FIELD OF THE INVENTION
[0001] This invention relates to a new fuel oil composition for diesel engines, more particularly
the composition characterized by base stock which contains a specific content of normal
paraffin compounds having a carbon number of 20 or more, has a specific carbon number
distribution in the high-boiling normal paraffin compounds, contains a specific content
of polynuclear aromatic hydrocarbon compounds and sulfur at 0.05wt.% or less, and
is incorporated with a flow improver and lubricity improver.
BACKGROUND OF THE INVENTION
[0002] Diesel engines are widely used for various purposes, e.g., for driving automobiles,
ships and construction machines, and are still spreading further. As a result, fuel
for diesel engines is increasingly in demand, and becoming heavier to satisfy the
increased demands, because straight-run diesel fuel oil is distilled deeper and/or
blended with heavier fractions. This is accompanied by several problems, e.g., deteriorated
fluidity at low temperature (i.e., increased pour point and/or cold flow plugging
point). It is anticipated, therefore, that several engine troubles, e.g., clogging
of fuel passage or fuel filter, may occur in a normal temperature range at which the
engine is operated in some districts. The other concerns are increased nitrogen oxide
and particulate matter emissions, which further aggravate environmental pollution.
[0003] Several measures against deteriorated fluidity of diesel fuel oils at low temperature
have been proposed to provide fuel oils having adequate pour point and cold flow plugging
point (CFPP) properties for temperature conditions, in particular in cold districts.
These measures include limitation on end point of straight-run diesel oil, limitation
on use of heavier fractions as the blending stocks, use of lighter blending stocks,
and use of adequate additives, e.g., fluidity improver, including pour point depressant
and flow improver (FI), to improve fluidity at low temperature. For example, Japanese
Laid-open Patent Application No. 8-157839 discloses fuel oil composition characterized
by base stock which contains normal paraffin compounds at 15wt.% or less, normal paraffin
compounds having a carbon number of 20 or more at 1.2wt% or less, and sulfur at 0.15wt.%
or less, as the composition serviceable in cold districts, high in density, sufficiently
low in pour point and allowing the engine to produce a high power.
[0004] Japanese Laid-open Patent Application No. 7-331261 discloses a diesel fuel oil composition
composed of diesel oil having an end point in a range from 320 to 340°C, incorporated
with 0.1 to 2.0 vol.% of a fraction containing normal paraffin compounds having a
carbon number of 26 to 31 and 100 to 600 ppm of an ethylene vinyl acetate-based additive
to improve fluidity at low temperature. This composition is aimed at abatement of
particulate emissions from a diesel engine and improvement of low-temperature fluidity,
measured by CFPP.
[0005] Limitation on end point of straight-run diesel oil and limitation on use of heavier
fractions as the blending stocks to secure low-temperature fluidity of diesel fuel
oils provide a good pour point, but are difficult to provide a good CFPP. Moreover,
these approaches little contribute to increasing diesel fuel oil supplies. Blending
diesel fuel oil with a lighter fraction decreases flash point and also decreases engine
output. Use of an additive, such as pour point depressant or FI, involves some problems.
For example, a pour point depressant, although decreasing pour point, will not decrease
CFPP. An FI, on the other hand, although generally decreasing pour point and CFPP,
may not efficiently decrease CFPP, depending on type of stock for base stock which
constitutes diesel fuel oil or distillation properties of base stock.
[0006] The techniques to abate emissions, e.g., nitrogen oxides and particulate matter,
from diesel engines have been also developed from various angles. These include improvement
of combustion chamber shapes, installation of exhaust gas recycle (EGR) systems, exhaust
gas cleaning-up catalytic converters and particulate matter collectors, and improvement
of diesel fuel oils and lubricants. None of these, however, brings satisfactory results
in terms of abatement effect, economic efficiency or stability for extended periods.
