LUERICANT ADDUCTS AND THEIR PREPARATION
This invention relates to lubricant adducts and their preparation. More particularly, this invention relates to improved lubricant fluid oppositions comprising these adducts alone or blended with synthetic or mineral oil lubricant compositions; and to fuel compositions comprising these adducts.
According to one aspect of the present invention, there is provided an adduct preparable by catalytically reacting : i) at least one compound comprising at least
one olefinic group; a hydrocarbyl
substituent; and, optionally, at least one heteroatom; with ii) a substituted or unsubstituted, fused or
unfused, polynuclear, aromatic compound which may contain at least one chalcogen atom.
The hydrocarbyl substituent of i) may be aliphatic or cyclic (including aromatic and alicyclic) and may be linear or branched. Suitably, the hydrocarbyl substituent comprises an adduct according to claim 1 wherein the hydrocarbyl substituent comprises a C3 to C500 alkyl, alkenyl or alkynyl group, a C7 to C500 aralkyl or alkaryl group or a C6 to C500 aryl group.
Preferably, the hydrocarbyl substituent comprises from 6 to 50 carbon atoms; for example, from 8 to 18 carbon atoms.
Preferably, compound i) comprises an alpha olefin. Where compound i) comprises a heteroatom this may be S,N,O,P and/or F.
In accordance with the invention, compound ii) preferably has the general formula :
in which :
X represents an oxygen or sulphur atom or a
methylene group; and
Y represents a sulphur atom or two hydrogen atoms attached to different aromatic rings.
The aromatic rings of compound ii) may be substituted on one or more positions of any aromatic ring. Substitution by an alkyl group is preferred, especially with at least one alkyl group on each ring.
It is preferred that compound ii) comprises an adduct according to claim 7 wherein ii) comprises diphenyl ether, diphenyl sulphide, diphenylmethane or phenoxathiin.
The adducts of this invention prepared over zeolite catalysts have a higher VI at a given viscosity.
In accordance with a second aspect of this invention, there is provided a process for the preparation of an adduct, which process comprises catalytically reacting: i) at least one compound comprising at least one olefinic group; a hydrocarbyl
substituent; and, optionally, at least one heteroatom; with
ii) a substituted or unsubstituted, fused or unfused, polynuclear, aromatic compound which may contain at least one chalcogen atom at a temperature from ambient to 350°C; a molar ratio of i) : ii) from 0.5:1.0 to 10.0:1.0; and a ratio of catalyst : ii) from 1g : 1 mol, preferably 5g:1 mol, to 100 g: 1 mol.
This invention also provides a high temperature stable lubricant fluid comprising an adduct as herein described. The invention further provides a fuel composition comprising an adduct as herein described and a liquid hydrocarbon or oxygenated fuel.
This invention, in a further aspect, provides for the use of an adduct as herein described in a high temperature stable lubricant fluid or a fuel composition for its improved antiwear, high and law temperature antioxidant, antispalling,
antisquawking, antifatique, antistaining, additive solubility, load carrying, extreme pressure, thermal and oxidative,
anticorrosion, demulsifying/emulsifying, detergent or cleanliness properties.
The preparation of these adducts may be by means of a thermal or catalytic addition reaction. The exact mechanism of the reaction is not important to the purposes of this invention, so long as the hydrocarbyl substituent becomes attached to the compound (ii) described herein.
One preferred method of reaction between compound i) and compound ii) is the combination of these reactants in the presence of specific zeolite catalysts; for example Octacat USY
and MCM-22. Additional catalysts which could be used
advantageously in this invention are ZSM-12 and other large-pore and/or relatively large pore zeolites. FOC Octacat USY is described in U.S. Patent No. 4,898,846. MCM-22 is described in U.S. Patent No. 4,983,276. This reaction is effected at temperatures from ambient to 350ºC, preferably from 100-250ºC and most preferably from 180 to 240ºC over a period required to produce the desired conversion of reactants to product. The reaction can be performed in a batch or semi-batch mode by continuous or partial addition of catalyst or hydrocarbyl substituent to the compound ii).
The catalyst can be used at levels from 1 gram/mole of compound ii) to 100 grams/mole of compound ii), preferably from 5 g/mole of compound ii) to 50 grams/mole of compound ii) and most preferably from 10 to 30 grams catalyst/mole of compound ii). Generally speaking, the molar ratio of compound i) to compound ii) is from 0.5:1.0 to 10.0:1.0 and preferably from 1.0:1.0 to 4.0:1.0.
