Background of the Invention
1. Field of the Invention.
[0001] This invention relates to improved unleaded gasoline compositions. More particularly,
the invention relates to the incorporation of molybdenum(VI) compounds into an unleaded
gasoline for the purpose of reducing elevated steady state octane requirement and
suppressing octane requirement increase in spark ignition internal combustion engines.
2. Description of the Prior Art.
[0002] A great number of gasoline additives, including antiknock agents, deposit reducing
agents, demulsifiers, etc., have been developed in recent years. A commercially important
antiknock agent, tetraalkyl lead, has, until recently, been universally used to prevent
engine knock by increasing the octane number of gasoline. However, with increased
sensitivity to lead in the environment and with the use of catalytic converters that
can be poisoned by lead, broad restrictions have been placed on the use of lead in
gasoline. In the absence of lead, greater amounts of expensive, high octane blending
stock must be used to produce gasoline having sufficient octane for current production
automobiles.
[0003] Along with the increased cost of production of unleaded gasoline, a particularly
harmful problem has arisen. Engines operating on unleaded gasoline commonly experience
increasing incidence and severity of knock as they age. A new or "clean" engine can
operate efficiently and without knock using a gasoline having a research octane number
of about 85. The same engine with about 8,000-12,000 accumulated miles can often require
a gasoline having an octane number about 95-100 or higher. This increase in the octane
number required to prevent knock is called octane requirement increase (ORI).
[0004] ORI is believed to be one result of thermally insulating combustion chamber deposits
formed from gasoline contaminants and from the incomplete combustion of gasoline
and lubricating oil. Initially the rate of deposit formation is substantially greater
than the rate of disintegration, and the deposits rapidly build. As the deposits thicken,
the rate of disintegration approaches and eventually equals the rate of formation.
At this point, the deposits reach a steady state thickness. Knock in the engine appears
to increase in incidence and severity as the deposit builds and reaches a constant
or steady state elevated rate of incidence and severity corresponding to the steady
state thickness of the deposit. At this point the engine commonly has an elevated
steady state octane requirement which can be 2 to 15 research octane numbers greater
than the octane requirement when new.
[0005] While we do not wish to be limited to a theory of ORI, we believe that the combustion
chamber deposits have the substantial ability to prevent transfer of thermal energy
from the combustion chamber into engine coolant, causing accumulation of thermal energy
in the deposits and in the combustion chamber. When a spark ignites the air/fuel mixture
in the combustion chamber, a flame front is initiated and combustion rapidly and smoothly
progresses from the spark plug to the "end-gas region" opposite to the spark plug.
The high pressure flame front rapidly compresses the unburned air/fuel mixture which
is at a relatively lower pressure in the end-gas region as the front progresses through
the chamber. Commonly, the combustion progresses through the combustion chamber, and
knock is not heard. However, if the temperature of the combustion chamber and the
air/fuel mixture has been substantially increased by the insulating properties of
the deposits, the rapid compression of the air/fuel mixture in the end-gas region
causes an immediate autodetonation which is different than normal progressive combustion.
This autodetonation causes the "knocking" or "pinging" sound, can reduce operating
efficiency and can cause engine damage. See J. D. Benson, "Some Factors Which Affect
Octane Requirement Increase," SAE Paper 750933, Detroit, Michigan, October 1975, for
a detailed treatment of ORI.
[0006] ORI can readily be remedied with leaded gasoline by increasing the lead concentration.
In unleaded fuels, a greater amount of high octane blending stock must be used to
increase the octane. However, high octane blending stock commonly contains aromatic
constituents that are more likely to leave thermally insulating deposits and increase
ORI.
[0007] With the suppression of ORI, more gasoline with a lower octane number could be produced
per barrel of crude oil at lower cost. Since the production of high octane gasoline
consumes more energy than the production of lower octane gasoline, refining operations
would become more energy efficient. Further, in the absence of ORI, engine manufacturers
could build more fuel efficient engines by increasing compression and adjusting spark
timing. Such engines would perform satisfactorily with a fuel having the same or lower
octane as is currently available.
[0008] In this application, octane requirement increase shall mean the gradual increase
in octane requirement observed as an engine ages. Elevated steady state octane requirement
shall mean the octane requirement of an engine with combustion chamber deposits that
have reached a steady state both in thickness and in resistance to thermal energy
flow.
[0009] The incorporation of certain specific molybdenum compounds into gasoline has been
suggested for the purpose of providing a composition having improved lubricating and
antiwear properties. U.S. Patent Nos. 4,164,473; 4,176,073; and 4,176,074 disclose
the use of molybdenum complexes of hydroxy amines, molybdenum complexes of lactone
oxazoline dispersants, and molybdenum complexes of oxazoline dispersants respectively
for this purpose. Similarly, U.S. Patent Nos. 4,192,757 and 4,201,683 disclose, for
this purpose, the use of molybdenum complexes which are obtained by reaction of a
hydrocarbyl substituted thio-bis-phenol with a molybdenum compound in the presence
of an amine in an alkyl substituted phenol or alkanol solvent, respectively. In addition,
U.S. Patent No. 3,994,697 teaches that a solid pellet comprising various metals in
combination with molybdenum disulfide can be placed in the fuel reservoir of an internal
combustion engine where it slowly disintegrates to produce extremely minute particles
which are dispersed in the fuel and are delivered to the fuel-contacting parts of
the engine to deposit a lubricant film thereon.
[0010] U.S. Patent Nos. 3,615,293 and 3,755,195 disclose the incorporation of various organic
molybdenum compounds into a gasoline fuel which contains an organomanganese antiknock
agent. These patents teach that the molybdenum compounds are effective in reducing
spark plug fouling by gasoline fuels which contain organomanganese antiknock agents.
It is further disclosed that suitable organic molybdenum compounds include molybdenum
salts and chelates. However, these references fail to suggest the incorporation of
a molybdenum compound into gasoline for any purpose in the absence of an organomanganese
antiknock agent.
[0011] U.S. Patent No. 3,317,571 discloses the preparation of organomolybdenum compounds
wherein one or more molecules containing an amide or thioamide linkage are bonded
to the molybdenum atom through a sulfur or oxygen linkage and which is stabilized
by additional covalent bonding to a plurality of carbonyl groups. This patent discloses
that such compounds can be used in gasoline, either alone or in combination with lead
alkyls, as antiknock agents. It fails, however, to either teach or suggest the use
of a molybdenum(VI) compound for any purpose.
