Background of the Invention
[0001] This invention is related to wax-containing petroleum distillate having improved
low temperature flow properties. More specifically, the present invention is related
to a wax-containing middle distillate fuel oil having a boiling range within the limits
of about 120
0C and about 450
0C.
[0002] The problem of improving the cold flow properties of wax-containing distillates has
become more pronounced recently because of increases in the demand for certain petroleum
products, including kerosene and the middle distillates. Kerosene, which acts as a
solvent for n-paraffin wax, normally had been a component of middle distillate fuel
oils. The increased demand for kerosene in jet fuels has reduced the amount of kerosene
available for use in middle distillate fuel oils. In addition, the increased demand
for middle distillate fuel oils, particularly diesel fuel, while demand for gasoline
has remained essentially flat, has made it attractive to maximize the production of
middle distillates.
[0003] The wax present in middle distillates precipitates at low temperature, forming large
waxy crystals which tend to plug the small pore openings of fuel filters. This problem
is particularly acute for diesel fuels, where the openings in the fuel filter typically
are between about 5.0 and about 50 microns. Conventional pour depressants, which lower
the pour point, i.e. the point at which the fuel can no longer be poured, may not
be completely satisfactory for preventing pluggage of the fuel filters. While pour
depressants often prevent the fuel from setting up as a gel, large wax crystals may
be formed. However, to improve the cold flow properties of wax-containing middle distillate
fuels oils so that the wax does not plug the fuel filter pores, it is necessary that
only fine wax crystals be formed.
[0004] Considerable work has been directed at additives which improve the cold flow properties
of the wax-containing middle distillate fuels. U.S. Patent No. 3,790,359 is directed
at the addition of from about 0.1 to about 3 weight percent of an essentially saturated
hydrocarbon fraction substantially free of normal paraffinic hydrocarbons having a
number average molecular weight in the range of about 600 to about 3,000, in combination
with a copolymer of ethylene and an unsaturated ester, where the copolymer has less
than 6 methyl terminating side branches per 100 methylene groups. The weight ratio
of the saturated hydrocarbon- fraction to the copolymer was disclosed to range between
about 25:1 to about 1:1.
[0005] U.S. Patent No. 3,999,960 discloses the use of ethers, particularly alkyldiphenylether,
to improve the cold flow properties of wax-containing middle distillate fuels.
[0006] U.S. Patent No. 3,883,318 describes the combination of wax-naphthalene and ethylene
vinyl acetate as a pour depressant for middle distillate fuels.
[0007] U.S. Patent No. 3,982,909 discloses the combination of (a) maleic acid monoamides
of hydrogenated tallow amine neutralized with the same amine; (b) an ethylene-vinyl
acetate copolymer; and (c) a wax-naphthalene condensate produced a cold flow improver
for middle distillate fuels.
[0008] U.S. Patent No. 4,014,663 discloses the combination of (a) an alkylated diphenyl
ether with (b) the reaction product of hydrogenated tallow amine and alkenylsuccinic
anhydride.
[0009] U.S. Patent No. 3,910,776 discloses the combination of (a) ethylene and an unsaturated
ester; and (b) the condensation product of wax and naphthalene in improving the cold
flow properties of distillate petroleum fuels.
[0010] U.S. Patent No. 4,402,708 discloses the use of oil-soluble dialkyl amine derivatives,
such as salts of phthalic anhydride as low temperature flow improvers for middle distillate
fuels.
[0011] With the increasing demand for middle distillate fuels it is advantageous to maximize
the production of middle distillates. Therefore, the middle distillate fuels are expected
to have n-paraffinic wax contents at least as great as are presently found. Frequently,
these fuels having high wax appearance points do not respond well even to combinations
of additives, such as those noted above.
[0012] Other additives have been utilized which contain amorphous wax from petroleum derived
products, such as Foots oil or petrolatum in combination with a synthetically prepared
wax crystal modifier. However, amorphous wax has to be used at relatively high treat
rates of about 0.2 to about 0.3 weight percent, is difficult to dissolve in the middle
distillate fuel and is not always available. In addition, the composition of the wax
may vary widely, which may affect its utility.
