Methods and compositions for reducing corrosion and increasing engine durability in engines combusting alcohol-containing fuels

Abstract

The present disclosure provides compositions and methods for reducing corrosion and improving durability in engines combusting a fuel containing ethanol and a corrosion inhibitor. The present disclosure also provides compositions and methods for reducing corrosion and improving durability in engines combusting a fuel containing ethanol, a corrosion inhibitor, and a dispersant.

1 . A method for reducing corrosion in an internal combustion engine susceptible to corrosion and combusting an alcohol-containing fuel composition comprising a corrosion inhibitor, said method comprising:
 (a) combining the fuel with at least one dispersant fuel additive selected from the group consisting of a succinimide dispersant, a succinamide dispersant, an amide dispersant, a Mannich base dispersant, and a polyalkylene amine dispersant, and   (b) combusting the fuel and the at least one dispersant fuel additive in the engine,   wherein corrosion in the engine is reduced relative to the corrosion in an engine occurring when combusting the alcohol-containing fuel with a corrosion inhibitor but without the at least one dispersant fuel additive.   
     
     
         2 . The method of  claim 1 , wherein the fuel further comprises gasoline. 
     
     
         3 . The method of  claim 1 , wherein the alcohol is selected from the group consisting of methanol, ethanol, propanol, butanol, and mixtures of any combination thereof. 
     
     
         4 . The method of  claim 1 , wherein the alcohol is ethanol. 
     
     
         5 . The method of  claim 4 , wherein the ethanol content of the fuel composition is from about 10 wt. % to about 100 wt. %. 
     
     
         6 . The method of  claim 4 , wherein the ethanol content of the fuel composition is from about 15 wt. % to about 85 wt. %. 
     
     
         7 . The method of  claim 4 , wherein the ethanol content of the fuel composition is from about 74 wt. % to about 85 wt. %. 
     
     
         8 . The method of  claim 1 , wherein the corrosion inhibitor comprises a dodecenyl succinic acid (DDSA). 
     
     
         9 . The method of  claim 1 , wherein the corrosion inhibitor is selected from the group consisting of those materials having a structure NH 2 (CH 2 ) n —NH—(CH 2 ) m O—C 8-10  where n and m are independently 1 to about 10. 
     
     
         10 . The method of  claim 1 , wherein the corrosion inhibitor is selected from the group consisting of those materials having a structure NH 2 (CH 2 ) n —NH—C 8-10  where n is 1 to about 10. 
     
     
         11 . The method of  claim 1 , wherein the corrosion inhibitor comprises the result of combining a carboxylic acid or diacid and an amine, diamine or polyamine. 
     
     
         12 . The method of  claim 1 , wherein the corrosion inhibitor has a molecular weight of less than 700 and is selected from the group consisting of monoamines, diamines, triamines, polyamines, etheramines, imines, imidazolines, thiadiazoles, monocarboxylic acids, dicarboxylic acids, p-phenylenediamine, dicyclohexylamine, alkyl substituted succinic anhydrides and acids, mixtures and reaction products thereof and salts thereof. 
     
     
         13 . The method of  claim 1 , wherein the fuel additive comprises a polyisobutylene amine dispersant. 
     
     
         14 . The method of  claim 1 , wherein the method further comprises:
 combining the fuel with at least one fuel additive selected from the group consisting of a phenolic; a hindered phenolic; a polyolefin amine; an aryl amine; a diphenyl amine; a monocarboxylic acid; a dicarboxylic acid; a polycarboxylic acid; an oxylated alkylphenolic resin; a formaldehyde polymer with 4-(1,1-dimethylethyl)phenol, a methyloxirane, and oxirane; an octane enhancer materials selected from the group consisting of tetraethyl lead, methylcyclopentadienyl manganese tricarbonyl, an azide, a peroxide, and an alkyl nitrates; a monoester, a diester, an ether, a ketone, a diether, a polyether, a glyme, a glycol, an oxirane, a C1-C8 aliphatic hydrocarbon, a butylene oxide, a propylene oxide, an ethylene oxide, an epoxide, a butane, a pentane, a xylene, a nitrous oxide, a nitromethane, a phenate, a salicylate, a sulfonate, a nonylphenol ethoxylate, a fuel-soluble alkali detergent, and an alkaline earth metal-containing detergent.   
     