An EGR system, which is considered to be one of efficient means, recycles part of
exhaust gases into the combustion air stream. However, this approach causes various
problems, e.g., decreased durability and reliability of the engine, deterioration
of the lubricant, increased particulate matter emissions and decreased engine output,
because exhaust gases contain sulfate ions and particulate matter. These problems
will be further aggravated, when an EGR system is installed for a direct injection
diesel engine which is required to operate under a high load. Sulfate ions are derived
from sulfur contained in diesel fuel oil, and low-sulfur diesel fuel oil containing
sulfur at 0.05wt.% or less has now become a social need.
[0007] Sulfur contained in a diesel fuel oil can be reduced by refining, in particular catalytic
hydrogenation, of the base stock. This, however, is accompanied by decreased lubricity
of diesel fuel oil itself, and will damage the injection device of the engine. It
is known that wear of the injection pump notably increases as sulfur content decreases
from 0.2wt.%.
[0008] Improving fuel oil quality has been attracting attention as an effective means to
abate pollutant emissions, because it needs essentially no engine modification. For
example, Japanese Laid-open Patent Application No. 8-225789 discloses diesel fuel
which contains sulfur at 0.05 wt.% or less, benzothiophene at 30 wt.ppm or more as
sulfur, and polynuclear aromatic hydrocarbon compounds having 3 rings or more at 0.2
to 1.4 wt.%, and this diesel fuel further containing indoles at 13 wt.ppm or less
as nitrogen. It is claimed that these fuel oils satisfy the environmental requirement
for low sulfur content and exhibit sufficient lubricity without using an additive,
e.g., friction modifier.
[0009] Japanese Laid-open Patent Application No. 8-291292 discloses a diesel fuel oil composition
which contains sulfur at 0.01 to 0.05wt.%, and (A) an ester of a nitrogen compound
having hydroxide group and straight-chain saturated fatty acid, and (B) 15 to 2000
mg/L of at least one type of polymer selected from the group consisting of the polymers
from monomers of olefin compounds, ethylenic unsaturated alkyl carboxylates and saturated
aliphatic vinyl compounds. It is claimed that this composition exhibits good lubricity
in spite of very low sulfur content, improved low-temperature fluidity and no deterioration
of exhaust gases without causing troubles at the fuel injection pump in the diesel
engine.
[0010] These prior-art techniques, however, give diesel fuel oils insufficient in low-temperature
fluidity, abatement of pollutant emissions and lubricity, and are also economically
unsatisfactory. Therefore, they can rarely give diesel fuel oil compositions showing
good CFPP and lubricity, while efficiently controlling pollutant emissions (in particular,
particulate matter) and containing sulfur at 0.05wt.% or less.
[0011] It is an object of the present invention to provide a diesel fuel oil composition
efficiently controlling pollutant emissions, showing good CFPP and lubricity, and
containing sulfur at 0.05wt.% or less by improving the prior-art techniques.
SUMMARY OF THE INVENTION
[0012] The applicants of the present invention have extensively studied the effects of normal
paraffin content, carbon number distribution of the normal paraffin compounds and
polynuclear aromatic hydrocarbon compound content on low-temperature fluidity and
lubricity of the diesel fuel oil incorporated with an FI and lubricity improver and
also on quantity of particulate matter (PM) emissions exhausted when it is combusted,
for diesel fuel base stock containing sulfur at 0.05wt.% or less, to find that PM
emissions are greatly reduced and good CFPP and lubricity can be secured when the
base stock containing sulfur at 0.05wt.% or less satisfies the relationships of 0
<A 4.00 (wherein, A is content (wt.%), based on total normal paraffin compounds present
in the base stock, of normal paraffin compounds having a carbon number of 20 or more),
0.04 [B / C] 0.40 (wherein, B is content (wt.%) of normal paraffin compounds having
a carbon number of (n + 5), C is content (wt.%) of normal paraffin compounds having
a carbon number of (n); [B/C] is average B/C ratio; and (n) is a positive integer
when total content of normal paraffin compounds having a carbon number of (n) or more
is 3.0 wt.% or less and closest thereto, based on the total normal paraffin compounds
in the base stock), and 0 <D 8.0 (wherein, D is content (vol.%), based on the whole
base stock, of polynuclear aromatic hydrocarbon compounds), and is incorporated with
0.01 to 0.10wt.% (as the active component) of an FI and 0.002 to 0.1wt.% (as the active
component) of a lubricity improver, reaching the present invention.
