U.S. patent application number 12/092417 was filed with the patent office on 2009-09-03 for method of controlling by-products or pollutants from fuel combustion.
This patent application is currently assigned to The Lubrizol Corporation. Invention is credited to David Hobson, Alex F. Psaila, David L. Spivey.
Application Number | 20090217570 12/092417 |
Document ID | / |
Family ID | 38609976 |
Filed Date | 2009-09-03 |
United States Patent
Application |
20090217570 |
Kind Code |
A1 |
Hobson; David ; et
al. |
September 3, 2009 |
Method of Controlling By-Products or Pollutants from Fuel
Combustion
Abstract
The invention provides a method of controlling by-products or
pollutants from fuel combustion, comprising corn-busting a fuel
containing a dispersion, the dispersion comprises: (a) a mixture of
at least two metal bases, wherein each metal of the metal bases has
an average oxidation state of (+2) or higher, (b) at least one
surfactant; and (c) at least one organic medium, wherein the metal
bases are uniformly dispersed in the organic medium.
Inventors: |
Hobson; David; (Derbyshire,
GB) ; Psaila; Alex F.; (Biggin Hill Westerham,
GB) ; Spivey; David L.; (Staffordshire, GB) |
Correspondence
Address: |
THE LUBRIZOL CORPORATION;ATTN: DOCKET CLERK, PATENT DEPT.
29400 LAKELAND BLVD.
WICKLIFFE
OH
44092
US
|
Assignee: |
The Lubrizol Corporation
Wickliffe
OH
|
Family ID: |
38609976 |
Appl. No.: |
12/092417 |
Filed: |
November 9, 2006 |
PCT Filed: |
November 9, 2006 |
PCT NO: |
PCT/US06/60716 |
371 Date: |
August 21, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60735941 |
Nov 10, 2005 |
|
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|
Current U.S.
Class: |
44/370 ; 44/354;
44/357; 44/385; 44/388; 44/397; 44/450; 44/457; 44/500 |
Current CPC
Class: |
C10L 1/238 20130101;
C10L 1/1881 20130101; C10L 10/02 20130101; C10L 1/1233 20130101;
C10L 1/10 20130101; C10L 1/2437 20130101; C10L 1/1616 20130101;
C10L 1/198 20130101; C10L 10/04 20130101; C10L 1/2383 20130101;
C10L 1/1981 20130101 |
Class at
Publication: |
44/370 ; 44/457;
44/388; 44/385; 44/450; 44/354; 44/357; 44/397; 44/500 |
International
Class: |
C10L 1/24 20060101
C10L001/24; C10L 1/12 20060101 C10L001/12; C10L 1/18 20060101
C10L001/18; C10L 5/00 20060101 C10L005/00 |
Claims
1. A method of controlling by-products or pollutants from fuel
combustion, comprising combusting a fuel containing a dispersion,
the dispersion comprises: (a) a mixture of at least two metal
bases, wherein each metal of the metal bases has an average
oxidation state of about (+2) or higher, (b) at least one
surfactant; and (c) at least one organic medium, wherein the metal
bases are uniformly dispersed in the organic medium.
2. The method of claim 1, wherein the average oxidation state of
each metal base ranges from about (+2) to about (+4), or from about
(+2) to about (+3).
3. The method of claim 1, wherein the metal base comprises oxides,
carbonates, bicarbonates, hydroxides sulphonates, carboxylates, or
mixtures thereof.
4. The method of claim 1, wherein the mixture of at least two metal
bases comprises: (i) a first metal base containing a metal selected
from the group consisting of iron, magnesium, calcium and mixtures
thereof; (ii) a second metal base containing a metal selected from
the group consisting of magnesium, calcium, cerium, iron, copper,
chromium, and mixtures thereof, with the proviso that the first
metal base is different from the second metal base; and (iii)
optionally another metal base other than the metal base of (i) or
(ii).
5. The method of claim 4, wherein the first metal base is present
at greater than about 50 wt % of the total weight of metal base
present; and the second metal base is present at less than about 50
wt % of the total weight of metal base present.
6. The method of claim 4, wherein the first metal base is present
at greater than about 75 wt % of the total weight of metal base
present; and the second metal base is present at less than about 25
wt % of the total weight of metal base present.
7. The method of claim 1, wherein the dispersion has the metal base
present in the range from about 25 wt % to about 80 wt %, or from
about 35 wt % to about 70 wt % of the dispersion.
8. The method of claim 1, wherein the metal base has a mean
particle size in the dispersion ranging from about 20 nanometres to
less than about 1 .mu.m.
9. The method of claim 1, wherein the surfactant has a hydrophilic
lipophilic balance (HLB) ranging from about 1 to about 40.
10. The method of claim 1, wherein the surfactant comprises at
least of hydrocarbyl substituted aryl sulphonic acids, a
polyolefin-substituted acylating agent, or salixarenes.
11. The method of claim 1, wherein the dispersion comprises: (a)
40-65 wt % of a metal base; (b) 5-25 wt % of a surfactant; and (c)
an organic medium in which the metal base is dispersed.
12. The method of claim 1, wherein the fuel comprises a liquid
fuel, a solid fuel, or mixtures thereof.
13. The method of claim 1, wherein the by-products or pollutants
from fuel combustion comprise two or more properties from modified
sulphur oxide emissions, modified nitrogen oxide emissions,
modified particulate matter production, modified vanadate
production or mixtures thereof.
14. A method of controlling by-products or pollutants from fuel
combustion, comprising combusting a fuel containing a dispersion,
the dispersion comprises: (a) a mixture of at least three metal
bases, wherein each metal of the metal bases has an average
oxidation state of (+2) or higher, (b) at least one surfactant; and
(c) at least one organic medium, wherein the metal bases are
uniformly dispersed in the organic medium.
15. The method of claim 14, wherein the mixtures of at least three
metal bases comprise: (i) a first metal base contains a metal
selected from the group consisting of iron, magnesium, calcium and
mixtures thereof; (ii) a second metal base contains a metal
selected from the group consisting of magnesium, calcium, cerium,
iron, copper, chromium, and mixtures thereof, with the proviso that
the first metal base is different from the second metal base; and
(iii) at least one other metal base, wherein the metal of the metal
base is selected from the group consisting of calcium, magnesium,
cerium, iron, copper, chromium, barium, platinum, lead, manganese,
strontium, and mixtures thereof, with the proviso that the third
metal base is a different from the metal base already employed in
(i) and (ii).
16. A composition comprising: (i) a fuel; and (ii) a dispersion,
the dispersion comprises: (a) a mixture of at least two metal
bases, wherein each metal of the metal bases has an average
oxidation state of about (+2) or higher, (b) at least one
surfactant; and (c) at least one organic medium, wherein the metal
bases are uniformly dispersed in the organic medium.
17. The composition of claim 16, wherein the dispersion comprises
at least three metal bases.
