greater than the corresponding viscosity for a conventional Group II base stock. Additionally, the resulting Group II base stocks can have one or more properties that are indicative of a high quality base stock.