US2004129603A1PendingUtilityA1

High viscosity-index base stocks, base oils and lubricant compositions and methods for their production and use

42
Priority: Oct 8, 2002Filed: Oct 3, 2003Published: Jul 8, 2004
Est. expiryOct 8, 2022(expired)· nominal 20-yr term from priority
Inventors:Kim FyfeEugenio SanchezDavid J. BaillargeonJames W. GleesonIan A. CodyWilliam J. MurphySylvain HantzerDavid W. LarkinJohn E. GallagherJeenok T. Kim
C10N 2060/02B01J 29/041B01J 29/74C10G 45/12C10N 2020/02C10G 69/00C10M 2203/1006C10N 2030/02C10G 45/64C10N 2020/085C10M 171/02C10M 2205/173C10N 2040/25C10G 45/62C10N 2030/54C10N 2030/74C10G 65/043C10G 45/08
42
PatentIndex Score
0
Cited by
0
References
0
Claims

Abstract

This invention relates to base stocks and base oils that exhibit an unexpected combination of high viscosity index (130 or greater) and a ratio of measured-to-theoretical high-shear/low-temperature viscosity at −30C or lower and the methods of making them. Specifically, the present invention relates to low-volatility/low-viscosity lubricant base stocks, lubricant base stocks and base oils, formulated lubricant compositions or functional fluids comprising these base stocks and methods of making them. More particularly, this invention relates to lubricant compositions of low-temperature flow capability and low viscosity for passenger car motor lubricants of SAE 0W-XX grade (where XX=40 or lower), methods for optimizing fuel economy using the same, and methods or processes to produce them.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A base stock or base oil comprising the properties of: 
 (a) a viscosity index (VI) of about 130 or greater,    (b) a pour point of about −10C or lower,    (c) a ratio of measured-to-theoretical low-temperature viscosity equal to about 1.2 or less, at a temperature of about −30C or lower, where the measured viscosity is cold-crank simulator viscosity and where theoretical viscosity is calculated at the same temperature using the Walther-MacCoull equation,    wherein said base stock or base oil is not a Group IV base stock or base oil.    
     
     
         2 . A base stock or base oil comprising the properties of: 
 (a) a viscosity index (VI) of about 130 or greater,    (b) a pour point of about −10C or lower,    (c) a ratio of measured-to-theoretical low-temperature viscosity equal to about 1.2 or less, at a temperature of about −30C or lower, where the measured viscosity is cold-crank simulator viscosity and where theoretical viscosity is calculated at the same temperature using the Walther-MacCoull equation, and    (d) a percent Noack volatility no greater than that calculated by the formula    −6.882Ln(CCS@−35C)+67.647,    where CCS@−35C is the base oil CCS viscosity in centipoise, tested at −35C, and that value as used in the equation is less than 5500 cP, and    wherein said base stock or base oil is not a Group IV base stock or base oil.    
     
     
         3 . A base stock or base oil with a VI of at least 130 produced by a process which comprises: 
 (1) hydrotreating a feedstock having a wax content of at least about 60 wt. %, based on feedstock, with a hydrotreating catalyst under effective hydrotreating conditions such that less than 5 wt. % of the feedstock is converted to 6500F (343° C.) minus products to produce a hydrotreated feedstock whose VI increase is less than 4 greater than the VI of the feedstock;    (2) stripping the hydrotreated feedstock to separate gaseous from liquid product; and    (3) hydrodewaxing the liquid product with a dewaxing catalyst which is at least one of ZSM-48, ZSM-57, ZSM-23, ZSM-22, ZSM-35, ferrierite, ECR-42, ITQ-13, MCM-71, MCM-68, beta, fluorided alumina, silica-alumina or fluorided silica alumina under catalytically effective hydrodewaxing conditions wherein the dewaxing catalyst contains at least one Group 9 or Group 10 noble metal.    
     
     
         4 . A base stock or base oil with a VI of at least 130 produced by a process which comprises: 
 (1) hydrotreating a feedstock having a wax content of at least about 50 wt. %, based on feedstock, with a hydrotreating catalyst under effective hydrotreating conditions such that less than 5 wt. % of the feedstock is converted to 650° F. (343° C.) minus products to produce a hydrotreated feedstock to produce a hydrotreated feedstock whose VI increase is less than 4 greater than the VI of the feedstock;    (2) stripping the hydrotreated feedstock to separate gaseous from liquid product; 
 (3) hydrodewaxing the liquid product with a dewaxing catalyst which is at least one of ZSM-22, ZSM-23, ZSM-35, ferrierite, ZSM-48, ZSM-57, ECR-42, ITQ-13, MCM-68, MCM-71, beta, fluorided alumina, silica-alumina or fluorided silica-alumina under catalytically effective hydrodewaxing conditions wherein the dewaxing catalyst contains at least one Group 9 or 10 noble metal; and  
   (4) hydrofinishing the product from step (3) with a mesoporous hydrofinishing catalyst from the M41S family under hydrofinishing conditions.    
     