18. The composition of claim 16 further comprising at least other
performance additive selected from the group consisting of metal
deactivators, detergents, dispersants, friction modifiers,
corrosion inhibitors, antioxidants, foam inhibitors, demulsifiers,
pour point depressants, seal swelling agents, biocides,
anti-foulants, flow improvers, cold flow improvers, and mixtures
thereof
19. A dispersion comprising: (a) a mixture of at least three metal
bases, wherein each metal of the metal bases has an average
oxidation state of about (+2) or higher, (b) at least one
surfactant; and (c) at least one organic medium, wherein the metal
bases are uniformly dispersed in the organic medium.
20. The use of a dispersion in a fuel for the reduction of
by-products or pollutants formed from fuel combustion, wherein the
dispersion comprises: (a) a mixture of at least two metal bases,
wherein each metal of the metal bases has an average oxidation
state of about (+2) or higher, (b) at least one surfactant; and (c)
at least one organic medium, wherein the metal bases are uniformly
dispersed in the organic medium.
Description
FIELD OF INVENTION
[0001] The present invention relates to a method comprising
supplying to the fuel a dispersion, the dispersion comprises: (a) a
mixture of at least two metal bases, wherein each metal of the
metal bases has an average oxidation state of (+2) or higher. The
method is capable of controlling by-products or pollutants from
fuel combustion.
BACKGROUND OF THE INVENTION
[0002] In recent years attempts have been made to reduce the amount
of pollutants/emissions released from combustion of fuels. Examples
of pollutants include sulphur oxides (e.g. sulphur trioxide),
nitrogen oxides, carbon monoxide, carbon dioxide and particulate
matter. These pollutants are known to adversely affect levels of
green-house gases or contribute to other problems, such as, smog.
In the case of particulate matter, studies have also indicated
adverse effects on human, animal and plant well being. Other
by-products of fuel combustion include vanadate deposits. Vanadate
deposits are believed to form corrosive low-melting slag that forms
deposits. It would be desirable to combust fuels whilst keeping
pollutants to a minimum.
[0003] International Publication WO 2005/097952 discloses providing
a fuel composition containing a metal base with a solids content of
greater than about 35 wt % of the dispersion. The composition
disclosed employs one metal base per dispersion.
[0004] International Publication WO 04/026996 discloses a fuel
additive composition capable of reducing vanadate deposits. The
composition contains a metal inorganic oxygen containing compound,
a liquid soluble in oil and a dispersant including fatty acid or
ester derivatives thereof.
[0005] However, none of the dispersions provide an improved method
of reducing numerous pollutants emitted during fuel combustion.
Therefore it would be advantageous to provide a method of
controlling pollutants from fuel combustion. The present invention
provides such a method, by providing a dispersion which
synergistically reduces numerous pollutants emitted during fuel
combustion.
SUMMARY OF THE INVENTION
[0006] The present invention provides a method of controlling
by-products or pollutants from fuel combustion, comprising
combusting a fuel containing a dispersion, the dispersion
comprises: (a) a mixture of at least two metal bases, wherein each
metal of the metal bases has an average oxidation state of about
(+2) or higher, (b) at least one surfactant; and (c) at least one
organic medium, wherein the metal bases are uniformly dispersed in
the organic medium.
[0007] In one embodiment the invention provides a method of
controlling by-products or pollutants from fuel combustion,
comprising combusting a fuel containing a dispersion, the
dispersion comprises: (a) a mixture of at least three metal bases,
wherein each metal of the metal bases has an average oxidation
state of about (+2) or higher, (b) at least one surfactant; and (c)
at least one organic medium, wherein the metal bases are uniformly
dispersed in the organic medium.
[0008] In one embodiment the invention provides a dispersion
comprising: (a) a mixture of at least three metal bases, wherein
each metal of the metal bases has an average oxidation state of
about (+2) or higher, (b) at least one surfactant; and (c) at least
one organic medium, wherein the metal bases are uniformly dispersed
in the organic medium.
[0009] In one embodiment the invention provides a composition
comprising: (i) a fuel; and (ii) a dispersion, wherein the
dispersion comprises: (a) a mixture of at least two metal bases,
wherein each metal of the metal bases has an average oxidation
state of about (+2) or higher, (b) at least one surfactant; and (c)
at least one organic medium, wherein the metal bases are uniformly
dispersed in the organic medium.
[0010] In one embodiment the invention provides a composition
comprising: (i) a fuel; and (ii) a dispersion, the dispersion
comprises: (a) a mixture of at least three metal bases, wherein
each metal of the metal bases has an average oxidation state of
about (+2) or higher, (b) at least one surfactant; and (c) at least
one organic medium, wherein the metal bases are uniformly dispersed
in the organic medium.
[0011] In one embodiment the invention provides for the use of a
dispersion, (the dispersion comprises: (a) a mixture of at least
three metal bases, wherein each metal of the metal bases has an
average oxidation state of about (+2) or higher, (b) at least one
surfactant; and (c) at least one organic medium, wherein the metal
bases are uniformly dispersed in the organic medium) in a fuel for
the reduction of by-products or pollutants formed from fuel
combustion.
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present invention provides a method of controlling
by-products or pollutants from fuel combustion as disclosed above.
The invention further provides a composition as disclosed
above.
[0013] In one embodiment the invention is other than a
water-containing emulsion.
[0014] As used herein the term "free of" for all chemistry
disclosed herein except for the metal base, as used in the
specification and claims, defines the absence of a material except
for the amount which is present as impurities, e.g., a trace amount
or a non-effective amount. Typically in this embodiment, the amount
present will be less than about 0.05% or less than about 0.005 wt %
by weight of the dispersion.
[0015] As a person skilled in the art will appreciate, impurities
in the metal base are typically about 1 wt % to about 3 wt % of the
metal base. The reason for the impurities being typically about 1
wt % to about 3 wt % of the metal base is believed to be due to
mining processes. Typically the major impurities in the metal base
include calcium carbonates, silica or silicates.
[0016] In different embodiments the dispersion may be opaque or
semi-translucent or translucent or transparent, or any gradation
between such descriptions.
Fuel
[0017] The fuel comprises a liquid fuel, biofuel, a solid fuel, or
mixtures thereof. In one embodiment the fuel is a solid fuel. In
another embodiment the fuel is a liquid fuel. Examples of a
suitable solid fuel include coal.
[0018] When the fuel comprises a liquid fuel, the liquid fuel may
also be utilized as a suitable organic medium for preparing the
dispersion. Therefore to avoid duplication of description a more
detailed description of the liquid fuel is disclosed below in the
organic medium section.
Metal Base
[0019] The dispersion of the metal base comprises di-, tri-,
tetra-valent metal or a mixture thereof.
[0020] In embodiment the metal base may further comprise a
monovalent metal base. In one embodiment the metal base is derived
from a monovalent metal including lithium, potassium, sodium,
copper, or mixtures thereof. In one embodiment the metal oxidation
state of the metal base is other than (+1).
