[0001] The present invention relates to the use of certain compounds to improve the lubricating
properties of low sulfur-content fuels and to fuels and additive concentrates comprising
the compounds.
[0002] Sulfur contained in fuel, for example middle distillate fuels such as diesel fuel
and jet fuel, is said to constitute a serious environmental hazard. Hence strict regulations
limiting the amount of sulfur which may be present in such fuels have been introduced.
Unfortunately, fuels having a suitably low sulfur content exhibit very poor inherent
lubricity and this can lead to problems when the fuel is used. For example, the use
of low sulfur fuel in diesel engines frequently results in damage to the fuel injector
pump which relies on the natural lubricating properties of the fuel to prevent component
failure. There is therefore a need to improve the lubricating properties of low sulphur
fuels.
[0003] It has now been found that the lubricating properties of low sulfur fuels can be
improved by the use of certain additive compounds as described in detail below. This
enables mechanical failure, for example fuel injector pump failure, caused by inadequate
fuel lubricity to be avoided while retaining the environmental benefit of using a
low sulfur fuel.
[0004] In the present context the term "low sulfur-content fuel" is intended to mean fuels
typically having a sulfur content of 0.2% by weight or less, for example 0.05% by
weight or less and, more especially, 0.005% by weight or less. Examples of fuels in
which the additive compounds may be used include low sulfur middle distillate fuels
such as diesel and jet fuels and bio-diesel fuel. The latter is derived from a petroleum
or vegetable source or mixture thereof and typically contains vegetable oils or their
derivatives, such as esters produced by saponification and re-esterification or trans-esterification.
Middle distillate fuels are usually characterised as having a boiling range of 100
to 500°C, more typically from 150 to 400°C.
[0005] In accordance with the present invention the additive compound used to improve the
lubricity of low sulfur-content fuel is a carboxylic acid which is substituted by
at least one hydroxy group, or a derivative of this hydroxy-substituted acid. The
derivative may be an ester formed by reaction of the acid with a polyhydric alcohol
or alkanolamine, or an amide.
[0006] The hydroxy-substituted carboxylic acid or acid derivative may be used alone or in
combination with any other hydroxy-substituted acid and/or acid derivative. The hydroxy-substituted
acid used in the present invention typically contains up to 60 carbon atoms. The hydroxy-substituted
acid may be a mono- or poly-carboxylic acid or a dimerized acid. When hydroxy-substituted
mono-carboxylic acids are used they typically contain 10 to 40 carbon atoms, more
commonly 10 to 30 and especially 12 to 24 carbon atoms. The preferred acid of this
type is the fatty acid, ricinoleic acid. When hydroxy-substituted poly-carboxylic
acids are used, such as di- or tri-carboxylic acids, they typically contain 3 to 40
carbon atoms, more commonly 3 to 30 and especially 3 to 24 carbon atoms. Examples
of this kind of hydroxy-substituted poly-carboxylic acid include malic, tartaric and
citric acids.
[0007] It is also possible to use as the hydroxy-substituted acid, dimerized acids. Herein
such compounds are referred to as dimer and trimer acids. When used the dimerized
acid typically contains 10 to 60, preferably 20 to 60 and most preferably 30 to 60,
carbon atoms. Such acids are prepared by dimerizing unsaturated acids and introducing
a hydroxyl functionality. Such acids typically consist of a mixture of monomer, dimer
and trimer acid. According to a preferred embodiment of the invention the acid is
a hydroxy-substituted dimerized fatty acid, for example of oleic and linoleic acids.
Typically this dimer exists as a mixture of 2% by weight monomer, 83% by weight dimer
and 15% by weight of trimer and possibly higher acids. The preferred dimer acid, as
well as the other acids described above, are commercially available or may be prepared
by the application or adaption of known techniques.
[0008] As described above, the additive compound(s) used may be in the form of a carboxylic
acid derivative. One kind of derivative which may be used is an ester of the acid
with a polyhydric alcohol. The polyhydric alcohol from which the ester may be derived
typically contains from 2 to 7 carbon atoms. Examples of suitable alcohols include
alkylene glycols such as ethylene glycol, diethylene glycol, triethylene glycol and
dipropylene glycol, glycerol, arabitol, sorbitol, mannitol, pentaerythritol, sorbitan,
1,2-butanediol, 2,3-hexanediol, 2,4-hexanediol, pinacol and 1,2-cyclohexanediol. These
alcohols are readily available. Of the alcohols mentioned it is preferred to use glycerol
or sorbitan. In a preferred embodiment the ester has at least one free hydroxyl group
in the moiety derived from the polyhydric alcohol, i.e. not all of the hydroxyl groups
of the polyhydric alcohol are esterified. The use of glycerol monoricinoleate is particularly
preferred.