[0013] Accordingly, it is desirable to provide an additive comprising synthetically prepared
components for improving the low temperature flow properties of middle distillate
fuels.
[0014] It also is desirable to provide a middle distillate fuel additive for improving the
low temperature flow properties which is relatively inexpensive and which is effective
at relatively low treat rates.
[0015] It also is desirable to provide an additive which did not significantly affect the
combustion properties of the fuel.
[0016] The present invention is directed at the addition to a middle distillate fuel of
an additive comprising:
A. an amide and/or amine salt of carboxylic acid and/or anhydride;
B. an ethylene-containing polymer and/or copolymer;
C. a wax-naphthalene condensation product; and
D. an alkylated diphenyl ether.
Summary of the Invention
[0017] The present invention is directed at a wax-containing petroleum distillate fuel having
a boiling range between about 120°C and about 450°C which has improved low temperature
flow properties by the addition thereto of:
A. an amide and/or amine salt of carboxylic acid and/or anhydride;
B. an ethylene-containing polymer and/or copolymer;
C. a wax-naphthalene condensation product; and
D. an alkylated diphenyl ether.
[0018] The amide and/or amine salt of carboxylic acid and/or anhydride preferably is selected
from the group consisting of oil soluble amine salts and/or amides which generally
will be formed by reaction of at least one molar proportion of hydrocarbyl substituted
amines with a molar proportion of hydrocarbyl acid having 1-4 carboxylic acid groups
or their anhydrides. The ethylene-containing polymer preferably is selected from the
group of polymers consisting of ethylene vinyl acetate and ethylene vinyl chloride.
The wax-naphthalene condensation product preferably is selected from the group of
condensation products consisting of chlorinated n-paraffin waxes condensed with naphthalenes.
The diphenyl ether preferably is alkylated with a compound selected from the group
consisting of dimers of alpha olefins having from about 16 to about 40 carbon atoms.
[0019] The present invention also is directed at a method for improving the low temperature
flow properties of a middle distillate fuel boiling in the range of about 120
0C to about 450
0C, which comprises adding to the middle distillate fuel an effective amount of an
additive comprising:
A. an amide and/or amine salt of carboxylic acid and/or anhydride;
B. an ethylene-containing polymer and/or copolymer;
C. a wax-naphthalene condensation product; and
D. an alkylated diphenyl ether.
[0020] In a preferred embodiment the additive comprises at least about 0.005 weight percent
of the fuel to about 2.0 weight percent of the fuel, and preferably ranges between
about 0.03 weight percent and 0.50 weight percent of the middle distillate fuel.
[0021] The additive may be added to the middle distillate fuel as a concentrate in which
a heavy aromatic naphtha preferably is present as a diluent. The preferred concentration
ranges of the various components in the concentrate are as follows:

[0022] The multi-component additive may be added to the distillate fuel at any point which
will assume good mixing of the additive with the middle distillate fuel.
Detailed Description of the Invention
[0023] As used herein the term "middle distillate fuels" refers to fuels having an atmospheric
boiling point ranging between about 120°C and about 450°C, preferably ranging between
about 120°C and about 425°C, more preferably between about 120°C, and about 400°C,
and most preferably between about 135°C and about 360°C. Commonly used middle distillate
fuels comprise diesel fuel, Number 2 fuel oil, kerosene and turbine fuel.
[0024] The present invention is directed at the combination of an additive comprising:
A. an amide and/or amine salt of carboxylic acid/anhydride;
B. a wax modifying random polymer/copolymer of ethylene;
C. a wax-naphthalene condensation product; and
D. an alkylated diphenyl ether.
for improving the cold flow properties of a wax-containing middle distillate fuel.
[0025] The preparation and composition of each of these compounds is set forth below:
A. Amide and/or Amine Salt of Carboxylic Acid/Anhydride
[0026] The preparation of the amides and/or amine salts of carboxylic acid/anhydride is
described in U.S. Patent No. 4;402,708, the disclosure of which is incorporated herein
by reference. The alkyl amine salts of phthalic anhydride and maleic anhydride are
particularly preferred, with an alkyl amine salt of phthalic anhydride being especially
preferred. The alkyl amine salt of phthalic anhydride can be readily formed by the
reaction of phthalic anhydride or its monoester, with alkyl amines, preferably secondary
alkyl amines so as to form compounds having a minimum of three C
16-C
40, preferably C
16-C
24 alkyl or alkenyl groups, more preferably alkyl groups, of which at least two of said
alkyl groups are of said secondary amine. Preferably at least one, and more preferably
all, of the alkyl groups are straight chain.