[0012] U.S. Patent No. 3,272,606 discloses that small amounts of a covalent molybdenum polycarbonyl
compound can be used in gasoline in combination with an organolead antiknock agent
to enhance the antiknock properties of the organolead antiknock agent. However, this
reference fails to suggest the incorporation of a molybdenum compound into gasoline
for any purpose in the absence of an organolead antiknock agent.
[0013] U.S. Patent No. 2,086,775 is directed to the incorporation of various organometallic
compounds into a liquid fuel for an internal combustion engine. Suitable organometallic
compounds are those of cobalt, nickel, manganese, iron, copper, uranium, molybdenum,
vanadium, zirconium, beryllium, platinum, palladium, thorium, chromium, aluminum,
and the rare earth metals. In addition, the liquid fuel may also contain an organolead
antiknock agent. It is disclosed that use in an internal combustion engine of a fuel
containing small amounts of these organometallic compounds results in the formation
of a catalytic deposit within the combustion chambers of the engine which is effective
for the elimination of knock and the improvement of combustion within the engine.
However, this patent offers no guidance for selecting a molybdenum(VI) compound for
use in a gasoline composition which is substantially free of other metals for the
purpose of suppressing octane requirement increase and reducing elevated steady state
octane requirement in spark ignition internal combustion engines.
[0014] U.S. Patent No. 3,155,620 is directed to the use of cycloheptatriene transition metal
coordination compounds of the Group VIB metals as additives for liquid hydrocarbon
compositions. This patent teaches that such additives can be used to increase the
octane of liquid fuels and to provide improved lubricating properties when incorporated
into lubricating oil compositions. It is further disclosed that these coordination
compounds can be used in combination with antiknock agents such as organolead compounds.
However, this patent fails to either teach or suggest the use of a molybdenum(VI)
compound for any purpose.
[0015] U.S. Patent No. 3,440,028 is directed to the incorporation of a metal halide hydrocarbyl
orthophosphate additive into leaded gasoline compositions for the purpose of suppressing
the tendency of the lead to increase undesirable surface ignition within the combustion
chambers of an engine. The metal of the additive can be selected from the group consisting
of manganese and metals of Groups IB, IIA, IIB, IVA, VIB and VIII of the Periodic
Table. Similarly, U.S. Patent No. 3,240,576 discloses that the addition to leaded
gasoline of a gasoline soluble organomolybdenum compound will provide a substantial
reduction of surface ignition in the combustion chambers of a spark ignition internal
combustion engine. These patents do not, however, suggest the addition of a molybdenum
compound to unleaded gasoline for any purpose.
[0016] U.S. Patent No. 3,401,184 is directed to a method for the preparation of metal organo
orthophosphates wherein the metal can be selected from Groups II, IV, VI and VIII
of the Periodic Table. It is disclosed that these compounds have utility as gasoline
additives and that when so used they impart rust inhibition, surface ignition suppression,
carburetor detergency, carburetor icing alleviation and reduction in octane requirement
increase to the gasoline composition. In addition, U.S. Patent No. 3,282,838 discloses
the use of amine salts of chromic or molybdic acid as corrosion inhibitors in petroleum
hydrocarbons such as gasoline. These amine salts contain either a chromic or molybdic
ion of +6 valence and are used at a concentration level between about 0.005 and 5
weight percent.
[0017] Finally, U.S. Patent No. 3,003,859 discloses the incorporation into a liquid hydrocarbon,
such as gasoline, of about 0.005 to about 5 percent by weight of a metal-organic
material which is obtained by heating a normally-solid metallic chelate compound formed
from a
beta-keto ester to a temperature above its melting point. It is further disclosed that
these metal chelates can be formed from metallic elements of the Periodic Table comprising
the Groups IA, IB, IIA, IIB, IIIA, IIIB, IVA, IVB, VA, VB, VIB, VIIB and VIII including
the lanthanide and actinide series of rare earth elements. This patent, however, fails
to offer any guidance for selecting a molybdenum(VI) compound for the purpose of suppressing
octane requirement increase and reducing elevated steady state octane requirement
in spark ignition internal combustion engines.
Summary of the Invention
[0018] The present invention is directed to the discovery that the incorporation of small
amounts of a gasoline soluble molybdenum(VI) compound into unleaded gasoline affords
a fuel composition which is effective in reducing elevated steady state octane requirement
and suppressing octane requirement increase in spark ignition internal combustion
engines.
[0019] One embodiment of the invention is a gasoline fuel composition comprising a major
proportion of a liquid hydrocarbon fuel of gasoline boiling range in combination with
a molybdenum(VI) compound which is soluble in said hydrocarbon fuel, wherein the amount
of said molybdenum(VI) compound is from about 0.1 to about 20.0 parts per one million
parts of hydrocarbon fuel, said fuel composition is substantially free of metals other
than molybdenum, and said molybdenum(VI) compound is selected from the group consisting
of molybdenum(VI) sulfonates, molybdenum(VI) diamine complexes, amine salts of molybdic
acid and isopolymolybdic acid, and molybdenum(VI) compounds which are free of nitrogen,
sulfur and phosphorus.
[0020] Another embodiment of the invention is a gasoline fuel composition comprising a major
proportion of a liquid hydrocarbon fuel of gasoline boiling range in combination with
a molybdenum(VI) compound which is soluble in said liquid hydrocarbon fuel, wherein
the amount of said molybdenum(VI) compound is effective to suppress octane requirement
increase in a spark ignition internal combustion engine, said fuel composition is
substantially free of metals other than molybdenum, and said molybdenum(VI) compound
is selected from the group consisting of molybdenum(VI) sulfonates, molybdenum(VI)
diamine complexes, amine salts of isopoly molybdic acid, and molybdenum(VI) compounds
which are free of nitrogen, sulfur and phosphorus.