[0009] Another kind of fatty acid derivative which may be used is the ester of the hydroxy-substituted
acid with an alkanolamine of formula:

in which p is 2 to 10, q is 0 to 10, Y is -N(R
1)
2, 4-morpholinyl or 1-piperazinyl N-substituted by a group R
1 or a group -[(CH
2)
pN(R
1)]
qR
1 in which p and q are as defined above and each substituent R
1 is independently selected from alkyl groups having from 1 to 6 carbon atoms and a
group of formula:

in which r is 0 to 10, R
2 is an alkylene group having 2 to 6 carbon atoms and R
3 is an hydroxyalkyl group having 2 to 6 carbon atoms, provided at least one group
R
1 is -(R
2O)
rR
3. Thus, the alkanolamine is one which does not contain any hydrogen-bearing nitrogen
atoms. The presence of free hydrogen atoms would be expected to lead to the formation
of an amide on reaction with the acid. The alkanolamines which may be used are commercially
available or may be made by the application or adaptation of known methods.
[0010] According to a preferred embodiment, in the alkanolamine of the above formula Y is
-N(R
1)
2, p is 2 and q is 0 to 3. It is further preferred that each R
1 is a C
2-4, hydroxyalkyl group, C
2 or C
3 hydroxyalkyl being particularly preferred. Specific examples of such compounds include
triethanolamine, triisopropylamine and ethylene diamine and diethylene triamine in
which each nitrogen atom is substituted by hydroxyethyl or hydroxypropyl groups.
[0011] In another preferred embodiment, in the alkanolamine Y is 4-morpholinyl or substituted
1-piperazinyl, q is 0 or 1 and p is from 2 to 6. Examples of such alkanolamines include
aminoethylpiperazine, bis-(aminoethyl)piperazine and morpholine, N-substituted by
an hydroxypropyl group.
[0012] The alkanolamines are commercially available or may be made by the application or
adaptation of known techniques.
[0013] It is also possible to use as the hydroxy-substituted acid derivative, an amide such
as that formed by reaction of the substituted fatty acid with ammonia or a nitrogen-containing
compound of formula:

in which p is 2 to 10, q is 0 to 10, Y is -N(R
1)
2, 4-morpholinyl or 1-piperazinyl optionally N-substituted by a group R
1 or a group -[(CH
2)
pN(R
1)]
qR
1 in which p and q are as defined above and each substituent R
1 is independently selected from hydrogen and alkyl groups having 1 to 6 carbon atoms
and a group of formula:

in which r is 0 to 10, R
2 is an alkylene group having 2 to 6 carbon atoms and R
3 is an hydroxyalkyl group having 2 to 6 carbon atoms, provided that at least one group
R
1 is hydrogen.
[0014] According to a preferred embodiment, in the nitrogen-containing compound Y is -N(R
1)
2, p is 2 and q is 0 to 3. Examples of such compounds include diethanolamine, tris(hydroxymethyl)aminomethane,
triethylene tetramine or diethylene triamine optionally N-substituted by two hydroxypropyl
groups.
[0015] In another embodiment, in the nitrogen-containing compound Y is 4-morpholinyl or
optionally N-substituted 1-piperazinyl, p is 2 to 6, q is 0 or 1 and each R
1 is hydrogen. Examples of such compounds include aminoethylpiperazine, bis-(aminoethyl)piperazine
or morpholine.
[0016] The compounds used to form the acid amides are commercially available or may be made
by the application or adaptation of known techniques.
[0017] The alkanolamines and nitrogen-containing compounds of the above formulae in which
r is 1 or more, i.e. those containing an ether or polyether linkage, can be prepared
by reaction of a suitable amine, morpholine or piperazine compound with a molar excess
of one or more alkylene oxides. When the same kind of alkylene oxide is used R
2 and R
3 contain the same alkylene moiety. When different kinds of alkylene oxides are used
R
2 and R
3 may contain the same or different alkylene groups.