     
         5 . A base stock or base oil with a VI of at least 130 produced by a process which comprises: 
 (1) hydrotreating a feedstock having a wax content of at least about 60 wt. %, based on feedstock, with a hydrotreating catalyst under effective hydrotreating conditions such that less than 5 wt. % of the feedstock is converted to 650° F. (343° C.) minus products to produce a hydrotreated feedstock to produce a hydrotreated feedstock whose VI increase is less than 4 greater than the VI of the feedstock;    (2) stripping the hydrotreated feedstock to separate gaseous from liquid product;    (3) hydrodewaxing the liquid product with a dewaxing catalyst which is ZSM-48 under catalytically effective hydrodewaxing conditions wherein the dewaxing catalyst contains at least one Group 9 or 10 noble metal; and    (4) Optionally, hydrofinishing the product from step (3) with MCM-41 under hydrofinishing conditions.    
     
     
         6 . The process as in  claim 3 ,  4 , or  5  wherein said feedstock is a synthetic gas to liquid feedstock.  
     
     
         7 . The process as in claims  3 ,  4 , or  5  wherein said feedstock is made by a Fischer-Tropsch process.  
     
     
         8  A lubricant comprising the base stock or base oil of claims  1 ,  2 ,  3 ,  4  or  5 .  
     
     
         9 . A lubricant comprising the base stock or base oil of claims  1 ,  2 ,  3 ,  4  or  5 . and at least one performance enhancing additive.  
     
     
         10 . A lubricant comprising a base stock or base oil, said base stock or base oil having the properties of: 
 (a) a viscosity index (VI) of about 130 or greater,    (b) a pour point of about −10C or lower,    (c) a ratio of measured-to-theoretical low-temperature viscosity equal to about 1.2 or less, at a temperature of about −30C or lower, where the measured viscosity is cold-crank simulator viscosity and where theoretical viscosity is calculated at the same temperature using the Walther-MacCoull equation.    wherein said base stock or base oil is not a Group IV base stock or base oil.    
     
     
         11 . A lubricant comprising a base stock or base oil, said base stock or base oil having the properties of: 
 (a) a viscosity index (VI) of about 130 or greater,    (b) a pour point of about −10C or lower,    (c) a ratio of measured-to-theoretical low-temperature viscosity equal to about 1.2 or less, at a temperature of about −30C or lower, where the measured viscosity is cold-crank simulator viscosity and where theoretical viscosity is calculated at the same temperature using the Walther-MacCoull equation, and    (d) a percent Noack volatility no greater than that calculated by the formula    −6.882Ln(CCS@−35C)+67.647,    where CCS@−35C is the base oil CCS viscosity in centipoise, tested at −35C, and that value as used in the equation is less than 5500 cP, and 
 wherein said base stock or base oil is not a Group IV base stock or base oil.  
   
     
     
         12 . A lubricating comprising at least one base stock or base oil wherein said base stock or base oil has a VI of at least 130 produced by a process which comprises: 
 (1) hydrotreating a feedstock having a wax content of at least about 60 wt. %, based on feedstock, with a hydrotreating catalyst under effective hydrotreating conditions such that less than 5 wt. % of the feedstock is converted to 6500F (343° C.) minus products to produce a hydrotreated feedstock whose VI increase is less than 4 greater than the VI of the feedstock;    (2) stripping the hydrotreated feedstock to separate gaseous from liquid product; and    (3) hydrodewaxing the liquid product with a dewaxing catalyst which is at least one of ZSM-48, ZSM-57, ZSM-23, ZSM-22, ZSM-35, ferrierite, ECR-42, ITQ-13, MCM-71, MCM-68, beta, fluorided alumina, silica-alumina or fluorided silica alumina under catalytically effective hydrodewaxing conditions wherein the dewaxing catalyst contains at least one Group 9 or Group 10 noble metal.    
     