[0013] That is, the present invention provides a diesel fuel oil composition characterized
by base stock satisfying the relationships 0 <A 4.00 (wt.%), 0.04 [B/ C ] 0.4 0 and
0 <D 8.0 (vol.%), containing sulfur at 0.05wt.% or less, and being incorporated with
0.01 to 0.10wt.% of an FI and 0.002 to 0.1wt.% of a lubricity improver.
[0014] The present invention, relating to the above diesel fuel oil composition, includes
the following preferred embodiments:
(1) the diesel fuel oil composition composed of a base stock having a [B/C] ratio
of 0.07 to 0.20,
(2) the diesel fuel oil composition composed of a base stock having a D value of 0
to 5.0 vol.%,
(3) the diesel fuel oil composition of(1), wherein said base stock has a D value of
0 to 5.0 vol.%,
(4) the diesel fuel oil composition of (1), wherein active ingredient of the FI is
at least one type of compounds selected from the group consisting of ethylene glycol
ester-based compounds and ethylene-vinyl acetate-based copolymers,
(5) the diesel fuel oil composition of one of (1) to (3), wherein active ingredient
of the FI is at least one type of compounds selected from the group consisting of
ethylene glycol ester-based compounds and ethylene-vinyl acetate-based copolymers,
(6) the diesel fuel oil composition, wherein content of the active component for the
FI is 0.03 to 0.07wt.%,
(7) the diesel fuel oil composition of one of (1) to (5), wherein content of the active
component for the FI is 0.03 to 0.07wt.%,
(8) the diesel fuel oil composition, wherein the active component for the lubricity
improver is an ester-based compound,
(9) the diesel fuel oil composition of one of (1) to (7), wherein the active component
for the lubricity improver is an ester-based compound,
(10) the diesel fuel oil composition, wherein content of the active component for
the lubricity improver is 0.005 to 0.05wt.%, and
(11) the diesel fuel oil composition of one of (1) to (9), wherein content of the
active component for the lubricity improver is 0.005 to 0.05wt.%.
the present invention provides a fuel oil composition for diesel engines which
efficiently controls PM emissions and exhibits good CFPP and lubricity by incorporating
a base stock satisfying the relationships 0 <A 4.00 (wt.%), 0.04 [B/C] 0.40 and 0
<D 8.0 and containing sulfur at 0.05wt.% or less with an adequate FI and lubricity
improver.
Detailed Description of the Invention
[0015] The present invention is described below in detail. The diesel fuel oil composition
of the present invention is characterized by base stock which has the component A,
[B/C] ratio and component D in specific ranges, contains sulfur at 0.05wt.% or less,
and is incorporated with 0.01 to 0.10wt.% of an FI and 0.002 to 0.1wt.% of a lubricity
improver.
[0016] The base stock for the present invention mainly comprises a mineral oil, having a
flash point of 40°C or higher and 90% distillation temperature of 360°C or lower.
The mineral oil for the present invention is a petroleum fraction, including a petroleum
fraction obtained by atmospheric distillation of crude oil, and petroleum fraction
obtained by atmospheric or vacuum distillation of crude oil and refined by an adequate
process, e.g., hydrogenation, hydrocracking, catalytic cracking and a combination
thereof. These petroleum fractions can be used individually or in combination. The
base stock component other than petroleum fraction includes vegetable oil, e.g., soybean,
coconut and rape oil, and animal oil, e.g., whale and fish oil.
[0017] The diesel fuel oil composition of the present invention is composed of a base stock
which satisfies the relationship 0 <A 4.00 (wt.%) (wherein, A is content, based on
all normal paraffin compounds present in the base stock, of normal paraffin compounds
having a carbon number of 20 or more). When A is above 4.00wt.%, the normal paraffin
compounds may separate out as ambient temperature decreases, to cause problems, e.g.,
clogging of the fuel passage or fuel filter in the diesel engine.