[0021] In another embodiment the average oxidation state of the
metal base ranges from about (+2) to about (+4), or from about (+2)
to about (+3). Typically the metal of the metal base is a divalent
or trivalent metal. In one embodiment the metal base is derived
from a divalent metal including magnesium, calcium, barium or
mixtures thereof. The metal may also have multiple valences, e.g.,
mono- or di- or tri-valent with cerium, copper or iron as examples.
In one embodiment the metal base is derived from a tetravalent
metal including cerium.
[0022] In different embodiments the base of the metal base
comprises oxides, carbonates, bicarbonates, hydroxides,
sulphonates, carboxylates (e.g. C.sub.1-30 or C.sub.8-24 linear or
branched alkyl carboxylates), nitrates, phosphates, sulphates,
sulphites, nitrites, phosphonates, or mixtures thereof.
[0023] In different embodiments the base of the metal base
comprises oxides, carbonates, bicarbonates, hydroxides,
sulphonates, carboxylates, or mixtures thereof. Optionally the
metal base further comprises water of crystallization or adsorped
(or absorbed) water. In one embodiment the metal base is
crystalline.
[0024] In different embodiments a first metal base comprises iron
oxide (Fe.sub.2O.sub.3, FeO or Fe.sub.3O.sub.4), iron carboxylates
(e.g. an octadecanoic acid salt with iron), magnesium hydroxide,
calcium hydroxide, calcium carbonate, magnesium carbonate, calcium
oxide, magnesium oxide or mixtures thereof.
[0025] In different embodiments a second metal base comprises
cerium oxide (CeO or CeO.sub.2), cerium sulphonate, iron oxide
(Fe.sub.2O.sub.3, FeO or Fe.sub.3O.sub.4), iron carboxylates (e.g.
an octadecanoic acid salt with iron), copper oxide (CuO) or
chromium oxides.
[0026] In one embodiment the metal base is substantially free of
metal bases other than two or three bases selected from the group
consisting of magnesium hydroxide, calcium hydroxide, calcium
carbonate, magnesium carbonate, calcium oxide, magnesium oxide,
cerium oxide (CeO or CeO.sub.2), iron oxide (Fe.sub.2O.sub.3, FeO
or Fe.sub.3O.sub.4), copper oxide (CuO) or chromium oxides, and
mixtures thereof.
[0027] In one embodiment a first metal base contains a metal
selected from the group consisting of iron, magnesium, calcium and
mixtures thereof; and a second metal base contains a metal selected
from the group consisting of magnesium, calcium, cerium, iron,
copper, chromium, and mixtures thereof, with the proviso that the
first metal base is different from the second metal base.
[0028] In one embodiment when there are at least two metal bases in
the mixture, each metal of the metal bases has an oxidation state
of about (+2) or higher are employed, and the metals may be chosen
from:
[0029] (i) a first metal base contains a metal selected from the
group consisting of iron, magnesium, calcium and mixtures
thereof;
[0030] (ii) a second metal base contains a metal selected from the
group consisting of magnesium, calcium, cerium, iron, copper,
chromium, and mixtures thereof, with the proviso that the first
metal base is different from the second metal base; and
[0031] (iii) optionally another metal base other than the metal
base of (i) or (ii).
[0032] In one embodiment the first metal base is present in a
weight greater than the second metal base. The weight of the first
metal base present may be greater than about 50 wt %, or greater
than about 75 wt %, or greater than about 95 wt % of the total
amount of metal base present. The weight of the second metal base
present may be less than about 50 wt %, or less than about 25 wt %,
or less than about 5 wt % of the total amount of metal base
present.
[0033] In one embodiment when there are at least three metal bases
in the mixture, each metal of the metal bases has an oxidation
state of about (+2) or higher are employed, and the metals may be
chosen from: [0034] (i) a first metal base contains a metal
selected from the group consisting of iron, magnesium, calcium and
mixtures thereof; [0035] (ii) a second metal base contains a metal
selected from the group consisting of magnesium, calcium, cerium,
iron, copper, chromium, and mixtures thereof, with the proviso that
the first metal base is different from the second metal base; and
[0036] (iii) at least one other metal base, wherein the metal of
the metal base is selected from the group consisting of calcium,
magnesium, cerium, iron, copper, chromium, barium, platinum, lead,
manganese, strontium, and mixtures thereof, with the proviso that
the third metal base is a different from the metal base already
employed in (i) and (ii).
[0037] In one embodiment the metal of the metal base of (iii) is
selected from the group consisting of calcium, magnesium, cerium,
iron, copper, chromium, and mixtures thereof; with the proviso that
the third metal base is different from a metal base already
employed in (i) and (ii).
[0038] When at least three metal bases are employed in one
embodiment two of the metal bases are derived from a calcium and
magnesium base. The third (or higher i.e. fourth or fifth) metal
base may be derived from a metal selected from the group consisting
of cerium, iron, copper, chromium, and mixtures thereof.
[0039] The amount of metal base present in the dispersion, that is,
the solids content, is greater than about 15 wt % and may range
from about 17 wt % to about 90 wt %, or from about 25 wt % to about
80 wt %, or from about 35 wt % to about 70 wt %, or from about 40
wt % to about 65 wt % of the dispersion. This amount is determined
on the basis of the original dispersion and does not include any
additional diluent into which the dispersion may be subsequently
admixed to form, for instance, a fully formulated lubricating
composition, nor does it include solids or non-volatile components
from other sources.
[0040] The metal base is typically in the form of a solid and is
not appreciably soluble in the organic medium. In different
embodiments the metal base has a mean particle size in the
dispersion ranging from about 20 nanometres to less than about 1
.mu.m, or about 30 nanometres to about 0.7 .mu.m, or about 50
nanometres to about 0.4 .mu.m, or about 80 nanometres to about 0.3
.mu.m.
[0041] The metal base generally comprises at least one of oxides,
hydroxides or carbonates. Examples of a suitable metal base include
magnesium hydroxide, calcium hydroxide, calcium carbonate,
magnesium carbonate, calcium oxide, magnesium oxide, cerium oxide,
iron oxide or mixtures thereof. In one embodiment of the invention
the metal base is present in a mixture, for instance, dolmitic
lime, which is commercially available.
[0042] If the invention further comprises a metal base with an
oxidation state of (+1), examples of a suitable metal base include
sodium carbonate, sodium bicarbonate, potassium carbonate,
potassium bicarbonate, potassium hydroxide, sodium hydroxide,
anhydrous lithium hydroxide, lithium hydroxide monohydrate, lithium
carbonate, lithium oxide or mixtures thereof.
[0043] In one embodiment the dispersion further comprises a
co-ordination compound, such as, ferrocene (cyclopentadienyl
based), carboxylates or sulphonates.
