High Viscosity Group I 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 method involving radical coupling using a peroxide catalyst on a feedstock with specific properties, followed by fractionation, to produce a base stock with increased viscosity and desirable molecular weights, sulfur content, and aromatics content, achieving viscosities greater than 35 cSt at 100°C and 600 cSt at 40°C.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If solvent processing is used to produce high viscosity base stocks, then viscosity is improved, but sulfur and nitrogen content reduction is insufficient
Solution Approach 1:
The patent combines solvent processing with selective hydroprocessing to integrate the viscosity-preserving benefits of solvent processing with the heteroatom removal capabilities of hydroprocessing, creating a hybrid process that achieves both high viscosity and low sulfur/nitrogen content
Solution Approach 2:
The patent modifies hydroprocessing parameters (catalyst selection, temperature, pressure, residence time) to reduce sulfur and nitrogen content while minimizing viscosity loss, using optimized processing conditions to achieve selective removal of heteroatoms without excessive cracking
2Object-generated 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 partial hydroprocessing rather than severe hydrocracking, using controlled treatment levels that remove sufficient heteroatoms while preserving the bulk of the viscosity, avoiding excessive cracking that would lead to unacceptable viscosity loss
Solution Approach 2:
The patent optimizes hydroprocessing parameters including using milder catalysts, lower temperatures, reduced pressures, and shorter residence times to achieve heteroatom removal with minimal viscosity impact
3Productivity
If catalytic processing is used to produce base stocks, then production efficiency is improved, but maximum viscosity is limited to about 10 cSt at 100°C
Solution Approach 1:
The patent merges catalytic processing with solvent processing steps, using catalysis for efficient feedstock conversion followed by solvent processing to concentrate and isolate the high viscosity components that would otherwise be limited by catalytic cracking
Solution Approach 2:
The patent segments the processing into distinct stages: catalytic conversion followed by solvent extraction and fractionation, allowing each process to operate in its optimal range and preserve the high viscosity components through selective separation
4Temperature
If specialty polymeric materials are used to achieve high viscosity, then viscosity is improved, but production cost increases
Solution Approach 1:
The patent uses conventional, readily available feedstocks and standard processing equipment rather than expensive specialty polymers, achieving high viscosity through physical processing of common materials rather than costly chemical synthesis of specialized compounds
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 effectively produces high viscosity base stocks with improved properties, including a viscosity index of 50 to 150, polydispersity of at least 1.4, and a pour point of 0°C or less, while minimizing viscosity loss due to hydroprocessing, and retaining desirable characteristics of conventional low molecular weight Group I base stocks.
Implementation Method 1
radical coupling using a peroxide catalyst of a feedstock having a viscosity index of 50 to 120, a kinematic viscosity at 100°C of 12 cSt or less
Implementation Method 2
radical coupling using a peroxide catalyst under effective coupling conditions to form a coupled effluent
Implementation Method 3
fractionating at least a portion of the coupled effluent to form at least a first product fraction
Data Source
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AI summary
Methods are provided for producing Group I base stocks having high viscosity and also having one or more properties indicative of a high quality base stock. The resulting Group I 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 I bright stock formed by solvent processing. Additionally, the resulting Group I base stocks can have one or more properties that are indicative of a high quality base stock.