[0018] In the formulae for the alkanolamine compound p is 2 to 10, preferably 2 or 3, q
is 0 to 10, preferably 0 to 5 and r is 0 to 15, preferably 0 to 10. When R
1 is alkyl the moiety contains from 1 to 6 carbon atoms, preferably 2 to 4 carbon atoms.
R
2 is an alkylene group having 2 to 6 carbon atoms, preferably 2 to 4 carbon atoms.
R
3 is an hydroxyalkyl group having 2 to 6 carbon atoms, preferably 2 to 4 carbon atoms.
The hydroxyalkyl group typically contains 1 to 3 hydroxy groups. When r is greater
than zero R
3 is typically a mono-hydroxyalkyl group, for example hydroxyethyl or hydroxypropyl.
When r is zero R
3 is typically a mono- or poly-hydroxyalkyl group having up to 4 hydroxyl groups, for
example hydroxyethyl, hydroxypropyl or a 1-hydroxy-2,2-bis(hydroxymethyl)ethyl group.
The values p, q and r take are selected independently. This means for example that
when q is greater than zero, p may take different values in each repeat unit. Also,
when r is greater than zero, R
2 may be the same or different in each ether repeat unit.
[0019] Each of the acid derivatives described are commercially available or may be made
by the application or adaptation of known techniques. When used in the form of a derivative
it is preferred that the derivative is one derived from ricinoleic acid.
[0020] According to one aspect of the present invention, the lubricity enhancing additive
compound is a derivative of the hydroxy-substituted acid and contains at least one
free carboxylic group in the acid-derived moiety. This kind of compound may be formed
using as the starting hydroxy-substituted acid a polycarboxylic acid, for example
a dicarboxylic acid or a dimer or trimer acid. Suitably, the number of moles of the
acid and compound used to form the acid derivative which are reacted is controlled
such that the resulting compound contains at least one free carboxylic functional
group in the acid-derived moiety. For example, if an acid having two carboxylic functions
is used, such as a dicarboxylic or dimer acid, the mole ratio should be about 1:1.
[0021] In the case that the acid derivative contains at least one free carboxylic group
in the acid moiety, it may be used as is or it may be derivatised further to enhance
its properties. The kind of compound used to do this usually depends upon the kind
of acid used initially and the properties of the acid derivative it is desired to
influence. For example, it is possible to increase the fuel solubility of the acid
derivative by introducing into its molecule a fuel-solubilizing species. As an example
of such, long-chain alkyl or alkenyl may be mentioned. To this end the acid derivative
may be reacted with an alcohol, ROH or an amine, RNH
2 in which R is alkyl or alkenyl having up to 30 carbon atoms, for example 4 to 30
carbon atoms. The number of carbon atoms in the alkyl or alkenyl group may depend
upon the number of carbon atoms in the acid derivative itself. These compounds react
with the free carboxylic functional group(s) of the acid derivative to form a further
ester linkage or an amide linkage. Examples of particular alcohols and amides which
may be used include oleyl amine and oleyl alcohols. Alternatively, it is possible
to further react the acid derivative to introduce into its molecule one or more polar
head groups. This has the result of increasing the lubricity enhancing effect which
the acid derivative exhibits. This is believed to be due to the polar head group increasing
the affinity of the acid derivative to metal surfaces. Examples of compounds which
may be used to introduce one or more polar head groups include polyamines (e.g. ethylene
diamine and diethylene triamine), and alkanolamines and polyhydric alcohols such as
those described above.
[0022] Typically, unless the fatty acid derivative is one derived from a dimer or trimer
acid, the derivative is further reacted to introduce fuel-solubilising species. Dimer
and trimer acid derivatives tend already to contain in the acid backbone long chain
alkyl or alkenyl moieties sufficient to provide adequate fuel-solubility.
[0023] While it has been described above that it is the acid derivative which is reacted
further, it is quite possible that the same final species can be formed by first reacting
free carboxylic functional group(s) of a polycarboxylic acid to introduce fuel-solubilising
or polar head groups and then reacting the resultant product to form the acid derivative.
Of course, this assumes that the product formed after the initial reaction contains
at least one free carboxylic group in the acid-derived moiety such that acid derivative
formation is still possible.