Surfactant
[0044] The surfactant includes an ionic (cationic or anionic) or
non-ionic compound. Generally, the surfactant stabilises the
dispersion of the metal base in the organic medium.
[0045] Suitable surfactant compounds include those with a
hydrophilic lipophilic balance (HLB) ranging from about 1 to about
40, or about 1 to about 20, or about 1 to about 18, or about 2 to
about 16, or about 2.5 to about 15. In different embodiments the
HLB may be about 11 to about 14, or less than about 10 such as
about 1 to about 8, or about 2.5 to about 6. Combinations of
surfactants may be used with individual HLB values outside of these
ranges, provided that the composition of a final surfactant blend
is within these ranges. When the surfactant has an available acidic
group, the surfactant may become the metal salt of the acidic group
and where the metal is derived from the metal base.
[0046] Examples of surfactants suitable for the invention are
disclosed in McCutcheon's Emulsifiers and Detergents, 1993, North
American & International Edition. Generic examples include
alkanolamides, alkylarylsulphonates, amine oxides,
poly(oxyalkylene) compounds, including block copolymers comprising
alkylene oxide repeat units (e.g., Pluronic.TM.), carboxylated
alcohol ethoxylates, ethoxylated alcohols, ethoxylated alkyl
phenols, ethoxylated amines and amides, ethoxylated fatty acids,
ethoxylated fatty esters and oils, fatty esters, glycerol esters,
glycol esters, imidazoline derivatives, phenates, lecithin and
derivatives, lignin and derivatives, monoglycerides and
derivatives, olefin sulphonates, phosphate esters and derivatives,
propoxylated and ethoxylated fatty acids or alcohols or alkyl
phenols, sorbitan derivatives, sucrose esters and derivatives,
sulphates or alcohols or ethoxylated alcohols or fatty esters,
polyisobutylene succinicimide and derivatives.
[0047] In one embodiment the surfactant comprises polyesters as
defined in column 2, line 44 to column 3, line 39 of U.S. Pat. No.
3,778,287. Examples of suitable polyester surfactants are prepared
in U.S. Pat. No. 3,778,287 as disclosed in Polyester Examples A to
F (including salts thereof).
[0048] In one embodiment the surfactant is a hydrocarbyl
substituted aryl sulphonic acid (or sulphonate) of an alkali metal,
alkaline earth metal or mixtures thereof. The aryl group of the
aryl sulphonic acid may be phenyl or naphthyl. In one embodiment
the hydrocarbyl substituted aryl sulphonic acid comprises alkyl
substituted benzene sulphonic acid.
[0049] The hydrocarbyl (especially an alkyl) group typically
contains about 8 to about 30, or about 10 to about 26, or about 10
to about 15 carbon atoms. In one embodiment the surfactant is a
mixture of C.sub.10 to C.sub.15 alkylbenzene sulphonic acids.
Examples of sulphonates include dodecyl and tridecyl benzene
sulfonates or condensed naphthalenes or petroleum sulfonates, as
well as sulphosuccinates and derivatives.
[0050] In one embodiment the surfactant is in the form of a neutral
or overbased surfactant, typically salted with an alkali or
alkaline earth metal. The alkali metal includes lithium, potassium
or sodium; and the alkaline earth metal includes calcium or
magnesium. In one embodiment the alkali metal is sodium. In one
embodiment the alkaline earth metal is calcium.
[0051] In one embodiment the surfactant is a derivative of a
polyolefin. Typical examples of a polyolefin include polyisobutene;
polypropylene; polyethylene; a copolymer derived from isobutene and
butadiene; a copolymer derived from isobutene and isoprene; or
mixtures thereof.
[0052] Typically the derivative of a polyolefin comprises a
polyolefin-substituted acylating agent optionally further reacted
to form an ester and/or aminoester. The acylating agent may be
prepared from carboxylic reactants (which when reacted with a
polyolefin give the desired acylating agent, i.e. substrate for the
surfactant). The carboxylic reactants include functional groups,
such as a carboxylic acid or anhydride thereof. Examples of
carboxylic reactants include an alpha, beta-unsaturated mono- or
polycarboxylic acid, anhydride ester or derivative thereof.
Examples of carboxylic reactants thus include (meth) acrylic acid,
methyl(meth)acrylate, maleic acid or anhydride, fumaric acid,
itaconic acid or anhydride, or mixtures thereof, each of which may
typically be in the form of the saturated materials (e.g. succinic
anhydride) after reaction with the polyolefin.
[0053] In one embodiment the polyolefin is a derivative of
polyisobutene with a number average molecular weight of at least
250, 300, 500, 600, 700, or 800, to 5000 or more, often up to 3000,
2500, 1600, 1300, or 1200. Typically, less than about 5% by weight
of the polyisobutylene used to make the derivative molecules have
Mn less than about 250, more often the polyisobutylene used to make
the derivative has Mn of at least about 800. The polyisobutylene
used to make the derivative preferably contains at least about 30%
terminal vinylidene groups, more often at least about 60% or at
least about 75% or about 85% terminal vinylidene groups. The
polyisobutylene used to make the derivative may have a
polydispersity, Mw/ Mn, greater than about 5, more often from about
6 to about 20.
[0054] In various embodiments, the polyisobutene is substituted
with succinic anhydride, the polyisobutene substituent having a
number average molecular weight ranging from about 1,500 to about
3,000, or about 1,800 to about 2,300, or about 700 to 1 about 700,
or about 800 to about 1000. The ratio of succinic groups per
equivalent weight of the polyisobutene typically ranges from about
1.3 to about 2.5, or about 1.7 to about 2.1, or about 1.0 to about
1.3, or about 1.0 to about 1.2.
[0055] In one embodiment the surfactant is
polyisobutenyl-dihydro-2,5-furandione ester with pentaerythritol or
mixtures thereof. In one embodiment the surfactant is a
polyisobutylene succinic anhydride derivative such as a
polyisobutylene succinimide or derivatives thereof. In one
embodiment the surfactant is substantially free to free of a basic
nitrogen.
[0056] Other typical derivatives of polyisobutylene succinic
anhydrides include hydrolysed succinic anhydrides, esters or
diacids. Polyisobutylene succan derivatives are preferred to make
the metal base dispersions. A large group of polyisobutylene
succinic anhydride derivatives are taught in U.S. Pat. No.
4,708,753, and U.S. Pat. No. 4,234,435.