[0021] Another embodiment of the invention is a gasoline fuel composition comprising a major
proportion of a liquid hydrocarbon fuel of gasoline boiling range in combination with
a molybdenum(VI) compound which is soluble in said liquid hydrocarbon fuel, wherein
the amount of said molybdenum(VI) compound is effective to reduce elevated steady
state octane requirement in a spark ignition internal combustion engine, said fuel
composition is substantially free of metals other than molybdenum, and said molybdenum(VI)
compound is selected from the group consisting of molybdenum(VI) sulfonates, molybdenum(VI)
diamine complexes, amine salts of isopoly molybdic acid, and molybdenum(VI) compounds
which are free of nitrogen, sulfur and phosphorus.
[0022] A further embodiment of the invention is a method for reducing elevated steady state
octane requirement in a spark ignition internal combustion engine and maintaining
the resulting reduced steady state octane requirement which comprises operating said
engine on a first gasoline fuel composition until a reduced steady state octane requirement
is achieved and maintaining said reduced steady state octane requirement by operating
the engine on a second gasoline fuel composition, wherein said first fuel comprises
a major proportion of a liquid hydrocarbon fuel of gasoline boiling range in combination
with an amount of a soluble molybdenum(VI) compound which is sufficient to provide
from about 10 to about 1000 parts of molybdenum per million parts of liquid hydrocarbon
fuel, wherein said second fuel comprises a major proportion of a liquid hydrocarbon
fuel of gasoline boiling range in combination with an amount of a soluble molybdenum(VI)
compound which is sufficient to provide from about 0.01 to about 10 parts of molybdenum
per million parts of liquid hydrocarbon fuel, and wherein both of said first and second
fuels are substantially free of lead.
[0023] A further embodiment of the invention is a method for reducing elevated steady state
octane requirement and/or suppressing octane requirement increase in a spark ignition
internal combustion engine which comprises operating said engine with a gasoline fuel
composition comprising a major proportion of a liquid hydrocarbon fuel of gasoline
boiling range in combination with a molybdenum(VI) compound which is soluble in said
liquid hydrocarbon fuel, wherein the amount of said molybdenum (VI) compound is effective
to reduce elevated steady state octane requirement and/or suppress octane requirement
increase in said engine, said fuel composition is substantially free of metals other
than molybdenum, and said molybdenum (VI) compound is selected from the group consisting
of molybdenum (VI) sulfonates, molybdenum (VI) diamine complexes, amine salts of molybdic
acid and isopoly molybdic acid, and molybdenum (VI) compounds which are free of nitrogen,
sulfur and phosphorus.
[0024] A still further embodiment of the invention is a method for reducing elevated steady
state octane requirement in a spark ignition internal combustion engine having an
increased octane requirement of about 2 to about 7 units after operation with gasoline
substantially free of lead and molybdenum which com- prises operating said engine
with a gasoline fuel composition comprising a major proportion of a liquid hydrocarbon
fuel of gasoline boiling range in combina- tion with a molybdenum (VI) compound which
is soluble in said hydrocarbon fuel, wherein the amount of said molybdenum (VI) compound
is sufficient to provide from about 10 to about 1000 parts of molybdenum per million
parts of said hydrocarbon fuel, and the amount of said gasoline fuel composition is
effective to reduce said elevated steady state octane requirement by at least about
20%.
[0025] The general object of this invention is to sup-press ORI and reduce elevated steady
state octane requirement arising in internal combustion engines using unleaded fuels.
Another object is to modify the thermal conductivity of combustion chamber deposits
to increase heat conduction and thereby reducing elevated steady state octane requirement
and suppressing ORI. Still another object of the invention is to promote the formation
of thermally conductive deposits in internal combustion engines. A further object
of the invention is to provide low octane gasoline that can be used in an engine without
harmful knock arising as the engine ages. A still further object of the invention
is to increase the efficiency of gasoline production by producing more low octane
gasoline from crude oil.
Detailed Description of the Invention
[0026] We have discovered that the octane requirement increase and the elevated steady state
octane requirement caused by combustion chamber deposits in internal combustion engines
can be prevented or reduced by operation of an internal combustion engine wherein
the combustion processes in the combustion chamber are performed in the presence of
a hexavalent molybdenum, molybdenum(VI) or molybdenum +6 compound. The hexavalent
molybdenum compound can be provided to the combustion chamber by a gasoline substantially
free of lead compounds containing a gasoline soluble hexavalent molybdenum compound,
or by a lubricating oil containing the molybdenum compound which is transported into
the combustion chamber during the operation of the engine. We have further discovered
certain preferred hydrocarbon soluble compounds containing molybdenum in the +6
oxidation state that are effective in preventing octane requirement increase and are
effective in reducing elevated steady state octane requirement.
[0027] The generic use of molybdenum compounds of any oxidation state to prevent octane
requirement increase and reduce elevated steady state octane requirement has been
investigated by us previously. However, now we have found that only molybdenum(VI)
compounds serve to efficiently afford these results. Apparently, only molybdenum(VI)
compounds efficiently alter the thermal energy transfer characteristics of combustion
chamber deposits so that heat can be rapidly conducted from combustion chamber to
engine coolant. Since the modified deposits no longer impede efficient removal of
heat from the combustion chamber, the gasoline is ignited solely by the spark and
the fuel is burned uniformly in the combustion chamber, efficiently transmitting combustion
energy to the road in the absence of knock, ping, loss in efficiency or mechanical
damage.
[0028] Although the subject invention is not to be so limited, it is believed that a greater
thermal conductivity per unit mass of combustion chamber deposit results from higher
levels of organic oxygen and that such highly oxidized deposits are generated efficiently
in the presence of molybdenum only when the molybdenum is in the +6 oxidation state.
In principle, molybdenum of lower oxidation state could be oxidized to the +6 oxidation
state within an engine during the combustion of fuel. However, the conditions under
which gasoline is combusted in a spark ignition internal combustion engine appear
to be unsuitable to render such a process of significance. Among other possible factors,
it is believed that the fuel combustion cycles are too short to effect such a modification
of molybdenum oxidation state.
[0029] Briefly, the improved gasoline compositions of this invention can be prepared by
combining with a major portion of gasoline substantially free of lead compounds an
effective octane requirement increase suppressing or an effective steady state octane
requirement reducing amount of a gasoline soluble compound containing molybdenum(VI),
hexavalent molybdenum, or molybdenum +6. The improved lubricants of the invention
can be prepared by combining with a lubricant an effective amount of a hydrocarbon
soluble molybdenum(VI) compound.
