Polyalkyl(meth)acrylate Fuel Additive for Cold Flow

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Solution Overview

Problem

Current fuel additives for biodiesel and diesel fuels often show limited efficiency across varying fuel compositions and temperatures, leading to issues like clogged filters and poor cold flow properties, especially when used in blends of different fuel sources.

Innovation Solution

A composition comprising a polyalkyl(meth)acrylate polymer, a graft copolymer based on ethylene, and an ethylene-based copolymer with specific molecular weight ranges, which improves the cold flow properties and reduces the pour point and cold filter plugging point of biodiesel and diesel fuels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional fuel additives are used, then cold flow properties are improved to some extent, but efficiency is limited across varying fuel compositions and temperatures

Engineering Contradiction:

Improvecold flow propertiesVSAvoidefficiency across varying fuel compositions

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent employs a composite additive system comprising multiple polymer components with distinct functions: polyalkyl(meth)acrylate polymers for crystal growth inhibition, graft copolymers for nucleation control, and ethylene-based copolymers for dispersancy. This composite approach enables the additive package to effectively address cold flow issues across diverse fuel compositions including mineral diesel, biodiesel, and their blends, resolving the contradiction between reliability and adaptability

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The additive composition is designed to perform multiple functions simultaneously: modifying wax crystallization behavior, dispersing particles, and maintaining effectiveness across different fuel types and temperature conditions. This multi-functionality allows a single additive package to provide reliable cold flow improvement across varying fuel compositions without requiring formulation changes

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If wax crystals form at low temperatures, then flow properties deteriorate, but filter clogging occurs

Engineering Contradiction:

Improveflow properties at low temperatureVSAvoidfilter clogging

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

The additive package applies preliminary anti-action by introducing nucleators that promote the formation of numerous small wax crystals before they can grow into large platelet structures. The polyalkyl(meth)acrylate polymers and graft copolymers preemptively modify the crystallization process, creating a fine dispersion of wax particles that remain suspended in the fuel and do not aggregate to clog filters, thus preventing the harmful effect before it occurs

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The additives change the physical parameters of wax crystallization by modifying nucleation density and crystal growth rates. This results in a transformation from large, filter-clogging platelet crystals to small, dispersed spherical crystals that maintain fuel flowability and pass through filters without obstruction

Inventive Principle:

Principle #35Parameter changes

3Reliability

If polymer molecular weight is increased to improve cold flow properties, then handling properties deteriorate

Engineering Contradiction:

Improvecold flow improvementVSAvoidhandling properties

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent segments the polymer system into distinct molecular weight classes, each serving specific functions. High molecular weight components (Mn > 10,000 g/mol) provide effective cold flow modification through extensive wax interaction, while lower molecular weight components (Mn < 10,000 g/mol) ensure adequate solubility and handling properties. This segmentation allows the system to achieve reliable cold flow improvement without sacrificing ease of operation

Inventive Principle:

Principle #1Segmentation

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 solution significantly lowers the pour point and cold filter plugging point of biodiesel and diesel fuels, enhancing their cold flow properties and reducing the tendency of injector nozzle fouling, thereby improving fuel performance across different fuel blends and temperatures.

Implementation Method 1

the crystallization of relatively long-chain n-paraffins or saturated fatty esters which occurs at and below the cloud point temperature, which forms large e.g. platelet-shaped wax crystals

Methodology Applied

Scientific EffectCrystallization: Crystallisation

Implementation Method 2

nucleators for controlled formation of small crystals of the paraffins

Methodology Applied

Scientific EffectNucleation: Nucleation

Data Source

PatentEP2951274B2Cold flow improver with broad applicability in mineral diesel, biodiesel and blends thereof

Publication Date: 2024.12.11 EVONIK OPERATIONS GMBH

AI summary

The present application relates to compositions comprising at least one polyalkyl(meth)acrylate polymer, a graft copolymer comprising a copolymer based on ethylene as graft base and one or more polyalkyl(meth)acrylate polymer(s) grafted thereon, and at least one non-grafted ethylene-based copolymer, as well as to the use of such compositions to improve the performance, especially the cold flow properties and injector nozzle coking tendency of middle distillates, especially diesel fuels, biodiesel and blends thereof.