[0057] In another embodiment the surfactant comprises a salixarene
(or salixarate if in the form of a metal salt). The salixarene is
defined as an organic substrate of a salixarate. The salixarene may
be represented by a substantially linear compound comprising at
least one unit of the formulae (I) or (II):
##STR00001##
each end of the compound having a terminal group of formulae (III)
or (IV):
##STR00002##
such groups being linked by divalent bridging groups, which may be
the same or different for each linkage; wherein f is about 1, 2 or
3, in one embodiment about 1 or 2; R.sup.2 is hydroxyl or a
hydrocarbyl group and j is about 0, 1, or 2; R.sup.3 is hydrogen or
a hydrocarbyl group; R.sup.4 is a hydrocarbyl group or a
substituted hydrocarbyl group; g is about 1, 2 or 3, provided at
least one R.sup.4 group contains 8 or more carbon atoms; and
wherein the compound on average contains at least one of unit (I)
or (III) and at least one of unit (II) or (IV) and the ratio of the
total number of units (I) and (III) to the total number of units of
(II) and (IV) in the composition is about 0.1:1 to about 2:1.
[0058] The U group in formulae (I) and (III) may be an --OH or an
--NH.sub.2 or --NHR.sup.1 or --N(R.sup.X).sub.2 group located in
one or more positions ortho, meta, or para to the --COOR.sup.3
group. R.sup.1 is a hydrocarbyl group containing 1 to 5 carbon
atoms. When the U group comprises a --OH group, formulae (I) and
(III) are derived from 2-hydroxybenzoic acid (often called
salicylic acid), 3-hydroxybenzoic acid, 4-hydroxybenzoic acid or
mixtures thereof. When U is a --NH.sub.2 group, formulae (I) and
(III) are derived from 2-aminobenzoic acid (often called
anthranilic acid), 3-aminobenzoic acid, 4-aminobenzoic acid or
mixtures thereof.
[0059] The divalent bridging group, which may be the same or
different in each occurrence, includes an alkylene or methylene
bridge such as --CH.sub.2-- or --CH(R)-- and an ether bridge such
as --CH.sub.2OCH.sub.2-- or --CH(R)OCH(R)-- where R is an alkyl
group having 1 to 5 carbon atoms and where the methylene and ether
bridges are derived from formaldehyde or an aldehyde having 2 to 6
carbon atoms.
[0060] Often the terminal group of formulae (III) or (IV) further
contains 1 or 2 hydroxymethyl groups ortho to a hydroxy group. In
one embodiment of the invention hydroxymethyl groups are present.
In one embodiment of the invention hydroxymethyl groups are not
present. A more detailed description of salixarene and salixarate
chemistry is disclosed in EP 1 419 226 B1, including methods of
preparation as defined in Examples 1 to 23 (page 11, line 42 to
page 13, line 47).
[0061] In one embodiment the surfactant is substantially free of,
to free of, a fatty acid or derivatives thereof, such as esters. In
one embodiment the surfactant is other than a fatty acid or
derivatives thereof.
[0062] In one embodiment the surfactant comprises at least of
hydrocarbyl substituted aryl sulphonic acids, derivatives of
polyolefins, polyesters or salixarenes (or salixarates).
[0063] In different embodiments the surfactant is substantially
free of, to free of, phospholipids, (such as lecithin) and/or amino
acids (such as sarcosines).
[0064] In one embodiment the surfactant has a molecular weight of
less than 1000, in another embodiment less than about 950, for
example, about 250, about 300, about 500, about 600, about 700, or
about 800. The amount of surfactant and metal base in the
dispersion may vary as is shown in Table 1, the balance being the
organic medium and optionally water.
[0065] In one embodiment the amount of the organic medium present
in the dispersion varies from about 25 wt % to about 55 wt %.
TABLE-US-00001 TABLE 1 Embodiments (wt % of dispersion) Additive 1
2 3 4 Metal Base 17-90 25-80 35-70 40-65 Surfactant 0.01-30 1-30
2-30 5-25
Organic Medium
[0066] The organic medium may comprise an oil of lubricating
viscosity, a liquid fuel, a hydrocarbon solvent or mixtures
thereof. Typically the organic solvent comprises an oil of
lubricating viscosity or a liquid fuel.
[0067] Optionally the organic medium contains water, typically up
to about 1 wt %, or about 2 wt % or about 3 wt % of the dispersion.
In different embodiments the organic medium is substantially free
of, to free of, water.
Oils of Lubricating Viscosity
[0068] In one embodiment the organic medium comprises an oil of
lubricating viscosity. Such oils include natural and synthetic
oils, oil derived from hydrocracking, hydrogenation, and
hydrofinishing, unrefined, refined and re-refined oils and mixtures
thereof.
[0069] Unrefined oils are those obtained directly from a natural or
synthetic source generally without (or with little) further
purification treatment.
[0070] Refined oils are similar to the unrefined oils except they
have been further treated in one or more purification steps to
improve one or more properties. Purification techniques are known
in the art and include solvent extraction, secondary distillation,
acid or base extraction, filtration, percolation and the like.
[0071] Re-refined oils are also known as reclaimed or reprocessed
oils, and are obtained by processes similar to those used to obtain
refined oils and often are additionally processed by techniques
directed to removal of spent additives and oil breakdown
products.
[0072] Natural oils useful in making the inventive lubricants
include animal oils, vegetable oils (e.g., castor oil, lard oil),
mineral lubricating oils such as liquid petroleum oils and
solvent-treated or acid-treated mineral lubricating oils of the
paraffinic, naphthenic or mixed paraffinic-naphthenic types and
oils derived from coal or shale or mixtures thereof.
[0073] Synthetic lubricating oils are useful and include
hydrocarbon oils, such as, polymeric tetrahydrofurans, polymerised
and interpolymerised olefins (e.g., polybutylenes, polypropylenes,
propyleneisobutylene copolymers); poly(1-hexenes), poly(1-octenes),
poly(1-decenes), and mixtures thereof; alkyl-benzenes (e.g.
dodecylbenzenes, tetradecylbenzenes, dinonylbenzenes,
di-(2-ethylhexyl)-benzenes); polyphenyls (e.g., biphenyls,
terphenyls, alkylated polyphenyls); alkylated diphenyl ethers and
alkylated diphenyl sulphides and the derivatives, analogs and
homologs thereof or mixtures thereof.
[0074] Other synthetic lubricating oils include. Synthetic oils may
be produced by Fischer-Tropsch reactions and typically may be
hydroisomerised Fischer-Tropsch hydrocarbons or waxes.
[0075] Oils of lubricating viscosity may also be defined as
specified in the American Petroleum Institute (API) Base Oil
Interchangeability Guidelines. The five base oil groups are as
follows: Group I (sulphur content>0.03 wt %, and/or <90 wt %
saturates, viscosity index 80-120); Group II (sulphur
content.ltoreq.0.03 wt %, and .gtoreq.90 wt % saturates, viscosity
index 80-120); Group III (sulphur content.ltoreq.0.03 wt %, and
.gtoreq.90 wt % saturates, viscosity index.gtoreq.120); Group IV
(all polyalphaolefins (PAOs)); and Group V (all others not included
in Groups I, II, III, or IV). The oil of lubricating viscosity
comprises an API Group I, Group II, Group III, Group IV, Group V
oil and mixtures thereof. Often the oil of lubricating viscosity is
an API Group I, Group II, Group III, Group IV oil and mixtures
thereof. Alternatively the oil of lubricating viscosity is often an
API Group I, Group II, Group III oil or mixtures thereof.