[0027] Examples of C
16-C
40, preferably C1
6-C2
4 alcohols that can be used to make the monoester include 1-hexadecanol, 1-octadecanol,
stearyl alcohol, behenyl alcohol, ceryl alcohol, tricosanol, etc.
[0028] Examples of C
16-C
40 secondary amines include N,N-dihexadecyl amine; N,N-dioctadecyl. amine; N-hexadecyl;
N-octadecyl amine; N,N-dieicosenyl amine; N,N-distearyl amine; N,N-dibehenyl amine;
etc. A particularly useful amine is di-hydrogenated tallow amine, wherein the N-alkyl
groups are derived from tallow fat, of which a typical composition is about 3% C
14H
29, about 34 weight percent C
16H
33 and about 63 weight percent C
18H
37 alkyl groups.
[0029] Particularly preferred are the following orthophthalic derivatives:

tetraalkyl ammonium phthalamate particularly preferred,

dialkyl ammonium monoalkyl phthalate, and

tetraalkyl phthalamide, wherein R
1, R
2, R
4 and R
5 are the C
16-C
40· preferably C
16-C
24 straight chain alkyl groups of the secondary amine, and may be the same or different,
and R
3 is the C16-C40, preferably C
16-C
24 straight chain alkyl group of the alcohol. In it most preferred form, R
1, R
2, R
4 and R
5 are alkyl groups derived from tallow amine as discussed above.
[0030] The amides can be formed in a conventional manner by heating the secondary amine
with the ortho phthalic acid or acid anhydride. Similarly, the ester is prepared in
a conventional manner by heating the alcohol and the acid or the anhydride to partially
esterify the acid or anhydride (so that one carboxyl group remains for the reaction
with the amine to form the amide or amine salt). The ammonium salts are also conventionally
prepared by simply mixing the amine with the acid or acid anhydride, or the partial
ester of a polycarboxylic acid, or partial amide of a polycarboxylic acid, with stirring,
generally with mild heating.
B. Wax Modifying Ethylene Containing Polymer/Copolymer
[0031] Wax modifying ethylene-containing poly- mers/copolymers are described in U.S. Patent
No. 3,910,776, the disclosure of which is incorporated herein by reference.
[0032] In general, these polymeric pour depressants have a polyethylene backbone which is
divided into segments by hydrocarbon or oxy-hydrocarbon side chains. These oil-soluble
polymers will generally have a number average molecular weight in the range of about
500 to 50,000, preferably about 1,000 to about 5,000, as measured for example, by
Vapor Pressure Osmometer, such as using a Mechrolab Vapor Pressure Osmometer Model
310A. Generally, they will comprise about 3 to 40, preferably 4 to 20, molar proportions
of ethylene per molar proportion of a second ethylenically unsaturated monomer, which
latter monomer can be a single monomer or a mixture of such monomers in any proportion.
[0033] The unsaturated monomers, copolymerizable with ethylene, include unsaturated mono
and diesters of the general formula:

wherein R
1 is hydrogen or methyl; R
2 is a -OOCR
4 or -COOR
4 group wherein R
4 is hydrogen or a C
l to C
16, preferably C
l to C
4, straight or branched chain alkyl group; and R
3 is hydrogen or -COOR
4. The monomer, when R
1 and R
3 are hydrogen and R
2 is -OOCR
4 includes vinyl alcohol esters of C
2 to C
17 monocarboxylic acids, preferably C
2 to C
5 monocarboxylic acid. Examples of such esters include vinyl acetate, vinyl isobutyrate,
vinyl laurate, vinyl myristate,'vinyl palmitate, etc. When R
2 is -COOR
4, such esters include methyl acrylate, isobutyl acrylate, methyl methacrylate, lauryl
acrylate, C
13 Oxo alcohol esters of methacrylic acid, etc. Examples of monomers where R
1 is hydrogen and R
2 and R
3 are -COOR
4 groups, include mono and diesters of unsaturated dicarboxylic acids such as: mono