Optionally, the adducts of this invention can be prepared by reaction in the presence of MCI. and other Lewis acids or in the presence of Bronsted acids, as described in G. A. Olah's "Friedel-Crafts and Related Reactions", Vol. I, 1963,
Interscience Publishers.
The adducts of the present invention may be used as liquid lubricants or in liquid lubricant compositions, and as solid lubricants or in solid lubricant compositions including greases, such as polyurea, lithium carboxylate or clay-thickened greases.
These adducts may also be used in combination with known additives, for example, antioxidants, EP/antiwear agents, inhibitors, detergents and dispersants, and viscosity index
improvers. Examples of antioxidants include hindered phenols and aromatic amines. Examples of EP/antiwear additives include zinc phosphorodithioates, sulfurized esters, sulfurized olefins, phosphonates, phosphites and phosphorothionates. Examples of inhibitors include DMTD and phenothiazine. Examples of
detergents and dispersants include sulfonates, phenates, and polymeric succinimides. These can be either metallic or non-metallic. Metallic detergents can be calcium or magnesium derived and can be neutral or overbased.
The adducts of this invention can be used alone or in combination with other synthetic and/or mineral oil fluids.
When used in combination with other synthetic and/or mineral oil fluids oils of lubricating viscosity may be used. In general, mineral oils, both paraffinic, naphthenic and mixtures thereof, employed as the lubricant, or grease vehicle, may be of any suitable lubricating viscosity range, as for example, from 45 SSU at 100ºF to 6000 SSU at 100ºF and preferably, from 50 to 250 SSU at 210ºF. These oils may preferably have viscosity indexes up to 95. The average molecular weights of these oils may be from 250 to 800. Where the lubricant is to be employed in the form of a grease, the lubricating oil is generally employed in an amount sufficient to balance the total grease composition, after accounting for the desired quantity of the thickening agent, and other additive components to be included in the grease
formulation.
A wide variety of materials may be employed as thickening or gelling agents. These may include any of the conventional metal salts or soaps which are dispersed in the lubricating vehicle in grease-forming quantities in an amount to impart to the resulting grease composition the desired consistency. Other thickening agents that may be employed in the grease formulation may
comprise non-soap thickeners, such as surface-modified clays and silicas, aryl ureas, calcium complexes and similar materials.
In general, grease thickeners may be employed which do not melt and dissolve when used at the required temperature within a particular environment; however, in all other respects, any material which is normally employed for thickening or gelling hydrocarbon fluids for foaming grease can be used in preparing grease in accordance with the present invention.
In instances where synthetic oils, or synthetic oils employed as the lubricant or vehicle for the grease, are desired in preference to mineral oils, or in combination therewith, various compounds of this type may be successfully utilized.
Typical synthetic oils include polyisobutylene, polybutenes, hydrogenated polydecenes, polypropylene glycol, polyethylene glycol, trimethylpropane esters, neopentyl and pentaerythritol esters, di(2-ethylhexyl) sebacate, di(2-ethylhexyl) adipate, dibutyl phthalate, fluorcarbons, silicate esters, silanes, esters of phosphorus-containing acids, liquid ureas, ferrocene derivatives, hydrogenated synthetic oils, chain-type polyphenyls, siloxanes and silicones (polysiloxanes), alkyl-substituted diphenyl ethers typified by a butyl-substituted bis(p-phenoxy phenyl) ether, phenoxy phenylethers.
When used as additives the adducts of the invention have the ability to improve both the thermal and oxidative stability as well as the additive solubility of the oleagenous materials, i.e., synthetic and/or mineral oil fluids with which they have been blended.
It is to be understood, however, that the additives useful herein for their known purposes do not detract from the value of the compositions of this invention, rather these
materials enhance the beneficial characteristics of the disclosed adducts.
Lubricant compositions in accordance with the invention may comprise from less than about 1 to about 100% of the adducts of the invention and/or from less than about 100% to about 1% of a synthetic or mineral oil of lubricating viscosity or grease prepared therefrom and from 0.001 to 20 wt% of additive material based on the total weight of the composition.