[0030] One aspect of the invention is an unleaded gaso-line, used in "clean," new engines,
containing a low concentration of a hydrocarbon soluble molybdenum (VI) compound comprising
a major portion of gasoline and about 0.1 to about 20 parts of the molybdenum (VI)
compound per one million parts of gasoline. Alterna-tively, such a molybdenum (VI)
compound can be used in an amount which is sufficient to provide from about 0.01 to
about 10 parts of molybdenum, calculated as the metal, per million parts of gasoline.
[0031] Another aspect of the invention is a gasoline, for use in "dirty" engines that have
reached an elevated steady state octane requirement caused by deposits in the combustion
chamber, to substantially reduce the elevated steady state octane requirement. This
composition, which modifies the existing deposits and reduces the elevated steady
state octane require-ment, comprises a major portion of gasoline and about 20 to
about 10,000 parts of a hydrocarbon soluble molybdenum (VI) compound per one million
parts of gasoline. Alternatively, such a molybdenum (VI) com-pound can be used in
an amount which is sufficient to provide from about 10 to about 1000 parts of molybdenum,
calculated as the metal, per million parts of gasoline.
[0032] A further aspect of the invention is a concentrate of a hydrocarbon soluble molybdenum
(VI) compound con-taining about 0.1 to about 50 wt% of the compound in a suitable
diluent which can be dissolved in proper proportion in gasoline or lubricating oil
to provide about 0.1 to about 10,000 parts of molybdenum (VI) compound per one million
parts of gasoline or about 0.001 to about 5 wt% of molybdenbum (VI) compound in a
lubricating oil.
[0033] A still further aspect of the invention is a lubricating oil containing a hydrocarbon
soluble molybdenum compound which when used to lubricate an engine provides to the
combustion chamber a substantial amount of molybdenum(VI), by oxidation of a molybdenum
compound or by other means, that can suppress ORI or reduce elevated steady state
octane requirement. Commonly, lubricating oils contain about 0.001 to about 5 wt%;
preferably about 0.01 to about 2 wt%; and most preferably, to reduce molybdenum consumption
and provide maximum benefit, about 0.01 to about 1 wt% of molybdenum(VI) compound.
[0034] Significant amounts of lead and manganese compounds have been widely used in gasoline
as antiknock agents. Lead compounds, particularly tetraalkyl lead compounds, have
been most extensively used, whereas manganese compounds have been primarily used to
enhance the antiknock properties of lead compounds. However, the molybdenum(VI) containing
gasoline compositions of this invention are preferably substantially free of lead,
more preferably substantially free of both lead and manganese, and most preferably
substantially free of metals other than molybdenum.
[0035] Any hydrocarbon soluble molybdenum(VI) compound which is stable in hydrocarbon or
petroleum storage or distribution facilities can be used in gasoline in accordance
with this invention. Preferably, the molybdenum(VI) or compound is selected from the
group consisting of molybdenum(VI) sulfonates, molybdenum(VI) diamine complexes, amine
salts of molybdic acid and isopoly molybdic acid, and molybdenum(VI) compounds which
are free of nitrogen, sulfur and phosphorus. More preferably, the molybdenum(VI) compound
is selected from the group consisting of molybdenum(VI) sulfonates, molybdenum(VI)
diamine complexes, amine salts of isopoly molybdic acid, molybdenum(VI) carboxylates,
molybdenum(VI) salts of naphthenic acids, molybdenum(VI) phenates, molybdenum(VI)
alkoxides, molybdenum(VI) aryloxides, and molybdenum(VI)
beta-diketone complexes.
[0036] Although phosphorus containing compounds of molybdenum(VI) can be used in the practice
of this invention, they are ordinarily not preferred. This is a consequence of the
fact that phosphorus is considered to be harmful to the catalytic converters which
are currently employed to control the emission of hydrocarbons, carbon monoxide and
nitrogen oxides from automotive engines.
[0037] Molybdenum compounds useful to suppress ORI or reduce elevated steady state octane
requirement include a broad variety of molybdenum(VI) compositions.
[0038] A useful class of molybdenum(VI) compositions can be formed by the reaction of molybdenum
in a variety of forms with a ligand. Examples of these ligands are acetylacetone,
N-nitrosophenylhydroxylamine, dimethylglyoxime, ethylenediamine, ethylenediaminetetraacetic
acid, nitrilotriacetic acid, 8-hydroxyquinoline, benzoylacetone, 2,4-pentanediene,
beta-diketones, oxygen, halogens, Mannich products, phosphates, phosphine oxides, alkanol
amines, sulfoxides formamides and other similar well known chelating agents.
[0039] Another useful class of hydrocarbon soluble molybdenum compositions includes molybdenum(VI)
beta-diketonates wherein the
beta-diketone can be represented by the formula:

At least one proton on the carbon atom between the carbonyl groups is necessary for
the formation of the molybdenum complex. The removal of this proton generates a
beta-diketone anion which can chelate the metal ion present. R¹ and R² are hydrocarbyl
groups of 1 to 50 carbon atoms and include primary, secondary and tertiary alkyl,
alkenyl and aromatic groups. Preferred alkyl groups are methyl, ethyl, isopropyl,
t-butyl,
sec-amyl, 2-ethylhexyl, eicosyl, pentacontyl, having both normal chains and branched
chains. R³ can be hydrogen or a hydrocarbyl group of 1 to 50 carbon atoms. Preferably,
R³ is hydrogen or an alkyl group, for example methyl, ethyl, isopropyl,
t-butyl, amyl,
n-hexyl, pentacontyl, etc., having both normal and branched chain.
Beta-diketones are well known in the art, some are available commercially, and all are
readily prepared by methods well known in the art.