     
         13 . A lubricant comprising at least one base stock or base oil wherein said base stock has a VI of at least 130 produced by a process which comprises: 
 (1) hydrotreating a lubricating oil feedstock having a wax content of at least about 50 wt. %, based on feedstock, with a hydrotreating catalyst under effective hydrotreating conditions such that less than 5 wt. % of the feedstock is converted to 650° F. (343° C.) minus products to produce a hydrotreated feedstock to produce a hydrotreated feedstock whose VI increase is less than 4 greater than the VI of the feedstock;    (2) stripping the hydrotreated feedstock to separate gaseous from liquid product;    (3) hydrodewaxing the liquid product with a dewaxing catalyst which is at least one of ZSM-22, ZSM-23, ZSM-35, ferrierite, ZSM-48, ZSM-57, ECR-42, ITQ-13, MCM-68, MCM-71, beta, fluorided alumina, silica-alumina or fluorided silica-alumina under catalytically effective hydrodewaxing conditions wherein the dewaxing catalyst contains at least one Group 9 or 10 noble metal; and    (4) hydrofinishing the product from step (3) with a mesoporous hydrofinishing catalyst from the M41S family under hydrofinishing conditions.    
     
     
         14 . A lubricant comprising at least one base stock wherein said base stock has a VI of at least 130 produced by a process which comprises: 
 (1) hydrotreating a lubricating oil feedstock having a wax content of at least about 60 wt. %, based on feedstock, with a hydrotreating catalyst under effective hydrotreating conditions such that less than 5 wt. % of the feedstock is converted to 650° F. (343° C.) minus products to produce a hydrotreated feedstock to produce a hydrotreated feedstock whose VI increase is less than 4 greater than the VI of the feedstock;    (2) stripping the hydrotreated feedstock to separate gaseous from liquid product;    (3) hydrodewaxing the liquid product with a dewaxing catalyst which is ZSM-48 under catalytically effective hydrodewaxing conditions wherein the dewaxing catalyst contains at least one Group 9 or 10 noble metal; and    (4) Optionally, hydrofinishing the product from step (3) with MCM-41 under hydrofinishing conditions.    
     
     
         15 . The lubricant as in  claim 12 ,  13  or  14  wherein said feedstock is a synthetic gas to liquid feedstock.  
     
     
         16 . The lubricant as in claims  12 ,  13  or  14  wherein said feedstock is made by a Fischer-Tropsch process.  
     
     
         17 . A lubricant composition comprising the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity is less than or equal to about 7000 at −25C and the Noack Volatitlity is less than or equal to about 15 wt %.  
     
     
         18 . A lubricant composition comprising the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity is less than or equal to about 6600 at −30C and the Noack Volatitlity is less than or equal to about 15 wt %.  
     
     
         19 . A lubricant composition comprising the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity is less than or equal to about 6200 at −35C and the Noack Volatitlity is less than or equal to about 15 wt %.  
     
     
         20 . A lubricant composition comprising the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity is less than or equal to about 7000 at −25C and the Noack Volatitlity is less than or equal to about 13 wt %.  
     
     
         21 . A lubricant composition comprising the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity is less than or equal to about 6600 at −30C and the Noack Volatitlity is less than or equal to about 13 wt %.  
     
     
         22 . A lubricant composition comprising the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity is less than or equal to about 6200 at −35C and the Noack Volatitlity is less than or equal to about 13 wt %.  
     
     
         23 . A viscosity modifier solution comprising a viscosity modifier blended into the base stock of base oil of any one of the claims  1 ,  2 ,  3 ,  4  or  5 .  
     
     
         24 . An additive concentrate comprising the base stock or base oil of any one of the claims  1 ,  2 ,  3 ,  4  or  5 .  
     
     
         25 . The method of making a lubricant comprising incorporating a base stock or base oil having the properties of 
 (a) a viscosity index (VI) of 130 or greater,    (b) a pour point of −10C or lower,    (c) a ratio of measured-to-theoretical low-temperature viscosity equal to 1.2 or less, at a temperature of −30C or lower, where the measured viscosity is cold-crank simulator viscosity and where theoretical viscosity is calculated at the same temperature using the Walther-MacCoull equation.    wherein said base stock or base oil is not a Group IV base stock or base oil.    
     