[0018] The diesel fuel oil composition of the present invention is also composed of a base
stock which satisfies the relationship 0.04 [B / C] 0.40, preferably 0.07 [B/C] 0.20
(wherein, B is content (wt.%) of normal paraffin compounds having a carbon number
of (n + 5), C is content (wt.%) of normal paraffin compounds having a carbon number
of(n), [B/C] is average B/C ratio, and (n) is a positive integer when total content
of normal paraffin compounds having a carbon number of (n) or more is 3.0 wt.% or
less and closest thereto, based on the total normal paraffin compounds in the base
stock. Assuming that the component A in the base stock accounts for 3.0wt.% of the
total normal paraffin components of the base stock, the average of the (n-C
25)/(n-C
20), (n-C
26)/(n-C
21), (n-C
27)/(n-C
22) •••• ratios consecutively calculated is in a range from 0.04 to 0.40, inclusive.
When [B/C] is below 0.04, some of the normal paraffin compounds in the base stock
may separate out as large planar crystals as ambient temperature decreases, even when
the relationship 0 <A 4.00 (wt.%) is satisfied, to easily cause plugging of the fuel
filter. In other words, such a base stock has an excessively high CFPP. The similar
troubles will occur, when [B/C] exceeds 0.40.
[0019] The diesel fuel oil composition of the present invention is also composed of a base
stock which satisfies the relationship 0 <D 8.0 (vol.%), preferably 0 <D 5.0, more
preferably 0 <D 3.0 (wherein, D is content (vol.%), based on the whole base stock,
of polynuclear aromatic hydrocarbon compounds). When D exceeds 8.0 vol.%, PM content
in the exhaust gases may increase to an unacceptable level. Normally, a base stock
contains aromatic hydrocarbon compounds at 20 to 40 vol.%; single-ring aromatic hydrocarbon
compounds at 12 to 30 vol.% and polynuclear aromatic hydrocarbon compounds (having
two or more rings) at 2 to 15 vol.%.
[0020] Therefore, the fuel oil composition of the present invention for diesel engines shows
a good CFPP, even when ambient temperature decreases, when its base stock satisfies
the relationships 0 <A 4.00 (wt.%), 0.04 [B/C] 0.40 and 0 <D 8. 0 (vol.%).
[0021] The component A of the base stock for the present invention can be selected from
adequate petroleum fractions of different normal paraffin content. These petroleum
fractions include petroleum fractions obtained by atmospheric distillation of crude
of varying normal paraffin content, and petroleum fractions obtained by atmospheric
or vacuum distillation of crude and refined by an adequate process, e.g., solvent
dewaxing and catalytic dewaxing. [B/C] of the base stock can be adjusted by controlling
extent of rectification for the distillation operation. [B/C] increases as extent
of rectification decreases, and so is vice versa. The component D of the base stock
can be adjusted by adequately blending petroleum fractions of varying polynuclear
aromatic hydrocarbon content or petroleum fractions whose polynuclear aromatic hydrocarbon
content is adjusted by an adequate process, e.g., solvent extraction or hydrogenation.
Content of polynuclear aromatic hydrocarbon compounds can be determined by the method
proposed by Japanese Petroleum Institute (JPI-SS-49-97, based on HPLC). The above
petroleum fractions can be used individually or in combination to adjust A, [B/C]
and D levels for the base stock for the present invention.
[0022] The FI useful for the present invention can be selected from the known ones. These
include ethylene glycol ester-based compounds, ethylene-vinyl acetate copolymers,
ethylene alkylacrylate-based copolymers, chlorinated polyethylene, polyalkyl acrylate,
alkenyl succinamide-based compounds. The preferable ones are an ethylene glycol ester-based
compound and/or ethylene-vinyl acetate copolymer. An FI dosage below 0.01wt.% may
not satisfactorily decrease CFPP, and above 0.1wt.% is not economical, because CFPP
will not decrease as much as increased dosage. The preferable FI dosage is 0.03 to
0.07wt.%. The above FI's may be used individually or in combination.
