Homogeneous Copolymer for Fuel Cold Flow Improvement
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Solution Overview
Problem
Existing cold flow improvers for fuel oils, such as ethylene-vinyl carboxylate copolymers, lead to paraffin sedimentation issues due to higher density crystals settling at the bottom of storage vessels, causing filter blockages, especially in biodiesel blends, and result in reduced filterability and increased risk of disruptions during low temperatures.
Innovation Solution
A copolymer with high chemical homogeneity, comprising 50-70% C4-C24 hydrocarbyl esters of acrylic or methacrylic acid, 30-50% ethylene, and up to 10% copolymerizable monomers, produced through backmixing polymerization and subsequent esterification with C4-C24 hydrocarbinols, which maintains consistent acid numbers across different polymer fractions and improves cold flow properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If ethylene-vinyl carboxylate copolymers are used as cold flow improvers, then the cold flow properties of fuel oils are improved, but the paraffin crystals have higher density and tend to settle out, causing filter blockages
Solution Approach 1:
The patent modifies the chemical composition parameters of the copolymer by incorporating specific amounts of acrylic acid (0-10 wt%) and methacrylic acid (0-10 wt%) alongside vinyl esters and ethylene. This compositional adjustment changes the density and surface properties of the resulting paraffin crystals, preventing them from settling while maintaining cold flow improvement capabilities.
Solution Approach 2:
The invention creates a composite copolymer structure combining multiple monomer types (ethylene, vinyl esters, acrylic acid, methacrylic acid) in specific ratios. This composite material approach produces a complex molecular structure that interacts with paraffin crystals to maintain suspension stability while improving cold flow properties, resolving the contradiction between flow improvement and phase homogeneity.
2Ease of operation
If cold flow improvers are added to middle distillate fuels, then the flowability at low temperatures is improved, but the additives increase the complexity of the fuel composition and may cause sedimentation
Solution Approach 1:
The patent optimizes the compositional parameters of the copolymer additive, specifying precise ranges for each monomer component (ethylene: 60-80 wt%, vinyl esters: 10-30 wt%, acrylic acid: 0-10 wt%, methacrylic acid: 0-10 wt%). This parameter optimization ensures the additive achieves maximum flowability improvement with minimal impact on overall fuel composition complexity and reduced sedimentation risk.
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 copolymer effectively lowers the pour point and cloud point of fuel oils, prevents paraffin crystal settling, ensures uninterrupted fuel flow, and enhances filterability by maintaining a homogeneous phase, reducing the risk of blockages and improving the usability of cold flow improver additives.
Implementation Method 1
suitable additives can modify the crystal growth of the n-paraffins in middle distillate fuels. Very effective additives prevent middle distillate fuels from solidifying even at temperatures a few degrees celsius below the temperature at which the first paraffin crystals crystallize out.
Implementation Method 2
Instead, fine, readily crystallizing, separate paraffin crystals are formed, which, even when the temperature is lowered further, pass through filters in motor vehicles and heating systems
Data Source
AI summary
A copolymer with high chemical homogeneity, consisting of (A) 50 to 30% by weight of ethylene, (B) 50 to 70% by weight of C4- to C24-hydrocarbyl ester of (meth)acrylic acid, (C) 0 to 5% by weight of (meth)acrylic acid and (D) 0 to 10% by weight of copolymerizable monomers, obtainable by polymerizing a mixture of 80 to 60% by weight of ethylene, 20 to 40% by weight of (meth)acrylic acid and 0 to 10% by weight of copolymerizable monomers in a backmixing, continuous polymerization apparatus, and subsequently polymer-analogously esterifying the resulting copolymer with C4- to C24-hydrocarbinols. The inventive copolymer is suitable for improving the cold flow properties of fuel oils, for lowering the lower mixing temperature of cold flow improver additives into fuel oils, and for improving the filterability of fuel oils comprising cold flow improver additives.