[0024] Typically, the concentration of the lubricity enhancing additive in the fuel falls
in the range 10 to 1000 ppm, preferably 50 to 500 ppm, more preferably still from
100 to 400 ppm. When mixtures of additives are used the overall additive concentration
falls within the typical range quoted.
[0025] The present invention further provides a low sulfur fuel comprising a lubricity enhancing
additive as hereinbefore described. Such fuel is formulated by simple mixing of the
base fuel and the additive in the desired proportions. The base fuel may be a middle
distillate fuel or a bio-diesel fuel as described above For the sake of convenience,
the additive may be provided as a concentrate for dilution with fuel. Such a concentrate
forms part of the present invention and typically comprises from 99 to 1% by weight
additive and from 1 to 99% by weight of solvent or diluent for the additive which
solvent or diluent is miscible and/or capable of dissolving in the fuel in which the
concentrate is to be used. The solvent or diluent may, of course, be the low sulfur
fuel itself. However, examples of other solvents or diluents include white spirit,
kerosene, alcohols (e.g. 2-ethyl hexanol, isopropanol and isodecanol), high boiling
point aromatic solvents (e.g. toluene and xylene) and cetane improvers (e.g. 2-ethyl
hexylnitrate). Of course, these may be used alone or as mixtures.
[0026] The concentrate or fuel may also contain other fuel additives in the appropriate
proportions thereby providing a multifunctional fuel additive package. Examples of
conventional fuel additives which may be used include fuel stabilisers, dispersants,
detergents, antifoams, cold flow improvers, cetane number improvers, antioxidants,
corrosion inhibitors, antistatic additives, biocides, dyes, smoke reducers, catalyst
life enhancers and demulsifiers. The total treat rate for multifunctional formulations
containing the lubricity enhancing additive compounds described is typically 200 to
2000 ppm, more usually 300 to 1200 ppm.
[0027] The invention also provides a method of reducing fuel pump wear in an engine which
operates on a low sulfur-content fuel by using the low sulfur-content fuel described
herein. The fuel may be used to reduce wear in rotary and in-line fuel pumps, for
example as found in diesel engines, or in fuel transfer pumps. The latter are positioned
between the fuel tank and the high pressure pump. The fuel is particularly well suited
for reducing wear in fuel injector pumps. The fuel may also be used in the latest
unit injectors which combine pump and injector mechanisms. The invention is particularly
well-suited to the operation of diesel and jet engines.
[0028] The present invention is illustrated in the following Example.
Example
[0029] The efficacy of a number of diesel fuels was assessed using the Scuffing BOCLE (ball-on-cylinder
lubricity evaluator) test. This test is a modification of the standard aviation BOCLE
test (ASTM method D5001: "Standard Test Method for Measurement of Lubricity of Aviation
Turbine Fuels by the Ball-on-Cylinder Lubricity Evaluator (BOCLE)", ASTM Standards,
Section 5, Vol 3, 1993) in which a load of 1 kg is applied to a fixed ball in contact
with a rotating cylinder lubricated by the test fuel. In this standard test fuel lubricity
is assessed by measuring the size of the wear scar on the fixed ball resulting from
the constant load contact with the cylinder. However, the standard BOCLE test suffers
the disadvantage that the applied load is not high enough to model the type of severe
wear failure that occurs in the field, for example in fuel injector pumps.
[0030] The Scuffing BOCLE test offers the advantage over the standard test of allowing discrimination
and ranking of fuels of differing lubricity. The Scuffing test also simulates more
closely the severe modes of wear failure encountered in fuel pumps than other fuel
lubricity tests which run under mild wear conditions. The Scuffing BOCLE test therefore
provides results which are more representative of how the fuel would behave in service.
[0031] In the Scuffing BOCLE test a load (0.25-8.0 kg) is applied to a fixed ball in contact
with a rotating cylinder. The ball and cylinder are made of a standard grade steel.