[0040] The commonly used compounds are prepared from
beta-diketones wherein R¹ and R² represent alkyl groups of 1 to 20 carbon atoms and R³
represents hydrogen. More specifically, the preferred
beta-diketones are 2,4-pentanedione, 3-methyl-2,4-pentanedione, 3-isopropyl-2,4-pentanedione,
2,4-hexanedione, 2-methyl-3,5-hexanedione, 4-methyl-3,5-heptanedione, 3,5-heptanedione,
2,6-dimethyl-3,5-heptanedione, 2-methyl-4,6-heptanedione, 2-methyl-4,6-octanedione,
2,8-dimethyl-4,6-nonanedione, and 2,2,6,6-tetramethyl-3,5-heptanedione. Other
beta-diketone complexes are discussed by Morgan and Castell,
J. Chem. Soc., 3252 (1928).
[0041] Another useful class of hydrocarbon soluble molybdenum(VI) complexes that can be
used in the practice of this invention is composed of molybdenum(VI) diamine complexes
wherein the diamine ligand is represented by:
R⁴R⁵N-(CR⁴R⁵)
n-NR⁴R⁵
wherein n is an integer from 1 to 20, preferably for reasons of stability of the molybdenum-amine
product, n is 2 to 4. The R⁴ and R⁵ substituents can be independently hydrogen or
alkyl of 1 to 20 carbon atoms and the amino groups can be independently primary, secondary
or tertiary groups. Representative diamines include ethylenediamine, 1,2-propylenediamine,
1,3- propylenediamine, 2-methyl-1,3-diaminopropane, 2,2-dimethyl-1,3-diaminopropane,
ortho-phenylenediamine and the corresponding 1 to 20 carbon alkyl-substituted diamines.
[0042] Other useful hydrocarbon soluble molybdenum(VI) compounds include molybdenum-polyamine
Mannich complexes, molybdenum-polyamine substituted dicarboxylic acid complexes, disclosed
in U.S. Serial No. 190,590, filed September 25, 1980, which is expressly incorporated
by reference herein.
[0043] Another useful class of molybdenum(VI) compositions includes the neutralization products
of molybdic acid including iso and heteropoly molybdic acid with an oil soluble base
and the neutralization of an acid with a molybdenum base.
[0044] Gasoline soluble amine salts of the formula:
[R⁶R⁷R⁸NH]₂MoO₄
can be used in the practice of this invention wherein R6 is a hydrocarbyl radical,
and R⁷ and R⁸ are independently selected from the group consisting of hydrogen and
hydrocarbyl. Typical hydrocarbyl radicals include, for instance: alkyl, alkenyl, aryl,
alkaryl, arylalkyl, or alicyclic radicals. Examples of suitable hydrocarbyl radicals
are : methyl, ethyl, propyl, butyl, isohexyl, 2-ethylhexyl, neodecyl, dodecyl, octadecyl,
eicosyl, nonacosyl, phenyl, naphthyl, benzyl, cresyl, ethylphenyl, phenylhexyl, cyclohexyl,
cyclopropyl, cyclopentyl, butenyl, octenyl, linoleyl, etc.
[0045] Another useful class is composed of hydrocarbon soluble molybdenum(VI) dialkyl phosphates,
phosphorothioates and phosphorodithioates which are derived from a phosphorus containing
moiety of the formula:

wherein each X can be independently selected from oxygen or sulfur and each R⁹ is
independently selected from hydrocarbon alkyl and aryl groups having from one to about
30 carbon atoms. Examples of these molybdenum(VI) compositions are:
molybdenum-dimethylphosphorothioate
molybdenum-dioctylphosphorothioate
molybdenum-diphenylphosphate
molybdenum-dicresylphosphate
molybdenum-didecylphosphorodithioate
molybdenum-diamylphosphorotetrathioate
molybdenum-di-
tert-butylphosphorotrithioate
molybdenum-dixylylphosphorothioate
molybdenum-di-4-ethylphenylphosphorotrithioate
molybdenum-dioctadecylphosphorotetrathioate
molybdenum-cresylphenylphosphate
molybdenum-dinaphthylphosphorothioate
molybdenum-diisopropylphosphorothioate
molybdenum-dibenzylphosphate
molybdenum-dicresylphosphorodithioate
molybdenum-di-4-dodecylphenylphosphorodithioate
molybdenum-dibenzylphosphorodithioate
molybdenum-dilaurylphosphorodithioate
molybdenum-di-2-ethylhexylphosphorodithioate
molybdenum-dicyclohexylphosphorodithioate
molybdenum-diisoamylphosphorodithioate
molybdenum-dioctadecylphosphorodithioate
molybdenum-diundecylphosphorodithioate
molybdenum-diheptylphosphorodithioate
molybdenum-di-2,6-
tert-butylphenylphosphorodithioate
molybdenum-diethylphosphorodithioate
molybdenum-ditetradecylphosphorodithioate
molybdenum-diacetylphosphorodithioate
molybdenum-di-2,4-didodecylphenylphosphorodithioate
molybdenum-dihexylphosphorodithioate
and the like. Other compounds are taught by Revukas in U.S. Patent Nos. 3,440,028
and 3,401,184 which are expressly incorporated by reference herein. However, phosphorus
is currently considered harmful to catalytic converters. Consequently, phosphorus
containing compounds are not preferred for use in the practice of this invention.
[0046] Still another class of hydrocarbon soluble molybdenum(VI) compounds which can be
used in accordance with this invention comprises molybdenum(VI) carboxylates such
as those disclosed by Cavitt in U.S. Patent No. 3,595,891 and Hnizda in U.S. Patent
No. 3,755,195 which are expressly incorporated by reference herein.
[0047] Examples of suitable molybdenum(VI) carboxylates of this type are molybdenum pentanoate,
molybdenum octanoate, molybdenum oleate, molybdenum linoleate, molybdenum adipate,
molybdenum 2-ethylhexanoate, molybdenum benzoate, molybdenum tetradecanoate, molybdenum
orthophthalate, molybdenum 4-dodecylbenzoate, molybdenum stearate, molybdenum laurate
and the like. Molybdenum(VI) salts of mixtures of fatty acids obtained from natural
products such as olive oil, tall oil, cottonseed oil, tallow, coconut oil and the
like are also useful. Other molybdenum(VI) compounds of this type are the salts of
alicyclic carboxylic acids. Specific examples of useful molybdenum(VI) salts of alicyclic
carboxylic acids are molybdenum cyclopentanecarboxylate, molybdenum cyclopentylacetate,
molybdenum 3-methylcyclopentylacetate, molybdenum camphoate, molybdenum cyclohexanecarboxylate,
molybdenum 3-dodecylcyclohexanecarboxylate, molybdenum 2,6-dicyclohexylcyclohexanecarboxylate,
molybdenum 2-cyclohexyl-4,6-dipentyl-4-methylcyclohexanecarboxylate, molybdenum 4-methylcyclohexanecarboxylate,
molybdenum 2,2,6-trimethylcyclohexanecarboxylate and the like.