Liquid Fuel
[0076] The liquid fuel is normally a liquid at ambient conditions.
The liquid fuel includes a hydrocarbon fuel, a biofuel (such as,
bio-diesel), a nonhydrocarbon fuel, or a mixture thereof. The
hydrocarbon fuel may be a petroleum distillate such as a gasoline
as defined by ASTM (American Society for Testing and Materials)
specification D4814 or a diesel fuel as defined by ASTM
specification D975. In an embodiment the liquid fuel is a gasoline,
and in another embodiment the liquid fuel is a leaded gasoline, or
a nonleaded gasoline. In another embodiment the liquid fuel is a
diesel fuel. The hydrocarbon fuel includes a hydrocarbon prepared
by a gas to liquid process for example hydrocarbons prepared by a
process such as the Fischer-Tropsch process. The nonhydrocarbon
fuel includes an oxygen containing composition (often referred to
as an oxygenate), an alcohol, an ether, a ketone, an ester of a
carboxylic acid, a nitroalkane, or a mixture thereof. The
nonhydrocarbon fuel includes methanol, ethanol, methyl t-butyl
ether, methyl ethyl ketone, transesterified oils and/or fats from
plants and animals such as rapeseed methyl ester and soybean methyl
ester, and nitromethane. Mixtures of hydrocarbon and nonhydrocarbon
fuels include gasoline and methanol and/or ethanol, diesel fuel and
ethanol, and diesel fuel and a transesterified plant oil such as
rapeseed methyl ester. In one embodiment the liquid fuel is a
nonhydrocarbon fuel or a mixture thereof.
[0077] The dispersion may be used as a sole additive for a fuel
composition. In one embodiment the dispersion is used as one
additive in combination with other performance additives to provide
a fuel composition. In one embodiment the invention provides a fuel
composition comprising (i) a dispersion comprising: (a) a metal
base; (b) a surfactant; and (c) an organic medium in which the
metal base is dispersed; (ii) an oil of lubricating viscosity; and
(iii) other performance additives.
[0078] The fuel composition may thus comprise an oil of lubricating
viscosity as defined above, in addition to the amount which may be
present as the organic medium of the dispersion.
Other Performance Additives
[0079] The fuel composition optionally comprises other performance
additives. The other performance additives comprise at least one of
metal deactivators, detergents, dispersants, friction modifiers,
corrosion inhibitors, antioxidants, foam inhibitors, demulsifiers,
pour point depressants, seal swelling agents, biocides,
anti-foulants, flow improvers (include polymethacrylates, maleic
anhydride-styrene interpolymers, polyalphaolefins, and ethylene
vinyl acetates), cold flow improvers, or mixtures thereof.
Typically, fully-formulated fuel will contain one or more of these
performance additives.
[0080] Performance additives such as antiwear agents are typically
included in a fuel in 2-stroke marine diesel cylinder
lubricant.
Demulsifiers
[0081] Demulsifiers are known. In one embodiment the dispersion
further comprises demulsifiers, or mixtures thereof. Examples of
demulsifiers include trialkyl phosphates, polyethylene glycols,
polyethylene oxides, polypropylene oxides and (ethylene
oxide-propylene oxide) polymers, alkoxylated alkyl phenol resins or
mixtures thereof.
Dispersants
[0082] Dispersants are often known as ashless-type dispersants
because, prior to mixing in a lubricating oil composition, they do
not contain ash-forming metals and they do not normally contribute
any ash forming metals when added to a lubricant. Dispersants also
include polymeric dispersants. Ashless type dispersants are
characterised by a polar group attached to a relatively high
molecular weight hydrocarbon chain. Typical ashless dispersants
include N-substituted long chain alkenyl succinimides. Examples of
N-substituted long chain alkenyl succinimides include
polyisobutylene succinimide with number average molecular weight of
the polyisobutylene substituent in the range 350 to 5000, or 500 to
3000. Succinimide dispersants and their preparation are disclosed,
for instance in U.S. Pat. No. 4,234,435. Succinimide dispersants
are typically the imide formed from a polyamine, typically a
poly(ethyleneamine).
[0083] In one embodiment the invention further comprises at least
one dispersant derived from polyisobutylene succinimide with number
average molecular weight in the range 350 to 5000, or 500 to 3000.
The polyisobutylene succinimide may be used alone or in combination
with other dispersants.
[0084] In one embodiment the invention further comprises at least
one dispersant derived from polyisobutylene, an amine and zinc
oxide to form a polyisobutylene succinimide complex with zinc. The
polyisobutylene succinimide complex with zinc may be used alone or
in combination.
[0085] Another class of ashless dispersant is Mannich bases.
Mannich dispersants are the reaction products of alkyl phenols with
aldehydes (especially formaldehyde) and amines (especially
polyalkylene polyamines). The alkyl group typically contains at
least 30 carbon atoms.
[0086] In one embodiment the dispersant includes a
polyisobutylene-amine as described in U.S. Pat. Nos. 5,567,845 and
5,496,383; and commercially available from BASF.
[0087] The dispersants may also be post-treated by conventional
methods by a reaction with any of a variety of agents. Among these
are boron sources such as boric acid or borates, urea, thiourea,
dimercaptothiadiazoles, carbon disulphide, aldehydes, ketones,
carboxylic acids, hydrocarbon-substituted succinic anhydrides,
maleic anhydride, nitriles, epoxides, and phosphorus compounds.
Detergents
[0088] The fuel composition optionally further comprises neutral or
overbased detergents. Suitable detergent substrates include
sulphonates, salixarates, salicylates, carboxylates, phosphorus
acid salts, mono- and/or di-thiophosphoric acid salts, phenates
including alkyl phenates and sulphur coupled alkyl phenates, or
saligenins.
[0089] In different embodiments, the fuel composition further
comprises at least one of sulphonates and phenates. When present,
the detergents are typically overbased. The ratio of TBN delivered
by the dispersion to that delivered by the detergent may range from
1:99 to 99:1, or 15:85 to 85:15.
Antioxidant
[0090] Antioxidant compounds are known and include an amine
antioxidant (such as an alkylated diphenylamine), a hindered
phenol, a molybdenum dithiocarbamate, and mixtures thereof.
Antioxidant compounds may be used alone or in combination.
[0091] The hindered phenol antioxidant often contains a secondary
butyl and/or a tertiary butyl group as a sterically hindering
group. The phenol group is often further substituted with a
hydrocarbyl group and/or a bridging group linking to a second
aromatic group. Examples of suitable hindered phenol antioxidants
include 2,6-di-tert-butylphenol, 4-methyl-2,6-di-tert-butylphenol,
4-ethyl-2,6-di-tert-butylphenol, 4-propyl-2,6-di-tert-butylphenol
or 4-butyl-2,6-di-tert-butylphenol 2,6-di-tert-butylphenol. In one
embodiment the hindered phenol antioxidant is an ester and may
include, e.g., Irganox.TM. L-135 from Ciba. A more detailed
description of suitable ester-containing hindered phenol
antioxidant chemistry is found in U.S. Pat. No. 6,559,105.