The cylinder rotates at 290 rpm. Since the temperature of the lubricating fuel can
have a marked effect on the scuffing load, this is carefully controlled at 25°C. A
nitrogen atmosphere is used to blanket the ball on cylinder assembly. Following a
one minute run-in period the load is applied to the ball for two minutes. After this
run, the ball is removed from the assembly and the type and size of wear scar examined
by microscope. Further runs are then carried using increased applied loads in a stepwise
manner until scuffing wear failure occurs. The load at which wear failure occurs is
referred to as the scuffing load and is a measure of the inherent lubricity of the
fuel. The scuffing load is primarily identified by the size and appearance of the
wear scar on the ball, which is considerably different in appearance to that found
under milder non-scuffing conditions. Fuels giving a high scuffing load on failure
have better lubricating prqperties than fuels giving a low scuffing load on failure.
[0032] The base fuel used was a Class 2 Scandinavian diesel fuel. This is a diesel fuel
having a sulfur content of 0.005% by weight. The composition and distillation profile
of this fuel are shown below.
Density at 15°C (IP 160), g/ml |
0.8160 |
Paraffins, %vol |
89.6 |
Olefins, %vol |
0.7 |
Aromatics, %vol |
9.7 |
Distillation Characteristics (IP 123) |
|
Initial B.P., °C |
184 |
5% |
200 |
10% |
204 |
20% |
212 |
30% |
217 |
40% |
223 |
50% |
228 |
60% |
235 |
70% |
243 |
80% |
251 |
90% |
263 |
95% |
269 |
Final B.P., °C |
290 |
Recovered, % |
99 |
Residue, % |
1 |
Loos, % |
0 |
[0033] The table below shows the Scuffing BOCLE test results for a number of diesel fuels.
Samples C, E-G, I and K-N are fuels in accordance with the present invention.
[0034] Samples A, B, D, H and J are included for comparison.
Additive |
Concentration (ppm) |
Scuffing load (kg) |
A. None |
- |
2.7 |
B. Oleic acid |
200 |
3.1 |
C. Ricinoleic acid |
200 |
4.2 |
D. Glycerol monooleate |
200 |
3.4 |
E. Glycerol monoricinoleate |
100 |
3.8 |
F. Glycerol monoricinoleate |
200 |
4.1 |
G. Glycerol monoricinoleate |
400 |
5.0 |
H. Amide: Oleic acid + DETA |
200 |
3.1 |
I. Amide: Ricinoleic acid +DETA |
200 |
4.6 |
J. Amide: Oleic acid + DETA.2PO |
200 |
2.8 |
K. Amide: Ricinoleic acid + DETA.2PO |
200 |
4.0 |
L. Amide: Ricinoleic acid + DEA |
200 |
4.2 |
M. Amide: Ricinoleic acid + TETA |
200 |
4.7 |
N. Amide: Ricinoleic acid + THAM |
200 |
4.4 |
[0035] In the table above:
DEA stands for diethanolamine;
THAM stands for tris(hydroxymethyl)aminomethane;
DETA stands for diethylene triamine;
DETA.2PO indicates that the DETA is N-substituted by two hydroxypropyl groups; and
TETA stands for triethylene tetramine.
[0036] In runs D-N the mole ratio of fatty acid: derivatising species was in each case 1:1.
[0037] These results clearly demonstrate the improvement in lubricity of diesel fuels in
accordance with the present invention. The base fuel used has a very low inherent
lubricity giving a low scuffing load result of 2.7kg. The addition of 200 ppm of oleic
acid, i.e. a C
18 unsubstituted fatty acid, leads to a slight improvement in lubricity performance
exhibited as a higher scuffing load on failure of 3.1kg. Formulations of base fuel
and the corresponding hydroxy-substituted C
18 acid (ricinoleic acid) leads to significantly improved scuffing performance of 4.2kg
(run C). The free hydroxyl group in the 12-position of the ricinoleic acid tail is
believed to be responsible for this. Good results are also obtained for the fuels
of runs L, M and N which are in accordance with the present invention.
1. Use of a carboxylic acid substituted by at least one hydroxy group, or a derivative
of this hydroxy-substituted acid, as an additive for improving the lubricity of a
low sulfur-content fuel.
2. Use according to claim 1, wherein the fuel is a diesel fuel, jet fuel or bio-diesel
fuel.
3. Use according to claim 1 or 2, wherein the sulfur content of the fuel is 0.2% by weight
or less.
4. Use according to any one of claims 1 to 3, wherein the acid has from 10 to 60 carbon
atoms.
5. Use according to any one of claims 1 to 4, wherein the acid is an aliphatic fatty
acid substituted by up to 4 hydroxyl groups.