[0048] Another class of hydrocarbon soluble molybdenum(VI) compositions which is useful
in the practice of this invention are salts of the so-called naphthenic acids. The
term "naphthenic acids" is applied to a mixture of carboxylic acids obtained from
the alkali washes of petroleum. These acids are complex mixtures of normal and branched
aliphatic acids, alkyl derivatives of cyclopentane- and cyclohexane-carboxylic acids
and cyclopentyl and cyclohexyl derivates of aliphatic acids. The alicyclic carboxylic
acids appear to be the major constituents of these mixtures. The composition of these
naphthenic acids will vary depending on factors such as the source of petroleum, the
refining procedure, etc. A more detailed discussion of these naphthenic acids is presented
in "Chemical Technology of Petroleum," William A. Gruse and Donald R. Stevens, 3rd
edition, pp. 65-67, 1960, McGraw-Hill Publishing Company, which is incorporated by
reference.
[0049] Molybdenum(VI) sulfonates wherein the sulfonate moiety has the general formula:
ArSO

can also be used in the practice of this invention. Sulfonic acid compounds useful
to prepare molybdenum(VI) sulfonates can have the following general formula:
XSO₃-(Ar)
n-A
m
wherein A is hydrogen, an alkyl, or other hydrocarbyl group with hydroxy-, chloro-,
or bromo-substituents; Ar is an aryl unit including benzene, naphthalene, etc.; m
is an integer of 1 to 5; n is an integer of 0 to 5; and X is a halogen or hydrogen.
A can be any substantially hydrocarbyl or substituted hydrocarbyl group which results
in a hydrocarbon benzene sulfonic acid. A can be a hydrogen or a substantially aliphatic
group with about 1 to 15 carbon atoms, such as methyl, ethyl, propyl, isopropyl, butyl,
t-butyl, nonyl, decyl, dodecyl, pentadecyl and the like, with a molecular weight of
about 120 and greater; an intermediate molecular weight alkyl group such as polyisobutylene
or polypropylene polymers with 15 to 1,000 carbon atoms with a molecular weight of
about 200 to 14,000; a high molecular weight hydrocarbyl such as polyolefin having
a number average molecular weight in excess of 14,000; and others. A can be substituted
with groups such as chlorine, bromine, or hydroxy groups. Also, Ar can have more than
one substituent, for example, alkyl, hydroxyalkyl, or haloalkyl.
[0050] Other suitable oil soluble benzenesulfonic acids are the oil soluble, so-called petroleum
sulfonic acids which are also commonly referred to as mahogany acids, having a molecular
weight from about 350 to 750, aryl sulfonic acids, and alkaryl sulfonic acids. Examples
of other suitable sulfonic acids are diparaffin wax-substituted phenolsulfonic acid,
cetylchlorobenzenesulfonic acid, cetylphenoldisulfidesulfonic acid, cetylphenolmonosulfidesulfonic
acid, etc. Other suitable oil-soluble sulfonic acids are well described in the art
such as U.S. Patent Nos. 2,616,604; 2,626,207; 2,767,209; and others. The inexpensive,
low molecular weight polypropylbenzenesulfonic acids having a molecular weight of
about 200 to 1,200 are preferred.
[0051] Another class of useful compounds is comprised of molybdenum(VI) phenates which are
the reaction product of a molybdenum compound and a phenol compound. Examples of useful
phenol compounds include:
4-methylphenol,
4-octadecylphenol,
4-oleylphenol,
4-(2-ethyl-n-hexyl)phenol,
2,6-dimethylphenol,
2,4,6-trimethylphenol,
o-chlorophenol,
2-dodecylphenol,
2,4-didodecylphenol,
p-nonylphenol,
2-
tert-butylphenol
, 4-dodecylphenol,
4-polyisobutylene substituted phenol,
and the like.
[0052] An especially useful type of a molybdenum(VI) phenate is that derived from a commercial
mixture of alkylated phenols. Commercial alkylation of phenols generally is accomplished
by treating the phenol with an olefin, or polyolefin or mixtures thereof in the presence
of an alkylating agent. This commercial alkylation ordinarily produces a mixture of
various alkyl phenols. For example, if a phenol is alkylated with a C₉ olefin, the
product will contain monononylphenols, dinonylphenols, and trinonylphenols. Likewise,
if a mixture of C₉, C₁₀, and C₁₈ olefins is used in the alkylation, a mixture of various
C₉, C₁₀, and C₁₈ alkylated phenols is obtained.
[0053] Still another class of hydrocarbon soluble molybdenum(VI) compounds includes alkoxides
and aryloxides that can be prepared by reacting a molybdenum halide compound with
an alcohol or a phenol, for example:
MoO₂Cl₂ + 2ROH = MoO₂(OR)₂ + 2HCl
[0054] Preferred hydrocarbon soluble molybdenum(VI) compounds, for reasons of solubility
in gasoline and lubricating oil and the substantial reduction of octane requirement
increase and equilibrium octane requirement, include
cis-dioxobis(dipivaloylmethanato)molybdenum(VI), MoO₂(THD)₂ and
trans-dioxobis(dipivalolylmethanato)molybdenum(VI), molybdenum(VI) octoate and naphthanate,
methylenebis(2-oxo-4-dodecylphenol)molybdenum(VI), dioxo-N,Nʹ-(2-oxo-4-nonylbenzyl)ethylenediaminemolybdenum(VI),
molybdenum(VI) sulfonate, and molybdenum(VI) polyamine-Mannich complex comprising
the reaction product of a molybdenum compound and a Mannich reactant product of an
alkylphenol, formaldehyde, or a formaldehyde-yielding compound and a polyamine, and
the reaction product of a molybdenum compound with the material formed by reacting
an olefin with phosphorus pentasulfide.
[0055] The foregoing compounds are intended to be exemplary of hydrocarbon soluble molybdenum(VI)
compounds known and preferred at this time, and should not be used to unduly limit
the scope of the invention.