C
13 Oxo fumarate, di-C
13 Oxo fumarate, di-isopropyl maleate; di-lauryl fumarate; ethylmethyl fumarate; etc.
[0034] Another class of monomers that can be copolymerized with ethylene include C
3 to C
16 alpha monoolefins, which can be either branched or unbranched, such as propylene,
isobutene, n-octene-1, isooctene-1, n-decene-1, dodecene-1, etc.
[0035] Particularly preferred ethylene-containing polymers comprise ethylene vinyl acetate
and ethylene vinyl chloride.
[0036] Still other monomers include vinyl chloride, although essentially the same result
can be obtained by polyethylene chlorinated to contain about 5 to 35 weight percent
chlorine.
[0037] These polyethylene and ethylene copolymer pour depressant components are generally
formed using a free radical promoter, or in some cases they can be formed by thermal
polymerization, or they can be formed by Ziegler type polymerization in the case of
ethylene with other olefins. The polymers produced by free radical polymerization
appear to be the more important and can be formed as follows: Solvent, and 0-50 weight
percent, of the total amount of monomer other than ethylene, e.g. an ester monomer,
used in the batch, are charged to a stainless steel pressure vessel which is equipped
with a stirrer and cooling coil. The temperature of the pressure vessel is then brought
to the desired reaction temperature, e.g. 70° to 250°C, and pressured to the desired
pressure with ethylene, e.g. 800 to to 10,000 psig, usually 900 to 6,000 psig. Then
promoter, usually diluted with the reaction solvent, and additional amounts of the
second monomer, e.g. unsaturated ester, are added to the vessel continuously, or at
least intermittently, during the reaction time, which continuous addition gives-a
more homogeneous copolymer product as compared to adding all the unsaturated ester
at the beginning of the reaction. Also during this reaction time, as ethylene is consumed
in the polymerization reaction, additional ethylene is supplied through a pressure
controlling regulator so as to maintain the desired reaction pressure fairly constant
at all times. Following the completion of the reaction, usually a total reaction time
of 1/4 to 10 hours will suffice, the liquid products are withdrawn from the pressure
vessel, and the solvent removed by stripping, leaving the polymer as residue.
C. Wax-Naphthalene Condensation Product
[0038] The wax-naphthalene condensation product is described in U.S. Patent No. 3,910,776,
the disclosure of which is incorporated herein by reference.
[0039] These materials are usually made by the Friedel-Crafts condensation of a halogenated
paraffin or an olefin with an aromatic hydrocarbon. They are well known in the art,
primarily as lube oil pour depressants and as dewaxing aids. Usually, the halogenated
paraffin will contain from about 15 to 60, e.g. 16 to about 50 carbons, and from about
5 to about 25 weight percent, e.g. 10 to 18 weight percent, chlorine. Typically, the
halogenated paraffins are prepared by chlorinating to the above recited chlorine content
a paraffin wax having a melting point within the range of about 100° to 200°F. The
aromatic hydrocarbon used usually contains a maximum of three substituent groups and/or
condensed rings. It may be a hydroxyl compound such as phenol, cresol, xylenol, or
an amine such as aniline, but is preferably naphthalene, phenanthrene or anthracene.
[0040] Particularly preferred wax-naphthalene condensation products comprise the condensation
product of chlorinated n-paraffin wax and naphthalene.
D. Alkylated Diphenyl Ether
[0041] The alkylated diphenyl ethers may be prepared by alkylating diphenyl ether with dimerized
or polymerized -olefins as described in U.S. Patent No. 3,999,960, the disclosure
of which is incorporated herein by reference. Preferred ether compounds are diphenyl
ethers alkylated with an alpha olefin having from about 16 to about 50 carbon atoms
or with a dimer of an alpha olefin that has from about 16 to about 40 carbon atoms.