     
         15 . A method for improving the durability of an internal combustion engine combusting an alcohol-containing fuel composition comprising a corrosion inhibitor, said method comprising:
 (a) combining the fuel with at least one dispersant fuel additive selected from the group consisting of a succinimide dispersant, a succinamide dispersant, an amide, a Mannich base dispersant, and a polyalkylene amine dispersant, and   (b) combusting the fuel and the at least one dispersant fuel additive in the engine,   wherein durability of the engine is improved relative to the durability of an engine combusting the alcohol-containing fuel with a corrosion inhibitor but without the at least one dispersant fuel additive.   
     
     
         16 . A composition to reduce corrosion in an internal combustion engine combusting an alcohol-containing fuel, said composition comprising:
 (a) a corrosion inhibitor,   (b) an alcohol, and   (c) at least one of a succinimide dispersant, a succinamide dispersant, an amide dispersant, a Mannich base dispersant, and a polyalkylene amine dispersant.   
     
     
         17 . The composition of  claim 16 , wherein the corrosion inhibitor comprises a dodecenyl succinic acid (DDSA). 
     
     
         18 . The composition of  claim 16 , wherein the alcohol is selected from the group consisting of methanol, ethanol, propanol, butanol, and mixtures of any combination thereof. 
     
     
         19 . The composition of  claim 16 , wherein the alcohol comprises ethanol. 
     
     
         20 . The composition of  claim 19 , wherein the ethanol content of the fuel composition is from about 10 wt. % to about 100 wt. %. 
     
     
         21 . The composition of  claim 19 , wherein the ethanol content of the fuel composition is from about 15 wt. % to about 85 wt. %. 
     
     
         22 . The composition of  claim 19 , wherein the ethanol content of the fuel composition is from about 74 wt. % to about 85 wt. %. 
     
     
         23 . The composition of  claim 16 , wherein the dispersant of (c) comprises a polyisobutylene amine dispersant. 
     
     
         24 . The composition of  claim 16 , wherein the fuel further comprises gasoline. 
     
     
         25 . A method for reducing corrosion in an internal combustion engine susceptible to corrosion and combusting an alcohol-containing fuel composition, said method comprising:
 (a) combining the fuel with a dodecenyl succinic acid corrosion inhibitor, and   (b) combusting the fuel and the dodecenyl succinic acid corrosion inhibitor in the engine,   wherein corrosion in the engine is reduced relative to the corrosion occurring in the engine when combusting the alcohol-containing fuel with a corrosion inhibitor substantially free of a dodecenyl succinic acid corrosion inhibitor.   
     
     
         26 . The method of  claim 25 , wherein the fuel further comprises gasoline. 
     
     
         27 . The method of  claim 25 , wherein the alcohol is selected from the group consisting of methanol, ethanol, propanol, butanol, and mixtures of any combination thereof. 
     
     
         28 . The method of  claim 25 , wherein the alcohol comprises ethanol. 
     
     
         29 . The method of  claim 28 , wherein the ethanol content of the fuel composition is from about 10 wt. % to about 100 wt. %. 
     
     
         30 . The method of  claim 28 , wherein the ethanol content of the fuel composition is from about 15 wt. % to about 85 wt. %. 
     
     
         31 . The method of  claim 28 , wherein the ethanol content of the fuel composition is from about 74 wt. % to about 85 wt. %. 
     
     
         32 . The method of  claim 25 , wherein said method consists essentially of:
 (a) combining the fuel with a dodecenyl succinic acid corrosion inhibitor, and   (b) combusting the fuel and the dodecenyl succinic acid corrosion inhibitor in the engine.   
     
     
         33 . A method for improving the durability of an internal combustion engine combusting an alcohol-containing fuel composition, said method comprising:
 (a) combining the fuel with a dodecenyl succinic acid corrosion inhibitor, and   (b) combusting the fuel and the dodecenyl succinic acid corrosion inhibitor in the engine,   wherein durability of the engine is improved relative to the durability of an engine combusting the alcohol-containing fuel with a corrosion inhibitor substantially free of a dodecenyl succinic acid corrosion inhibitor.   
     