[0092] Suitable examples of molybdenum dithiocarbamates which may
be used as an antioxidant include commercial materials sold under
the trade names such as Vanlube 822.TM. and Molyvan.TM. A from R.
T. Vanderbilt Co., Ltd., and Adeka Sakura-Lube.TM. S-100, S-165 and
S-600 from Asahi Denka Kogyo K. K and mixtures thereof.
Antiwear Agent
[0093] The fuel composition optionally further comprises at least
one antiwear agent. Examples of suitable antiwear agents include a
sulphurised olefin, sulphur-containing ashless anti-wear additives,
metal dihydrocarbyldithiophosphates (such as zinc
dialkyldithiophosphates), thiocarbamate-containing compounds, such
as thiocarbamate esters, thiocarbamate amides, thiocarbamic ethers,
alkylene-coupled thiocarbamates, and bis(S-alkyldithiocarbamyl)
disulphides.
[0094] The dithiocarbamate-containing compounds may be prepared by
reacting a dithiocarbamic acid or salt with an unsaturated
compound. The dithiocarbamate containing compounds may also be
prepared by simultaneously reacting an amine, carbon disulphide and
an unsaturated compound. Generally, the reaction occurs at a
temperature from 25.degree. C. to 125.degree. C. U.S. Pat. Nos.
4,758,362 and 4,997,969 describe dithiocarbamate compounds and
methods of making them.
[0095] Examples of suitable olefins that may be sulphurised to form
an the sulphurised olefin include propylene, butylene, isobutylene,
pentene, hexane, heptene, octane, nonene, decene, undecene,
dodecene, undecyl, tridecene, tetradecene, pentadecene, hexadecene,
heptadecene, octadecene, octadecenene, nonodecene, eicosene or
mixtures thereof. In one embodiment, hexadecene, heptadecene,
octadecene, octadecenene, nonodecene, eicosene or mixtures thereof
and their dimers, trimers and tetramers are especially useful
olefins. Alternatively, the olefin may be a Diels-Alder adduct of a
diene such as 1,3-butadiene and an unsaturated ester such as
butyl(meth)acrylate.
[0096] Another class of sulphurised olefin includes fatty acids and
their esters. The fatty acids are often obtained from vegetable oil
or animal oil and typically contain 4 to 22 carbon atoms. Examples
of suitable fatty acids and their esters include triglycerides,
oleic acid, linoleic acid, palmitoleic acid or mixtures thereof.
Often, the fatty acids are obtained from lard oil, tall oil, peanut
oil, soybean oil, cottonseed oil, sunflower seed oil or mixtures
thereof. In one embodiment fatty acids and/or ester are mixed with
olefins.
[0097] In an alternative embodiment, the ashless antiwear agent may
be a monoester of a polyol and an aliphatic carboxylic acid, often
an acid containing 12 to 24 carbon atoms. Often the monoester of a
polyol and an aliphatic carboxylic acid is in the form of a mixture
with a sunflower oil or the like, which may be present in the
friction modifier mixture from 5 to 95, in different embodiments
from 10 to 90, or 20 to 85, or 20 to 80 weight percent of said
mixture. The aliphatic carboxylic acids (especially a
monocarboxylic acid) which form the esters are those acids
typically containing 12 to 24 or 14 to 20 carbon atoms. Examples of
carboxylic acids include dodecanoic acid, stearic acid, lauric
acid, behenic acid, and oleic acid.
[0098] Polyols include diols, triols, and alcohols with higher
numbers of alcoholic OH groups. Polyhydric alcohols include
ethylene glycols, including di-, tri- and tetraethylene glycols;
propylene glycols, including di-, tri- and tetrapropylene glycols;
glycerol; butane diol; hexane diol; sorbitol; arabitol; mannitol;
sucrose; fructose; glucose; cyclohexane diol; erythritol; and
pentaerythritols, including di- and tripentaerythritol. Often the
polyol is diethylene glycol, triethylene glycol, glycerol,
sorbitol, pentaerythritol or dipentaerythritol.
[0099] The commercially available monoester known as "glycerol
monooleate" is believed to include 60.+-.5 percent by weight of the
chemical species glycerol monooleate, along with 35.+-.5 percent
glycerol dioleate, and less than 5 percent trioleate and oleic
acid.
[0100] Other performance additives such as corrosion inhibitors
including octylamine octanoate, condensation products of dodecenyl
succinic acid or anhydride and a fatty acid such as oleic acid with
a polyamine; metal deactivators including derivatives of
benzotriazoles, 1,2,4-triazoles, benzimidazoles,
2-alkyldithiobenzimidazoles or 2-alkyldithiobenzothiazoles; foam
inhibitors including copolymers of ethyl acrylate and
2-ethylhexylacrylate and optionally vinyl acetate; pour point
depressants including esters of maleic anhydride-styrene,
polymethacrylates, polyacrylates or polyacrylamides; and friction
modifiers including fatty acid derivatives such as amines, esters,
epoxides, fatty imidazolines, condensation products of carboxylic
acids and polyalkylene-polyamines and amine salts of
alkylphosphoric acids may also be used in the lubricant
composition.
Process for Dispersion Preparation
[0101] The dispersion may be prepared by physical processes, that
is, by any one or more of various physical processes, i.e.,
physical processing steps. Examples of physical process include
agitating, milling, grinding, crushing or mixtures thereof.
Typically the process grinds the metal base to a mean average
particle size of at least 10 nanometres to less than 1 .mu.m.
Milling processes include using a rotor stator mixer, a vertical
bead mill, a horizontal bead mill, basket milling, ball mill, pearl
milling or mixtures thereof. In one embodiment, the physical
processes for preparing the dispersion comprise using a vertical or
horizontal bead mill.
[0102] In one embodiment the invention further provides a process
for preparing a dispersion comprising the steps of:
[0103] (1) mixing (a) at least two metal bases, wherein each metal
of the metal bases has an average oxidation state of about (+2) or
higher; (b) a surfactant and (c) a organic medium, to form a
slurry;
[0104] (2) grinding the slurry of step (1) to form a
dispersion.
[0105] In another embodiment the dispersion may be prepared by
forming a single metal dispersion as taught in WO 2005/097952, with
the additional step of combining multiple single metal base
dispersions (by mixing them together) to form a dispersion
comprising at least two metal bases, wherein each metal of the
metal bases has an average oxidation state of about (+2) or higher;
(b) a surfactant and (c) a organic medium. When a dispersion is
prepared by combining multiple single metal base dispersions, it is
common for all single metal base dispersions to comprise the same
or compatible surfactant compounds and organic media. If the
surfactants and organic media are not compatible, unstable
dispersions may be formed.