Fuel compositions of the invention comprising the adducts herein described include both hydrocarbon fuels, including gasoline, naphtha and diesel fuels or alcoholic fuels or mixtures of alcoholic and hydrocarbon fuels. Fuel compositions can contain 10 to 1,000 pounds of additive per 1,000 barrels of fuel or, more preferably, 25 to 250 pounds per 1,000 barrels of fuel.
The following Examples illustrate the invention.
EXAMPLE 1
15 g of FCC Octacat USY catalyst were added to a vigorously stirred mixture of diphenyl ether (170 g, 1.0 mole) and 1-tetradecene (196 g, 1.0 mole) in a flask fitted with thermocouple and reflux condenser. The mixture was then heated to 200ºC, with stirring, for six hours. After cooling to room temperature, the mixture was filtered to remove catalyst and vacuum distilled to 170ºC at 0.5-1.5 mmHg to remove unreacted starting materials.
EXAMPLE 2
Using the procedure of Example 1, diphenyl ether (170 g, 1.0 mole) and 1-tetradecene (196 g, 1.0 mole) were reacted using 30 grams of FCC Octacat USY catalyst. EXAMPLE 3
Using the procedure of Example 1, diphenyl ether (120 g, 1.0 mole) and 1-dodecene (168.32 g, 1.1 moles) were reacted using 15 grams of FCC Octacat USY catalyst.
EXAMPLE 4
2.0 g of anhydrous A1C1- were added to a stirred mixture of 1-octene, 224.2 g (2 moles), and diphenyl ether, 170 g (1 mole) and heated at reflux for six hours. The mixture was then cooled; washed to remove inoganic materials; and dried over anhydrous MgSO4. Gas chromatographic analysis showed essentially complete reaction of starting material. Color of this material ≥5 whereas the product of Example 1 was≤2.0.
EXAMPLE 5
Using the procedure in Example 4, 1-decene 168 g (1 mole) and diphenyl ether (170 g, 1 mole) were reacted with Aid. (2 grams) at reflux for six hours. Vacuum
distillation of the washed organic mixture to 170°C at
0.5-1.5 mmHg resulted in the desired hydrocarbyl diphenyl ether product.
EXAMPLE 6
18.2 g of FCC Octacat USY catalyst were added to a vigorously stirred mixture of diphenyl methane (168.24 g, 1.0 mole) and 1-tetradecene (196 g, 1.0 mole) in a flask fitted with thermocouple and reflux condenser. The mixture was then heated to 200ºC, with stirring, for six hours. After cooling to room temperature, the mixture was filtered to remove catalyst and vacuum distilled to 170ºC at 0.5-1.5 mmHg to remove unreacted starting materials.
EXAMPLE 7
Using the procedure of Example 6, diphenyl methane (168.24 g, 1.0 mole) and 1-tetradecene (196 g, 1.0 mole) were reacted using 36.4 grams of FOC Octacat USY catalyst.
EXAMPLE 8
Using the procedure of Example 6, diphenyl methane (168.24 g, 1.0 mole) and 1-hexadecene (224.43 g, 1.0 moles) were reacted using 19.6 grams of FCC Octacat USY catalyst. EXAMPLE 9
2.0 g of anhydrous AlCl3 were added to a stirred mixture of 1-octene, 224.2 g (2 moles), and diphenyl methane, 168.24 g (1 mole) and heated at reflux for six hours. The mixture wasthen cooled; washed to remove inorganic materials; and dried over anhydrous MgSO4. Gas chromatographic analysis showed essentially complete reaction of starting material. Color of this material was >5 whereas the product of Example 1 was <2.0.
EXAMPLE 10
19.5 g of FCC Octacat USY catalyst were added to a
vigorously stirred mixture of phenoxathin (202 g, 1.0 mole) and 1-tetradecene (196 g, 1.0 mole) in a flask fitted with
thermocouple and reflux condenser. The mixture was then heated to 200ºC, with stirring, for six hours. After cooling to room temperature, the mixture was filtered to remove catalyst and vacuum distilled to 170ºC at 0.5-1.5 mmBg to remove unreacted starting materials.
EXaAPLE 11
Using the procedure of Example 11, phenoxathin (202 g, 1.0 mole) and 1-tetradecene (196 g, 1.0 mole) were reacted using 39 grams of FCC Octacat USY catalyst.
EXAMPLE 12
Using the procedure of Example 11, phenoxathin (202 g, 1.0 mole) and 1-hexadecene (224.43 g, 1.0 moles) were reacted using 42.4 grams of FCC Octacat USY catalyst.