     
         34 . A composition to reduce corrosion in an internal combustion engine combusting an alcohol-containing fuel, said composition comprising
 (a) a dodecenyl succinic acid corrosion inhibitor, and   (b) an alcohol.   
     
     
         35 . The composition of  claim 34 , wherein the alcohol is selected from the group consisting of methanol, ethanol, propanol, butanol, and mixtures of any combination thereof. 
     
     
         36 . The composition of  claim 34 , wherein the alcohol comprises ethanol. 
     
     
         37 . The composition of  claim 34 , wherein the fuel further comprises gasoline. 
     
     
         38 . The composition of  claim 34 , wherein the composition consists essentially of (a) a dodecenyl succinic acid corrosion inhibitor, and (b) an alcohol. 
     
     
         39 . A method for increasing the engine oil drain interval in an engine combusting an alcohol-containing fuel composition comprising a corrosion inhibitor, said method comprising:
 (a) combining the fuel with at least one dispersant fuel additive selected from the group consisting of a succinimide dispersant, a succinamide dispersant, an amide dispersant, a Mannich base dispersant, and a polyalkylene amine dispersant, and   (b) combusting the fuel and the at least one dispersant fuel additive in the engine,   wherein the engine oil drain interval is increased relative to the engine oil drain interval in an engine combusting the alcohol-containing fuel with a corrosion inhibitor but without the at least one dispersant fuel additive.   
     
     
         40 . A method for increasing the engine oil drain interval in an engine combusting an alcohol-containing fuel composition comprising a corrosion inhibitor, said method comprising:
 (a) combining the fuel with a dodecenyl succinic acid corrosion inhibitor, and   (b) combusting the fuel and the dodecenyl succinic acid corrosion inhibitor in the engine,   wherein the engine oil drain interval is increased relative to the engine oil drain interval in an engine combusting the alcohol-containing fuel with a corrosion inhibitor substantially free of a dodecenyl succinic acid corrosion inhibitor.   
     
     
         41 . A method for providing an iron content of less than about 50 ppm in a used engine oil, wherein the engine oil lubricates an internal combustion engine combusting an alcohol-containing fuel composition comprising a corrosion inhibitor, said method comprising:
 (a) combining the fuel with at least one dispersant fuel additive selected from the group consisting of a succinimide dispersant, a succinamide dispersant, an amide dispersant, a Mannich base dispersant, and a polyalkylene amine dispersant, and   (b) combusting the fuel and the at least one dispersant fuel additive in the engine.   
     
     
         42 . A method for providing an iron content of less than about 50 ppm in a used engine oil, wherein the engine oil lubricates an internal combustion engine combusting an alcohol-containing fuel composition comprising a corrosion inhibitor, said method comprising:
 (a) combining the fuel with a dodecenyl succinic acid corrosion inhibitor, and   (b) combusting the fuel and the dodecenyl succinic acid corrosion inhibitor in the engine.   
     
     
         43 . A method for providing an AGV value of greater than about 100 in a used engine oil when tested according to the ASTM D6557 Ball Rust Test, wherein the engine oil lubricates an internal combustion engine combusting an alcohol-containing fuel composition comprising a corrosion inhibitor, said method comprising:
 (a) combining the fuel with at least one dispersant fuel additive selected from the group consisting of a succinimide dispersant, a succinamide dispersant, an amide dispersant, a Mannich base dispersant, and a polyalkylene amine dispersant, and   (b) combusting the fuel and the at least one dispersant fuel additive in the engine.   
     
     
         44 . A method for providing an AGV value of greater than about 100 in a used engine oil when tested according to the ASTM D6557 Ball Rust Test, wherein the engine oil lubricates an internal combustion engine combusting an alcohol-containing fuel composition comprising a corrosion inhibitor, said method comprising:
 (a) combining the fuel with a dodecenyl succinic acid corrosion inhibitor, and   (b) combusting the fuel and the dodecenyl succinic acid corrosion inhibitor in the engine.