[0106] In different embodiments the milling process may be carried
out in a vertical or horizontal bead mill. Either bead mill
processes cause the reduction of particle size of the metal base by
high energy collisions of the metal base with at least one bead;
and/or other metal base agglomerates, aggregates, solid particles;
or mixtures thereof. The beads typically have a mean particle size
and mass greater than the desired mean particle size of the metal
base. In some instances the beads are a mixture of different mean
particle size. The beads used in the grinding may be of materials
known to those skilled in the art, such as metal ceramic, glass,
stone, or composite materials.
[0107] The mill typically contains beads present at least about 40
vol %, or at least about 60 vol % of the mill. A range include for
example about 60 vol % to about 95 vol %. A more detailed
description of making the dispersion is disclosed in U.S. patent
application Ser. No. 05/010631.
INDUSTRIAL APPLICATION
[0108] The method of controlling by-products or pollutants from
fuel combustion dispersion is useful for numerous open or closed
flame combustion systems. Suitable combustion systems include power
stations, internal combustion engines, industrial and marine
compression engines and turbines (commonly combusting a distillate,
residual or heavy fuel oils).
[0109] In different embodiments a suitable dispersion is added to
the fuel in ranges from about 1 ppm to about 10,000 ppm, or from
about 20 ppm to about 7500 ppm, or from about 100 ppm to about 5000
ppm, or from about 200 ppm to about 3000 ppm, or from about 500 ppm
to about 2000 ppm.
[0110] In one embodiment, the invention provides a method of
controlling by-products or pollutants from fuel combustion,
comprising supplying thereto a fuel comprising the dispersion as
described herein. The use of the dispersion in a fuel may impart a
means of controlling by-products or pollutants from fuel
combustion. Typically, the by-products or pollutants from fuel
combustion comprise two or more properties from modified sulphur
oxide emissions, modified nitrogen oxide emissions, modified
particulate matter production, modified vanadate production or
mixtures thereof. In one embodiment the fuel dispersion comprises a
calcium base and the base is capable of modifying sulphur oxide
emissions, and particulate matter production. In one embodiment the
fuel dispersion comprises a magnesium base and the base is capable
of modifying vanadate production, sulphur oxide emissions, and
particulate matter production.
[0111] The following examples provide an illustration of the
invention. These examples are non exhaustive and are not intended
to limit the scope of the invention.
EXAMPLES
Preparative Examples of Dispersions
[0112] A series of dispersions (Preparative Examples 1 to 3)
containing a metal base, an organic medium and a surfactant were
prepared from a slurry weighing about 15 kg are prepared using a
lab scale Dyno-Mill ECM Multi-Lab horizontal bead mill commercially
available from W.A.B. A.G., Basel, using 0.3 mm O zirconia/yttria
beads and a residence time of about 10 minutes at a tip speed of
about 8 ms-1. Where appropriate, the mean particle size of the
dispersion particles is determined after cooling by Coulter.RTM.
LS230 Particle Size Analyser. The dispersions prepared are
pourable.
Preparative Example 1
Magnesium Oxide Dispersion
[0113] A dispersion is prepared by milling about 50 wt % Magnesium
oxide, Magchem 40 ex Martin Marietta, in the presence of about 40
wt % 100 N base oil and about 10 wt % of an alkyl benzene sulphonic
acid surfactant.
Preparative Example 2
Iron Oxide Dispersion
[0114] A dispersion is prepared by milling about 70 wt % of iron
oxide (Fe2O3) commercially available from Bayer as
Bayferrox.RTM.160, about 18 wt % of 100 N base oil and about 12 wt
% of an alkyl benzene sulphonic acid surfactant.
Preparative Example 3
Cerium Oxide Dispersion
[0115] A dispersion is prepared by milling about 50 wt % of cerium
oxide (CeO), about 40 wt % of 100 N base oil and about 10 wt % of a
surfactant (polyolefin amino ester esterified with
2-(dimethylamino)ethanol).
Example 1
Three Metal Dispersion
[0116] A three metal dispersion is prepared by mixing the product
of Preparative Example 1 with a commercially available cerium
sulphonate powder and a octdecanoic acid salt of iron. The final
product has a metal weight ratio of magnesium:cerium:iron of about
150:10:5. The product forms a stable dispersion that shows no
significant stratification after 12 weeks.
Example 2
Three Metal Dispersion
[0117] A three metal dispersion is prepared by blending portions of
the products formed in Preparative Examples 1 to 3. The final
product has a metal weight ratio of magnesium:cerium:iron of about
150:10:5. The product forms a stable dispersion that shows no
significant stratification after 12 weeks The dispersion has
greater than about 85% of dispersion particles have a particle size
of less than about 0.46 microns.
Example 3
Three Metal Dispersion
[0118] A three metal dispersion is prepared by blending in a powder
form magnesium oxide, calcium hydroxide and iron oxide
(Fe2O.sub.3). The resultant three metal powder is then added to
about 10 wt % of a succinimide surfactant, and about 39.6 wt % of
SN 100 base oil and about 0.4 wt % of a demulsifier. The final
dispersion contains 37.5 wt % magnesium oxide, about 10.5 wt %
calcium hydroxide and about 2 wt % iron oxide. The resultant
dispersion is pourable and with a mean particle size of about 0.14
to about 0.2 microns.
Fuel Compositions 1-3
[0119] Examples 1 to 3 are treated into a liquid fuel at about 1000
ppm respectively. The resultant fuel is combusted and the use of
the dispersion provides reduces by-products or pollutants from fuel
combustion.
Fuel Compositions 4-6
[0120] Examples 4 to 6 are treated into a liquid fuel at about 1300
ppm respectively. The resultant fuel is combusted and the use of
the dispersion provides reduces by-products or pollutants from fuel
combustion.
Fuel Compositions 7-9
[0121] Examples 7 to 9 are treated into a liquid fuel at about 1500
ppm respectively. The resultant fuel is combusted and the use of
the dispersion provides reduces by-products or pollutants from fuel
combustion.
Fuel Compositions 10-12
[0122] Examples 10 to 12 are treated into a liquid fuel at about
700 ppm respectively. The resultant fuel is combusted and the use
of the dispersion provides reduces by-products or pollutants from
fuel combustion.
Fuel Compositions 13-15
[0123] Examples 13 to 15 are treated into a liquid fuel at about
1750 ppm respectively. The resultant fuel is combusted and the use
of the dispersion provides reduces by-products or pollutants from
fuel combustion.
[0124] While the invention has been explained in relation to its
preferred embodiments, it is to be understood that various
modifications thereof will become apparent to those skilled in the
art upon reading the specification. Therefore, it is to be
understood that the invention disclosed herein is intended to cover
such modifications as fall within the scope of the appended
claims.
* * * * *