Polybutene-Free White Oil Lubricant for High-Pressure Compressor
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Solution Overview
Problem
High pressure compressors, such as hyper compressors, require lubricants that do not interfere with olefin polymerization and must be food-grade, as current polybutene-based lubricants cause viscosity issues and leakage into the polymerization reactor, affecting valve efficiency and polyolefin purity.
Innovation Solution
A lubricating composition comprising 85.0 wt% to 99.9 wt% white oil with a kinematic viscosity of 190 mm^2/sec to 240 mm^2/sec at 40°C and 19 mm^2/sec to 22 mm^2/sec at 100°C, free of polybutene, is used to lubricate compressor friction interfaces, reducing viscosity changes and preventing polybutene leakage into the reactor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If polybutene polymeric thickeners are added to white oil to increase viscosity, then the lubricant viscosity increases to required levels, but the white oil dissolves faster than polybutene under operation conditions, turning into a sticky fluid of very high viscosity that causes sluggish valve operation and reduced valve efficiency
Solution Approach 1:
The patent removes polybutene polymeric thickeners from the lubricating composition entirely, using only white oil with controlled viscosity (190-240 mm²/sec at 40°C). This extraction of the problematic thickening agent eliminates the dissolution issue while maintaining necessary lubrication properties through the white oil's inherent viscosity characteristics.
Solution Approach 2:
The patent changes the viscosity parameter of the white oil base stock to a higher range (190-240 mm²/sec at 40°C) without adding polymeric thickeners. This parameter change allows the lubricant to achieve required viscosity levels through the base oil itself, avoiding the complications of polybutene dissolution and sticky fluid formation.
2Reliability
If polybutene-based lubricants are used in high pressure compressors, then the lubricant provides adequate lubrication, but the lubricant leaks downstream into the polymerization reactor, interfering with polymerization and affecting polyolefin properties
Solution Approach 1:
The patent extracts and removes polybutene from the lubricating composition, using only refined white oil. This eliminates the source of contamination that would otherwise leak into the polymerization reactor and interfere with the polymerization process or affect polyolefin properties.
Solution Approach 2:
The patent applies a specialized lubricating composition with specific properties (polybutene-free, controlled viscosity) tailored for the compressor environment while ensuring compatibility with the downstream polymerization process. The local quality of the lubricant is optimized to provide lubrication where needed without harming the polymerization system.
3Ease of operation
If mineral oil with lower viscosity is used as lubricant, then the lubricant flows easily, but the lubricant leaks more into the polymerization reactor, increasing interference with polymerization
Solution Approach 1:
The patent increases the viscosity parameter of the white oil to a higher range (190-240 mm²/sec at 40°C), which reduces the tendency to leak into the polymerization reactor while still maintaining adequate flow characteristics for lubrication. This parameter change balances flow ease with contamination prevention.
4Temperature
If polybutene is used as thickener in food-grade white oil lubricant, then the lubricant achieves required viscosity, but heterogeneous material such as polymeric thickener contaminates the process gas, which is unacceptable for high purity applications like wire and cable manufacturing
Solution Approach 1:
The patent removes polybutene polymeric thickeners from the lubricating composition, using only refined white oil with controlled viscosity. This extraction eliminates heterogeneous polymeric material that would otherwise contaminate the process gas and compromise the high purity requirements for applications like wire and cable manufacturing.
Solution Approach 2:
The patent uses a homogeneous white oil base stock without polymeric thickeners, ensuring the lubricant consists of uniform, refined hydrocarbons. This homogeneity prevents the formation of heterogeneous contaminants in the process gas, meeting the stringent purity requirements for high-value polyolefin applications.
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 polybutene-free lubricating composition minimizes leakage and viscosity issues, maintaining compressor efficiency and improving polyolefin purity, especially in high-purity applications like high voltage cable materials.
Implementation Method 1
High pressure compressors, such as hyper compressors, require the use of lubricants in order to reduce friction between the moving parts
Implementation Method 2
In the primary compressor the olefin monomers are pressurized to a pressure of up to about 35 MPa and are then further pressurized in the following hyper compressor to the operating pressure of usually about 100 MPa to 310 MPa
Data Source
AI summary
The present invention relates to a polybutene-free lubricating composition, a method for lubricating a compressor using said lubricating composition and a method for pressurizing olefin in a compressor lubricated with said lubricating composition, the use of said lubricating composition for lubricating a compressor, a method of pressurizing olefin in a compressor lubricated with said lubricating composition and a method of preparing a high pressure polyolefin using a high pressure compressor lubricated with said lubricating composition.