EXAMPLE 13
2.0 g of anhydrous AlCl3 were added to a stirred mixture of 1-octene, 224.2 g (2 moles), and phenoxathin (202 g, 1 mole) and heated at reflux for six hours. The mixture was then cooled; washed to remove inorganic materials; and dried over anhydrous MgSO4. Gas chromatographic analysis showed essentially complete reaction of starting material. Color of this material was >5 whereas the product of Example 1 was <2.0.
EXAMPLE 14
19.1 g of FCC Octacat USY catalyst were added to a
vigorously stirred mixture of diphenyl sulfide (186.2 g, 1.0 mole) and 1-tetradecene (196.4 g, 1.0 mole) in a flask fitted with thermocouple and reflux condenser. The mixture was then heated to 200ºC, with stirring, for six hours. After cooling to
room temperature, the mixture was filtered to remove catalyst and vacuum distilled to 170ºC at 0.5-1.5 mmHg to remove unreacted starting materials.
EXAMPLE 15
Using the procedure of Example 14, diphenyl sulfide
(186.2g, 1.0 mole) and 1-tetradecene (196.4 g, 1.0 mole) were reacted using 38.2 grams of FCC Octacat USY catalyst.
EXAMPLE 16
Using the procedure of Example 14, diphenyl sulfide
(186.2g, 1.0 mole) and 1-hexadecene (224.4 g, 1.0 moles) were reacted using 19.1 grams of FCC Octacat USY catalyst.
EXAMPLE 17
2.0 g of anydrous Aid. were added to a stirred mixture of 1-octene, 224.2 g (2 moles), and diphenyl sulfide (186.2g, 1 mole) and heated at reflux for six hours. The mixture was then cooled, washed to remove inorganic materials; and dried over anhydrous MgSO4. Gas chromatographic analysis showed essentially complete reaction of starting material. Color of this material was >5 whereas the product of Example 1 was <2.0.
Typical properties of exemplified hydrocarbyl diphenyl ethers are shown in TABLE 1.
TABLE l
Hydrocarbyl C14 C10 C8
KV @ 100ºC,cSt 4.0 3.8 10.7
VI 111 94 103
Pour Point (ºC) ≤-54 ≤-54 -40
Flash Point(ºF) — 435 475
Typical properties of exemplified diphenyl methanes are shown in TABLE 2.
TABLE 2
Hydrocarbyl C1 4 C 1 6 C8
KV @100ºC, cSt 3.58 4.21 4.90
VI 111 112 134
Pour Point (ºC) <-58 <-58 -4
Flash Point (ºF) 446 457 478
Typical properties of exemplary hydrocarbyl phenoxathins are shown in TABLE 3.
TABLE 3
Hydrocarbyl C14 C 1 6 C8
KV @100ºC, cSt 7.8 7.93 9.13
VI 41.4 61.6 75.2
Pour Point (ºC) -35 -35 -30
Typical properties of exemplified hydrocarbyl diphenyl sulfides are shown in TABLE 4.
TABLE 4
Hydrocarbyl C14 C16 C18
KV @100ºC, cSt 4.12 4.80 5.32
VI 93.3 101 119
Pour Point (°C) -58 -58 -40
Flash Point (ºF) 426 480 594
EVALUATIO N OF PRODUCTS
Performance as a Lubricant Having Improved An tiwear
Tetradecene alkylated diphenyl ether hexadecene alkylated
phenoxathin and both tetradecene and hexadecene alkylated diphenyl sulfide were compared with polyolefin base stock in a Four-Ball Wear test. The results show that at higher load, both the alkyl diphenyl ether and sulfides and alkyl phenoxathin produced less wear than the other base stock, without any adverse effect on coefficient of friction (f).
The antiwear properties of the examples were
evaluated using the Four Ball Wear Test as shown in TABLE 5 below. The results clearly exhibit the excellent antiwear properties inherent in these compositions.
In the Four Ball Test three stationary balls are placed in a lubricant cup; a lubricant containing the compound to be tested is added thereto; and a fourth ball is placed in a chuck mounted on a device which can be used to spin the ball at known speeds and loads. The examples were tested using half inch stainless steel balls of 5200 steel for thirty minutes under 40 kg load at 600 and 1800 rpm and 200ºF. If additional information is desired consult test method ASIM D2266 anc3/or U.S. Patent 4,761,482.