6. Use according to claim 5, wherein the fatty acid is ricinoleic acid.
7. Use according to any one of claims 1 to 4, wherein the acid is a dimer acid of oleic
and linoleic acids.
8. Use according to any one of claims 1 to 7, wherein the acid derivative is an ester
of a polyhydric alcohol selected from ethylene glycol, diethylene glycol, triethylene
glycol, dipropylene glycol, glycerol, arabitol, sorbitol, mannitol, pentaerythritol,
sorbitan, 1,2-butanediol, 2,3-hexanediol, 2,4-hexanediol, pinacol and 1,2-cyclohexanediol.
9. Use according to claim 8, wherein the polyhydric alcohol ester is glycerol monoricinoleate.
10. Use according to any one of claims 1 to 7; wherein the derivative is an ester of an
alkanolamine of formula:

in which p is 2 to 10, q is 0 to 10, Y is -N(R
1)
2, 4-morpholinyl or 1-piperazinyl N-substituted by a group R
1 or a group -[(CH
2)
pN(R
1)]
qR
1 in which p and q are as defined above and each substituent R
1 is independently selected from alkyl groups having from 1 to 6 carbon atoms and a
group of formula:

in which r is 0 to 10, R
2 is an alkylene group having 2 to 6 carbon atoms and R
3 is an hydroxyalkyl group having 2 to 6 carbon atoms, provided at least one group
R
1 is -(R
2O)
rR
3.
11. Use according to claim 10, wherein the alkanolamine is triethanolamine, triisopropylamine
or ethylene diamine or diethylene triamine in which each nitrogen atom is substituted
by hydroxyethyl or hydroxypropyl groups.
12. Use according to claim 10, wherein the alkanolamine is (aminoethyl)piperazine, bis-(aminoethyl)piperazine
or morpholine, N-substituted by an hydroxypropyl group.
13. Use according to any one of claims 1 to 7, wherein the acid derivative is an amide
formed by reaction of the hydroxy-substituted carboxylic acid with ammonia or a nitrogen-containing
compound of formula:

in which p is 2 to 10, q is 0 to 10, Y is -N(R
1)
2, 4-morpholinyl or 1-piperazinyl optionally N-substituted by a group R
1 or a group -[(CH
2)
pN(R
1)]
qR
1 in which p and q are as defined above and each substituent R
1 is independently selected from hydrogen and alkyl groups having 1 to 6 carbon atoms
and a group of formula:

in which r is 0 to 10, R
2 is an alkylene group having 2 to 6 carbon atoms and R
3 is an hydroxyalkyl group having 2 to 6 carbon atoms, provided that at least one group
R
1 is hydrogen.
14. Use according to claim 13, wherein the nitrogen-containing compound is diethanolamine,
tris(hydroxymethyl)aminomethane, triethylene tetramine or diethylene triamine optionally
N-substituted by two hydroxypropyl groups.
15. Use according to claim 13, wherein the nitrogen-containing compound is aminoethylpiperazine,
bis-(aminoethyl)piperazine or morpholine.
16. Use according to any one of claims 1 to 15, wherein the acid derivative contains at
least one free carboxyl group in the acid-derived moiety.
17. Use according to claim 16, wherein the acid derivative is further derivatised by reaction
with a compound which introduces a fuel-solubilising species into the acid derivative
molecule or by reaction with a compound which introduces a polar head group into the
acid derivative molecule.
18. Use according to any one of claims 1 to 17, wherein the hydroxy-substituted carboxylic
acid or derivative of the acid is present in the fuel at a concentration of from 10
to 1000 ppm.
19. A low sulfur-content fuel comprising a hydroxy-substituted acid or derivative of the
acid as defined in claim 1 or in any one of claims 4 to 17.
20. An additive concentrate for use in low sulfur-content middle distillate fuel comprising
from 99 to 1% by weight of a hydroxy-substituted carboxylic acid or derivative of
the acid as defined in claim 1 or in any one of claims 4 to 17, and from 1 to 99%
by weight of solvent or diluent for the fatty acid or derivative which solvent or
diluent is miscible and/or capable of dissolving in the fuel in which the concentrate
is to be used.
21. A method of reducing fuel pump wear in an engine which operates on a low sulfur content
fuel which comprises using a fuel as defined in claim 19.