[0023] The lubricity improver useful for the present invention can be selected from the
known ones. These include a fatty acid, e.g., stearic, linolic and oleic acid, and
ester, e.g., those of the above fatty acid and polyalcohol, e.g., glycerin. The preferable
one is an ester. A lubricity improver dosage below 0.002wt.% may not satisfactorily
improve lubricity, and above 0.1wt.% is not economical, because lubricity will not
be improved as much as increased dosage. The preferable lubricity improver dosage
is 0.005 to 0.05wt.%. The above lubricity improvers may be used individually or in
combination.
[0024] The fuel oil composition of the present invention for diesel engines may be incorporated
with other known additives for fuel oil, so long as its performance is not damaged.
These additives include cetane improver, antioxidant, metal deactivator, detergent,
corrosion inhibitor, pour point depressant, de-icer, bactericide, combustion promoter,
antistatic agent, and coloring agent. A general dosage of the additive is 0.1 to 0.5wt.%
in the case of pour point depressant, although not limited to this level. One or more
of these additives may be used for the present invention, as required.
[0025] The diesel fuel oil composition of the present invention may be also incorporated
with one or more types of oxygenated compounds so long as its performance is not damaged.
These compounds include aliphatic alcohols, e.g., methanol, ethanol, isopropanol,
n-butanol, isobutanol, tert-butanol, amyl alcohol, isoamyl alcohol, n-octanol, 2-ethyl
hexanol, n-heptyl alcohol, tridecyl alcohol, cyclohexanol and methyl cyclohexanol;
ethers, e.g., methyl tert-butyl ether and ethyl tert-butyl ether; dialkyl phthalates,
e.g., diethyl phthalate, dipropyl phthalate and dibutyl phthalate; glycol-ether compounds,
e.g., ethylene glycol monoisobutyl ether, diethylene glycol mono-n-butyl ether, diethylene
glycol monoisobutyl ether, diethylene glycol dimethyl ether, triethylene glycol mono-n-butyl
ether, triethylene glycol dimethyl ether, propylene glycol monomethyl ether acetate
and dipropylene glycol mono-n-butyl ether; hydroxyl amine compounds; and diketones,
e.g., acetyl acetone. A general dosage of the oxygenated compound is 1 to 15wt.%,
although not limited to this level.
[0026] The present invention is described in more detail by EXAMPLES, below, which by no
means limit the present invention. The following base stocks, FI's and lubricity improver
were used for EXAMPLES and COMPARATIVE EXAMPLES. Measurements of CFPP, A, [B/C] and
D are also described.
(1) Base stock
(2) FI's
[0028] An ethylene glycol ester-based FI (ECA9911 produced by EXXON Chemical) and ethylene-vinyl
acetate-based FI (PF240, produced by EXXON Chemical) were used.
(3) Lubricity improver
[0029] A lubricity improver with ester-based compound as the active ingredient (PDN655,
produced by EXXON Chemical) was used.
(4) Measurement of CFPP
[0030] CFPP was measured as per JIS K-2288.
(5) Measurement of "A"
[0031] Content of an individual normal paraffin compound in each base stock was measured
by gas chromatography using an analyzer (GC-6AM, produced by Shimadzu), where each
sample was passed through a capillary column (inner diameter: 0.25mm, length: 15m,
impregnated with methyl silicon to a thickness of 0.1µm) at 50 to 350°C. "A" is defined
as total content of normal paraffin compounds having a carbon number of 20 or more.
(6) Measurement of [B/C]
[0032] [B/C] was determined by the following procedure. Content of an individual normal
paraffin compound in each base stock was measured by gas chromatography. Content of
the normal paraffin compound having the largest carbon number, and contents of the
normal paraffin compounds having smaller carbon numbers are calculated consecutively,
where (n) is defined as the number of carbon when total content of normal paraffin
compounds having a carbon number of (n) or more is 3.0 wt.% or less and closest thereto,
based on the total normal paraffin compounds in the base stock. Next, (content of
normal paraffin compounds having a carbon number of (n+5))/(content of normal paraffin
compounds having a carbon number of (n)) ratios are calculated consecutively, and
the average is taken as [B/C]. The same gas chromatography as that for measurement
of "A" was used.