[0056] In somewhat greater detail, the improved gasolines and lubricants of this invention
having the ability to prevent substantial octane requirement increase and to reduce
high equilibrium octane requirement are produced by combining a gasoline or a lubricating
oil with an amount of a hydrocarbon soluble hexavalent molybdenum compound which is
effective to reduce elevated steady state octane requirement and/or suppress octane
requirement increase.
[0057] Varying threshold concentrations exist for each of many molybdenum(VI) compounds
for reduction of the octane requirement increase. The threshold for each compound
lies between about 0.01 and 3.0 parts of molybdenum per one million parts of gasoline.
The threshold concentration varies due to the effect on the molybdenum of the radicals
or groups attached. In new engines, the concentration of the molybdenum can range
from 0.01 to about 10 parts of molybdenum per million parts of gasoline to prevent
substantial increase in octane requirement. In "dirty" engines, i.e., engines that
have been operated on unleaded gasoline not containing molybdenum compounds, which
have reached a high steady state octane requirement, a gasoline containing about 10
to about 1000 parts of molybdenum per million parts of gasoline can be used until
the steady state octane requirement has been reduced to near the "clean" octane requirement
level. At that point, the concentration of the molybdenum in the gasoline can be reduced
to about 0.01 to about 10.0 parts per million parts of gasoline.
[0058] The hydrocarbon fuels to which the molybdenum(VI) compounds can be added comprise
hydrocarbons boiling in the gasoline range which range is normally about 20°C-225°C.
The base fuel can comprise straight-chain or branched-chain paraffins, cycloparaffins,
olefins, and aromatic compounds or any mixture of such hydrocarbons obtainable from
straight-run naphtha, polymeric gasoline, natural gasoline, thermally or catalytically
cracked hydrocarbon stocks, alkylate gasoline and catalytically reformed stocks. The
fuels can have a research octane number of about 60 to about 100 or preferably about
85 to about 95 for reason of fuel economy and engine performance. The gasoline may
also contain conventional gasoline additives such as nonmetallic antiknock compounds,
dyes, antioxidants, anti-icing agents, rust inhibitors, detergents, anti-preignition
agents, stabilizers, intake valve deposit control additives and the like. Commonly,
gasolines contain a carrier fluid which remains stable and fluid in the induction
system and can promote induction system cleanliness by dissolving hydrocarbon soluble
deposits. A preferred embodiment of the invention involves the use of a minor amount
of methyl
t-butyl ether as an antiknock agent.
[0059] The molybdenum(VI) compounds are effective in lubricant compositions when used in
amounts providing about 0.001 to about 5 wt%, preferably about 0.01 to about 2 wt%
and more preferably about 0.01 to about 1 wt% of molybdenum(VI) compound based on
the oil. Suitable lubricating base oils are mineral oils, petroleum oils, synthetic
lubricating oils, and natural lubricating oils of animal or vegetable origin. Concentrates
of the additive in appropriate base oils containing about 10 to about 90 weight percent
of the additive based on the oil are convenient for producing finished lubricants
by dilution with additional base oil. A variety of other additives can be used beneficially
with the additives of this invention, including antioxidants, dispersants, corrosion
inhibitors, wear inhibitors, friction modifiers, detergents, antibacterial agents,
antifoam agents, etc.
[0060] The gasoline soluble molybdenum compounds are tested for ORI suppression and elevated
steady state octane requirement reduction using the CRC E-15 technique with primary
reference fuels and full boiling range reference fuels on an engine dynomometer. A
GM 3.7 liter (231 cubic inch) V-6, and a Ford 2.3 liter (140 cubic inch) 4-cylinder
in-line engine were connected to a load dynomometer. The fuel line is connected via
a valve to a test fuel containing various concentrations of molybdenum compound and
other containers containing standard fuel having known octane numbers. The conditions
of the test are as follows: the temperature of the coolant and oil is maintained at
93°C (200°F) ± 6°C (10°F), the temperature of the inlet air was 40°C-49°C (110°F-120°F),
and the temperature of the transmission was maintained at 82°C (180°F) ± 6°C (10°F).
The air/fuel ratio was held at about stoichiometric, ignition timing and exhaust gas
recirculation was maintained at the stock value. The engine was operated on fuel with
and without gasoline soluble molybdenum compound for up to 30,000 equivalent miles.
At intervals of 4,000 equivalent miles the standard test fuels were burned in the
engine to determine the octane requirement of the engine. After the octane requirement
was determined the engines were returned to the test fuel.
[0061] The following are examples of the preparation of gasoline soluble additive compounds
used in gasoline and tables of test results displaying the octane requirement activity
of molybdenum compounds in the engine. The examples and tables of data are illustrative
of the invention. Since many embodiments of the invention can be made, the examples
and data should not be used to limit the scope of the invention.
EXAMPLE I
[0062] Into a 3-liter, three-neck flask equipped with a mechanical stirrer, thermometer,
temperature control assembly, and an addition funnel and condenser on a side arm adapter
was charged 2 liters of anhydrous dioxane, a slurry of 180 grams (1.55 moles) of anhydrous
methyl trimethyl acetate, and 144 grams (3.0 moles) of a 50 percent oil dispersion
of sodium hydride. The mixture was stirred and heated to reflux and 160 grams (1.60
moles) of dry pinacolone (3,3-dimethyl-2-butanone) and 200 milliliters of anhydrous
dioxane were added dropwise to the stirred and heated mixture over a period of 2 hours.
After the addition of the pinacolone was complete, the mixture was held at reflux
for 5.5 hours. From the mixture hydrogen gas was evolved. The reaction mixture was
chilled in an ice bath and 360 milliliters of concentrated hydrochloric acid were
cautiously added to the cold mixture. The resulting acidified mixture was poured into
a 6-liter separatory funnel containing 1 liter of water and was extracted with 700
milliliters of pentane. The pentane phase was repeatedly washed with water, dried
over magnesium sulfate, and distilled to 93°C to remove pentane. Crude 2,2,6,6-tetramethylheptane-3,5-dione
(THDH) (260.7 grams) in oil was recovered. This procedure was repeated three times
and the preparations were combined and fractionally distilled to recover 531.6 grams
of THDH.