     
         26 . The method of making a lubricant comprising incorporating a base stock or base oil having the properties of 
 (a) a viscosity index (VI) of 130 or greater,    (b) a pour point of −10C or lower,    (c) a ratio of measured-to-theoretical low-temperature viscosity equal to 1.2 or less, at a temperature of −30C or lower, where the measured viscosity is cold-crank simulator viscosity and where theoretical viscosity is calculated at the same temperature using the Walther-MacCoull equation, and    (d) a percent Noack volatility no greater than that calculated by the formula    −6.882Ln(CCS@−35C)+67.647,    where CCS@−35C is the base oil CCS viscosity in centipoise, tested at −35C, and that value as used in the equation is less than 5500 cP, and    wherein said base stock or base oil is not a Group IV base stock or base oil.    
     
     
         27 . The method of making an additive concentrate incorporating a base stock or base oil having the properties of 
 (a) a viscosity index (VI) of 130 or greater,    (b) a pour point of −10C or lower,    (c) a ratio of measured-to-theoretical low-temperature viscosity equal to 1.2 or less, at a temperature of −30C or lower, where the measured viscosity is cold-crank simulator viscosity and where theoretical viscosity is calculated at the same temperature using the Walther-MacCoull equation.    wherein said base stock or base oil is not a Group IV base stock or base oil.    
     
     
         28 . The method of making an additive concentrate comprising incorporating a base stock or base oil having the properties of 
 (a) a viscosity index (VI) of 130 or greater,    (b) a pour point of −10C or lower,    (c) a ratio of measured-to-theoretical low-temperature viscosity equal to 1.2 or less, at a temperature of −30C or lower, where the measured viscosity is cold-crank simulator viscosity and where theoretical viscosity is calculated at the same temperature using the Walther-MacCoull equation, and    (d) a percent Noack volatility no greater than that calculated by the formula    −6.882Ln(CCS@−35C)+67.647,    where CCS@−35C is the base oil CCS viscosity in centipoise, tested at −35C, and that value as used in the equation is less than 5500 cP, and    wherein said base stock or base oil is not a Group IV base stock or base oil.    
     
     
         29 . The method of making an additive concentrate comprising incorporating a base stock or base oil of any one of the claims  3 ,  4  or  5 .  
     
     
         30 . The method of making a lubricant comprising incorporating said additive concentrate of either  claim 27  or  28 .  
     
     
         31 . The method of making a lubricant comprising incorporating an additive concentrate comprising incorporating a base stock or base oil of any one of the claims  3 ,  4  or  5 .  
     
     
         32 . A method of improving the CCS viscosity of a base stock comprising incorporating said base stock or base oil of any one of the claims  1 ,  2 ,  3 ,  4  or  5 .  
     
     
         33 . A method of improving the CCS viscosity of a lubricant comprising incorporating a base stock or base oil of any one of the claims  1 ,  2 ,  3 ,  4  or  5 .  
     
     
         34 . A method of reducing the Noack volatility of a base stock comprising incorporating a base stock or base oil of any one of the claims  1 ,  2 ,  3 ,  4  or  5 .  
     
     
         35 . A method of reducing the Noack volatility of a lubricant comprising incorporating a base stock or base oil of any one of the claims  1 ,  2 ,  3 ,  4  or  5 .  
     
     
         36 . A method of improving a lubricant by admixing the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity of the final mixture is less than or equal to about 7000 at −25C and the Noack Volatility is less than or equal to about 15 wt %.  
     
     
         37 . A method of improving a lubricant by admixing the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity of the final mixture is less than or equal to about 6600 at −30C and the Noack Volatility is less than or equal to about 15 wt %.  
     
     
         38 . A method of improving a lubricant by admixing the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity of the final mixture is less than or equal to about 6200 at −35C and the Noack Volatility is less than or equal to about 15 wt %.  
     
     
         39 . A method of improving a lubricant by admixing the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity of the final mixture is less than or equal to about 7000 at −25C and the Noack Volatility is less than or equal to about 13 wt %.  
     
     
         40 . A method of improving a lubricant by admixing the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity of the final mixture is less than or equal to about 6600 at −30C and the Noack Volatitlity is less than or equal to about 13 wt %.  
     
     
         41 . A method of improving a lubricant by admixing the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 , wherein the CCS viscosity of the final mixture is less than or equal to about 6200 at −35C and the Noack Volatitlity is less than or equal to about 13 wt %.  
     
     
         42 . A method of reducing the viscosity of a viscosity modifier solution by dispersing said solution in the base oil or base stock of any one of the claims  1 ,  2 ,  3 ,  4  or  5 .

Cited by (0)

No later patents cite this yet.

References (0)

No backward citations on record.