K, as reported in the Table, is the wear
coefficient calculated from the wear volume, V, of the
stationary ball. The wear volume is calculated from the
wear scar diameter D in mm as follows:
V= [15,5 D3 - 0.001033L] D × 103 mm3 where L is
the machine load in kg. This equation considers the elastic deformation of the steel balls.
Wear Coefficient K
Dimensionless K is defined as K = VH
dN
where V = wear volume, mm3
H = hardness 9725 kg/mm2 for 52100 steel
d = (23.3 mm/rev) (RPH × Time)
N = (0.408) (Load in kg)
The Four-Ball Wear Test results demonstrate the excellent antiwear properties of these compositions when used in
synthetic oils.
TABLE 5
FOUR-BALL WEAR TEST RESULTS
(200ºF/40 Kg/30 min)
600 RPM 1800 RPM
K f K f
C14-DPE 13.2 0.11 431 0.11 polyolefin basestock 11.4 0.09 1300 0.09
WSD mm
C16 - Phenoxathin 0.617 0.094 polyolef in basestock 1.66 0.076
WSD mm
C14-DPS - - 0.675 .093
C16-DPS 0.486 .098 0.630 .086
Performance as a Lubricant with Improved Additive Solubility
4.0 wt% of sulfurized isobutylene (as generally described by A. G. Horodysky in U.S. 3,703,504) and 0.5 wt% of a hindered phenolic inhibitor obtained from Ethyl Corp. as Ethyl 702 were added to a synthetic lubricant base stock. The mixture of additives was insoluble in the base stock and the sample was cloudy. In separate runs, 20 wt% C16 alkylated diphenyl methane; 21 wt% C14 alkylated diphenyl sulfide; and 21 wt% C14 alkylated
diphenyl ether were added to this mixture. The sample was mixed; in each case the additives completely dissolved and the mixture became clear.
Improved Thermal and Light Stability over Other lubricant Classes Thermal Stability Test
Sample % Viscosity Change After
72 hrs at 288°C 72 hrs at 310°C
C14-DEE* -1.4
C14-DPE -3.0
C14-DPM* -2.2
C16-DPM -5
C18-DPM -5
C16-phenoxathin -15
C18-DPS* -8.2
Commercial Synthetic Lubricant -14.8
Commercial Synthetic Lubricant -19.4
Commercial Synthetic Lubricant -38.8
Commercial Synthetic Lubricant -60.9
Commercial Synthetic Lubricant -67.9
Lube Ester -34.2
(* -DEP, -DPM and -DPS are abbreviations for alkylated diphenyl ether, alkylated diphenyl methane and alkylated sulfide,
respectively.)
Over Storage Tests (150ºC/5 days)
Color (Before) (After)
C14-DEE (Octacat USY) 2 2.5
C14-DPE (AICI3) 5.5 —
Commercial Synthetic lubricant 1 ~1.5 (Sample 1)
200-Second Solvent Paraffinic
Neutral Lubricating oil 2 ≥5.5
Light stability was good as no color change or precipitate was observed over two months.
Improbed Oxidative Stability Of Hydrocarbyl Diphenyl Methane Over Commercial Synthetic Lubricant
Rating1
Commercial Synthetic Lubricant 9-10
C16 DPM 3.5
1 Hot Tube Oxidation Test (315ºC/16 hrs)
Rating (0 = clean; 10 = black, plumed)
Tested as base stock components in synthetic diesel engine oil formulation
Performance As A Lubricant With Improved Load Carrying Properties
Load-carrying properties were measured using ASTM D2596 at both room temperature and 100ºC.
23ºC 100ºC
LNS LWI Weld INS LWI Weld
Polyolefin
base stock 50 22.7 126 32 14.6 126
C16 Phenoxathin 50 23.7 160 40 20.6 160
C14 DPS 40 22.5 160 32 17.9 126 C16 DPS 40 21.4 160 50 22.9 126
The use of adducts of this invention as a suitable
replacement for components of current lubricant formulations is highly desirable. For example, synthetic and/or mineral based lubricant composition containing esters for improved additive solubility would be significantly improved by replacement with adducts of this invention due to their excellent thermal
stability, additive solubility and/or EP/antiwear properties. Adducts prepared as described herein provide excellent base stock properties and could themselves serve as the base stock in formulations for various applications, for example, applications where high temperatures and EP are maintained.