[0042] The following examples demonstrate the utility of the present invention in improving
the cold flow properties of a middle distillate fuel.
[0043] The additives listed in Table I were added to a wax containing middle distillate
fuel having a Wax Appearance Point (WAP) of -13.3°C (+8°F) maintained at about 25
0C. This fuel was designated as Fuel A. A test has been devised which has been found
to be a relatively accurate indicator of cold flow performance of fuels in passing
through fuel filters. In this test, designated as Low Temperature Filterability Test
(LTFT) the test fuel is cooled at a rate of l
oC/hour to the desired test temperature and subsequently is passed through a screen
having openings 17 microns in diameter under a pressure of 6 inches of mercury. The
fuel is determined to pass the test if the fuel flow through the screen is completed
in 60 seconds or less.
[0044] In these tests the amide and/or amine salt of carboxylic acid/anhydride comprised
a dihydrogenated tallow amine salt of phthalic anhydride in which two moles of the
amine are reacted with one mole of phthalic anhydride.
[0045] The ethylene-containing polymer/copolymer comprised a mixture of two ethylene-vinyl
acetate copolymers, having different oil solubilities, so that one functions primarily
as a wax growth arrestor and the other as a nucleator, in accord with the teachings
of U.S. Pat. No. 3,961,916 which patent is hereby incorporated herein in its entirety.
More specifically, the ethylene-containg polymer/copolymer is a polymer mixture of
about 75 wt. % of wax growth arrestor and about 25 wt. % of nucleator.
[0046] The wax growth arrestor was a copolymer of ethylene and about 3-8 wt. % vinyl acetate,
and had a number average molecular weight of about 1800 as determined by Vapor Phase
Osometry (VPO). It is identified in said- U.S. Pat. No. 3,961,916 as Copolymer B of
Example 1 (column 8, lines 25-35).
[0047] The nucleator was a copolymer of ethylene and about 16 wt. % vinyl acetate and had
a molecular weight of about 3000 (VPO). It is identified in said U.S. Pat. No. 3,961,916
as Copolymer H (see Table I, columns 7-8).
[0048] The wax naphthalene condensation product comprised the condensation product of 100
parts by weight n-paraffin wax having a melting point of about 163°F chlorinated to
about 12 weight percent chlorine condensed with about 8.8 weight parts by weight naphthalene.
[0049] The alkylated diphenyl ether comprised a diphenyl ether alkylated with a dimer of
an alpha olefin having about 24 carbon atoms. The fuel utilized in all of the following
Comparative Examples and Examples had a.boiling range of about 120°C to about 400°C.
Comparative Example 1
[0050] In the first series of comparative tests Fuel A was utilized without any additives.
The lowest temperature at which this fuel passed the LTFT test was -14°C.
Comparative Example 2
[0051] In this test 0.06 weight percent of the previously described ethylene vinyl acetate
copolymer (EVA) and 0.015 weight percent wax naphthalene condensate (WNC) and 0.025
weight percent alkyl-diphenyl ether (ADPE) were added to the fuel. The lowest temperature
at which this sample passed the LTFT test was -17°C.
Comparative Example 3
[0052] In this test, 0.035 weight percent of a di- hydrogenated tallow amine salt of phthalic
anhydride (TAPA) 0.015 weight percent ethylene vinyl acetate copolymer and 0.02 weight
percent of alkyl-diphenyl ether were added to Fuel A. The lowest temperature at which
this sample passed the LTFT test was -19
0C.
Comparative Example 4
[0053] In this test 0.035 weight percent of di- hydrogenated tallow amine salt of phthalic
anhydride 0.02 weight percent ethylene vinyl acetate, and 0:005 weight percent wax-naphthalene
condensate were added to Fuel A. The lowest temperature at which this sample passed
the LTFT test was -18°C.
Comparative Example 5
[0054] In this test 0.05 weight percent dihydrogenated tallow amine salt of phthalic anhydride
and 0.025 weight percent alkylated diphenyl ether were added to Fuel A. The lowest
temperature at which this fuel sample passed the LTFT test was -19°C.