EXAMPLE II
[0063] Into a 250 milliliter Erlenmeyer flask attached to a reflux condenser was charged
a slurry of 50.0 grams (0.29 moles) of 2,2,6,6-tetramethyl-3,5-heptanedione (THDH)
and 9.8 grams (0.09 moles) of molybdenum trioxide (MoO₃). The mixture was stirred
magnetically and was heated to reflux for 20 hours. The amber colored solution was
filtered and upon standing changed to a blue-green solution. The mixture contained
11.5 wt. % molybdenum. Crystals of
cis-dioxobis(dipivaloylmethanato)molybdenum(VI) or MoO₂(THD)₂ were recovered upon slow
evaporation of the excess ketone.
EXAMPLE III
[0064] Into a 500 milliliter Erlenmeyer flask equipped with a distillation trap and condenser
was charged a slurry of 138 grams (0.75 moles) of 2,2,6,6-tetramethyl-3,5-heptanedione
(THDH) and 27.0 grams (0.188 moles) of MoO₃. The mixture was stirred and was heated
on a hot plate to reflux. The mixture was allowed to react for a period of 25.5 hours
while 5.0 milliliters of water were azeotropically removed from the reaction mixture
(1.48 moles of water per mole of molybdenum trioxide). The dark red brown solution
was filtered hot. The filtrate solidified to a dark brown mass upon standing. The
recovered substance was identified as trioxotetra(dipivaloylmethanato)dimolybdenum(V,VI)
by IR and NMR spectra and also by ESCA spectra of the product from a similar preparation.
EXAMPLE IV
[0065] Into a 500 milliliter Erlenmeyer flask equipped with a distillation trap and condenser
assembly was charged a slurry of 36.4 grams (0.25 moles) of MoO₃ and 196.1 grams (1.06
moles) of THDH. The mixture was stirred magnetically and heated to reflux temperature.
After 18.5 hours, 6.0 milliliters of water were azeotropically removed (1.32 moles
of water per mole of molybdenum trioxide). The reaction mixture was centrifuged and
the centrifugate solidified upon standing. The reaction product contained both molybdenum(VI)
and molybdenum(V) chelate as shown by a singlet M-O absorbance and a doublet O-Mo-O
absorbance in the IR spectrum.
EXAMPLE V
[0066] Into a 500 milliliter Erlenmeyer flask equipped with a condenser assembly and distillation
trap was charged a slurry of 9.8 grams (0.7 moles) of molybdenum trioxide and 50 grams
(0.27 moles) of THDH. The mixture was stirred mechanically and was heated to reflux
for 14.5 hours. 1.6 milliliters of water were azeotropically removed (1.31 moles
of water per mole of molybdenum trioxide). The THDH in the distillation trap was returned
to the reaction mixture, and the mixture was then stripped in vacuum of excess THDH.
The resulting product was recrystallized from ethanol.
Trans-dioxo(dipivaloylmethanato)molybdenum(VI) chelate (3.2 grams) was recovered as a first
crop from the more soluble
cis isomer.
EXAMPLE VI
[0067] Into a 5-liter, three-neck flask equipped with a mechanical stirrer, thermometer,
gas-sparge assembly, side arm adapter and dropping funnel and distillation trap condenser
was charged a mixture of 110.0 grams (5.0 moles) of nonylphenol and 150.3 grams (2.5
moles) of ethylenediamine. The mixture was stirred and heated to a temperature of
93°C under a nitrogen atmosphere. To this stirred and heated mixture was added 405.8
grams (5.0 moles) of 37 wt% aqueous formaldehyde solution. The mixture was stirred
and reacted for 0.5 hour at 93°C. Volatiles were removed from the reaction mixture
by stripping with nitrogen over 75 minutes at 121°C. The resulting product was filtered
through celite.
[0068] Into a 500 ml, three-neck flask equipped with a mechanical stirrer, thermometer,
sparge assembly, side arm adapter and dropping funnel, distillation trap and condenser
assembly was charged 104.8 grams (0.2 mole) of the above reaction product, 28.8 grams
(0.2 mole) molybdenum trioxide and 100 milliliters of xylene. The mixture was stirred
and heated to 149°C. Water was removed azeotropically with a nitrogen stream. After
30 minutes at 149°C, 3.6 milliliters of water were removed. The product was filtered
through celite and isolated by stripping to 149°C with nitrogen. The dark brown product,
which solidified on cooling, contained 11.8 wt% molybdenum and was identified as dioxo-
N,
Nʹ-(2-oxo-4-nonylbenzyl)ethylenediaminomolybdenum(VI).
EXAMPLE VII
[0069] To a 500 milliliter Erlenmeyer flask equipped with a magnetic stirrer and heater
was charged 54 grams of molybdic oxide (MoO₃), 106 grams of water and 22.5 grams of
28 percent aqueous ammonia. The mixture was stirred and heated until dissolution.
The ammonium and molybdate product was charged to a 3-liter 3-neck flask equipped
with a reflux condenser, water trap, dropping funnel and gas inlet tube containing
500 milliliters of normal heptane and 100 grams of a Mannich product comprising the
reaction product of a polyisobutylene substituted phenol having a molecular weight
of about 950, paraformaldehyde and diethylenetriamine and oleic acid. The mixture
was stirred and heated at reflux for 4.25 hours. Water of reaction was removed by
azeotropic distillation, and the mixture was centrifuged. The product was filtered
and stripped of heptane by heating to 138°C with a nitrogen stream. The product contained
2.2 wt% molybdenum, 1.31 wt% nitrogen, and had a 40°C viscosity of 2516 SSU.

[0070] An examination of Tables I and II shows that only molybdenum(VI) compounds provide
measurable suppression of ORI or reduction of elevated steady state octane requirement.
[0071] In the initially clean engines (Table I) only the Mo(VI)THD, the Mo(VI)Mannich and
the Mo(VI)octoate provided measurable octane requirement increase suppression. The
mixed Mo(V-VI)THD at 3 ppm and 6 ppm failed to give any measurable suppression.
[0072] In initially dirty engines (Table II) only the Mo(VI)octoate provided reduction of
elevated steady state octane requirement. The Mo(V-VI)THD provided no measurable benefit.