(7) Measurement of "D"
[0033] Content of polynuclear aromatic hydrocarbon compounds were determined by the method
proposed by Japanese Petroleum Institute (JPI-5S-49-97, based on HPLC). "D" was defined
as total content of polynuclear aromatic hydrocarbon compounds having 2 rings and
those having 3 rings or more.
EXAMPLES and COMPARATIVE EXAMPLES
(1) Measurement of lubricity
[0035] Lubricity was assessed by resistance of fuel oil to wear. Resistance to wear was
measured as per JPI-55-50-97 (gas oil/lubricant oil testing method). Size of the wear-caused
scar (µm) was determined using a high frequency reciprocating rig (HFRR, produced
by PCS) under the conditions shown in Table 8. Size of the scar increases as lubricity
of fuel oil decreases.
Table 8
| Liquid quantity |
2 ± 0.20ml |
| Stroke |
1 ± 0 03mm |
| Frequency |
50 ± 1Hz |
| Liquid temperature |
40 ± 2°C or 60 ± 2°C |
| Load |
200 ± 1 gf |
| Testing time |
75 ± 0.1 min |
| Liquid surface area |
6 ± 1 cm2 |
(2) Measurement of PM emissions
[0036] PM emissions in the exhaust gases were determined as per the "diesel vehicle 10-15
mode exhaust gas testing method (TRIAS-24-4-1993).
(a) Test engine and conditions
[0037] The test engine and conditions are given in Tables 9 and 10.
Table 9
| Engine type |
IDI (Toyota Corolla) |
| Inner cylinder diameter and stroke (mm) |
86.0 x 85.0 |
| Number of cylinders |
4 |
| Total displacement |
1974 |
| Compression ratio |
23 |
| Max. Output (PS/rpm) |
73/4700 |
Table 10
| Fuel oil temperature (°C), |
25 .0 |
| Outlet temperature of cooling water (°C), |
80 |
| Lubricant temperature (°C), |
90 |
| Intake air temperature (°C), |
25±2 |
| Intake air humidity (RH %) |
50±5 |
(b) Collection and measurement of PM
[0038] The exhaust gases were directed from the exhaust pipe to a dilution tunnel system
(Horiba Seisakusho), to measure PM emissions (g/km).
[0039] As shown in Tables 4 and 5, the fuel oil composition exhibits a notably low CFPP
of -9 to -16°C, when it comprises a base stock which has the component A, [B/C] ratio
and component D in specific ranges, contains sulfur at 0.05wt.% or less, and is incorporated
with an adequate FI and lubricity improver. Its CFPP is significantly lower than that
of the base stock by 6 to 11°C. It notably controls PM emissions. It also has high
resistance to wear, showing a wear-caused scar of 408 to 421 µm. By contrast, the
compositions prepared by COMPARATIVE EXAMPLES shown in Tables 6 and 7, which fail
to satisfy the relationship with respect to A or [B/C], has a CFPP value high and
virtually unchanged from that of the base stock, even when incorporated with an FI
and lubricity improver (COMPARATIVE EXAMPLES 1 to 3 and 9 to 12). It is also found
that a fuel oil composition shows insufficient CFPP, essentially on a level with that
of the base stock, in the absence of FI, even when its base stock has the component
A, [B/C] ratio and component D in specific ranges (COMPARATIVE EXAMPLES 4 and 7).
Similarly, a fuel oil composition shows notably low lubricity in the absence of lubricity
improver, even when its base stock has the component A, [B/C] ratio and component
D in specific ranges (COMPARATIVE EXAMPLES 5 and 8). Moreover, a fuel oil composition
gives, when combusted, a notably large quantity of PM emissions, when its base stock
has the component D out of the specific range, even when it has the component A and
[B/C] ratio in specific ranges, and is incorporated with FI and lubricity improver.
It is therefore essential for a fuel oil composition for diesel engines to comprise
a base stock which has the component A, [B/C] ratio and component D in specific ranges,
contains sulfur at 0.05wt.% or less, and is incorporated with an adequate FI and lubricity
improver, in order to efficiently control PM emissions and exhibit good CFPP and lubricity.