Example I
[0055] In this example 0.025 weight percent di- hydrogenated tallow amine of phthalic anhydride,
about 0.008 weight percent ethylene vinyl acetate, 0.002 weight percent wax-naphthalene
condensation-product, and 0.01 weight percent alkyl-diphenyl ether were added to Fuel
A. This combination passed LTFT tests at temperatures as low as -22
0C thereby demonstrating the utility of the present invention.
[0056] A summary of the LTFT test results on Fuel A in Comparative Examples 1-5 and in Example
I is presented in Table I. This table demonstrates that the use of the four component
system produced a fuel oil having a lower LTFT than any of the comparative examples
even though the total weight percent of additive used with the four component system
was lower than the weight percent of additive used in Comparative Examples 2-5.

[0057] A series of tests also were conducted on a second fuel sample, Fuel B, having a Wax
Appearance Point of -7.8
0C (+18
0F).
Comparative Example 6
[0058] When no additives were added to Fuel B, the lowest temperature at which the fuel
passed the LTFT test was -9
0C.
Comparative Example 7
[0059] In this test 0.05 weight percent of dihydrogenated tallow amine salt of phthalic
anhydride, 0.02 weight percent of ethylene vinyl acetate copolymer, and 0.005 weight
percent of wax-naphthalene condensation product were added to Fuel B. The lowest temperature
at which the fuel passed the LTFT test was -13°C.
Comparative Example 8
[0060] In this test about 0.038 weight percent of ethylene vinyl acetate copolymer, about
0.012 weight percent wax naphthalene condensation product and 0.025 weight percent
alkyl-diphenyl ether were added to Fuel B. The lowest temperature at which the fuel
passed the LTFT test was -13°C.
Comparative Example 9
[0061] In this test 0.06 weight percent ethylene vinyl acetate copolymer, 0.015 weight percent
wax-naphthalene condensation product and 0.025 weight percent alkyl-diphenyl ether
were added to Fuel B. The lowest temperature at which the fuel passed the LTFT test
was -15°C.
[0062] Comparative Example 10
[0063] In this test 0.05 weight percent of dihydrogenated tallow amine salt of phthalic
anhydride, and 0.025 weight percent of alkyl-diphenyl ether were added to Fuel B.
The lowest temperature at which the fuel passed the LTFT test was -12
0C.
Comparative Example 11
[0064] In this test 0.05 weight percent dihydrogenated tallow amine salt of phthalic anhydride,
0.05 weight percent wax napthalene condensation product, and 0.025 weight percent
alkylated diphenyl ether were added to Fuel B. The lowest temperature at which the
fuel passed the LTFT test was -14°C.
Example II
[0065] In this example about 0.038 weight percent of dihydrogenated tallow amine salt of
phthalic anhydride, 0.012 weight percent ethylene vinyl acetate copolymer, 0.003 weight
percent wax-naphthalene condensation product, and 0.015 weight percent alkyl-diphenyl
ether were added to Fuel B. This fuel passed the LTFT test at -20
0C, thereby also demonstrating the utility of the present invention.
[0066] A summary of the LTFT test results for Comparative Examples 6-11 and Example II is
presented in Table II. Here also it can be seen that the use of the four component
system in Example II produced a fuel oil having a lower LTFT than any of Comparative
Examples 6-11 even though the total weight percent of the additive used with the four
component system of Example II was lower than the weight percent of additive used
in Comparative Examples 6-11.

[0067] Based on the results in Tables I and II, it can be seen that the addition to wax-containing
distillate of all four components produced wax crystals which were sufficiently small
to permit the fuel to pass through the filter pores at lower temperatures than would
be possible using only two or three of the four components.
[0068] The individual components of the fuel additive of the present invention typically
may be present in the following concentrations in the fuel:

[0069] Fuel additives conventionally are sold as concentrates in solvent so that they can
be easily added to the distillate fuel which is to be treated to improve its cold
flow properties. Typically, a diluent is added so that the additive is a single phase
liquid. A typical additive concentrate has the following composition:
[0070]

[0071] A preferred diluent is a heavy aromatic naphtha. The additive preferably is added
to the fuel at a temperature substantially above the wax appearance point, since the
solubility of the additive in the fuel will be higher at elevated temperature.