FIELD OF THE INVENTION
[0001] This invention relates to a method for improving asphaltene dispersancy in a trunk
piston marine engine.
[0002] This invention also relates to use of a detergent system for improving asphaltene
dispersancy in a trunk piston marine engine.
[0003] This invention also relates to the use of a detergent system comprising a combination
of hydroxybenzoates in a trunk piston marine engine lubricating composition for a
medium-speed four-stroke compression-ignited (diesel) marine engine to improve the
asphaltene dispersancy performance of the composition.
BACKGROUND OF THE INVENTION
[0004] Marine trunk piston engines generally use Heavy Fuel Oil ('HFO') for offshore running.
Heavy Fuel Oil is the heaviest fraction of petroleum distillate and comprises a complex
mixture of molecules including up to 15% of asphaltenes, defined as the fraction of
petroleum distillate that is insoluble in an excess of aliphatic hydrocarbon (e.g.
heptane) but that is soluble in aromatic solvents (e.g. toluene). Asphaltenes can
enter the engine lubricant as contaminants either via the cylinder or the fuel pumps
and injectors, and asphaltene precipitation can then occur, manifested in 'black paint'
or 'black sludge' in the engine. The presence of such carbonaceous deposits on a piston
surface can act as an insulating layer which can result in the formation of cracks
that then propagate through the piston. If a crack travels through the piston, hot
combustion gases can enter the crankcase, possibly resulting in a crankcase explosion.
[0005] It is therefore highly desirable that trunk piston engine oils ('TPEO's) prevent
or inhibit asphaltene precipitation.
[0006] EP-B-1992 678 describes trunk piston engine oils that contain combinations of overbased alkylsalicylic
acid calcium salts for improving wear properties. No mention is made of asphaltene
dispersancy.
[0007] It is now found that, by using certain hydroxybenzoate combinations in a TPEO, it
is possible to achieve improved asphaltene dispersancy properties.
SUMMARY OF THE INVENTION
[0008] A first aspect of the invention is a method for improving asphaltene dispersancy
in a trunk piston marine engine, the method comprising lubricating the engine with
a lubricating oil composition comprising a detergent system that includes (i) an overbased
alkyl-substituted hydroxybenzoate calcium salt of TBN less than 250, which alkyl group
has 20-28 carbon atoms, and (ii) an overbased alkyl-substituted hydroxybenzoate calcium
salt of TBN less than 250, which alkyl group has 14-18 carbon atoms; the wt% Ca ratio
of (ii) to (i) being greater than one.
[0009] A second aspect of the invention is the use of a detergent system that includes (i)
an overbased alkyl-substituted hydroxybenzoate calcium salt of TBN less than 250,
which alkyl group has 20-28 carbon atoms, in a trunk piston marine lubricating oil
composition for a medium-speed compression-ignited marine engine during operation
of the engine, where the detergent system further comprises (ii) an overbased alkyl-substituted
hydroxybenzoate calcium salt of TBN less than 250, which alkyl group has 14-18 carbon
atoms, the wt% Ca ratio of (ii) to (i) being greater than one, said use being to improve
the asphaltene dispersancy performance of the composition.
[0010] A third aspect of the invention is the use of a detergent system that includes (i)
an overbased alkyl-substituted hydroxybenzoate calcium salt of TBN less than 250,
which alkyl group has 20-28 carbon atoms, in a trunk piston marine lubricating oil
composition for a medium-speed compression-ignited marine engine during operation
of the engine, fueled by a heavy fuel oil, and its lubrication by the composition,
where the detergent system further comprises (ii) an overbased alkyl-substituted hydroxybenzoate
calcium salt of TBN less than 250, which alkyl group has 14-18 carbon atoms, the wt%
Ca ratio of (ii) to (i) being greater than one, said use being to improve the asphaltene
dispersancy performance of the composition in comparison with that of analogous operation
using a detergent system whose wt% Ca ratio is one or less and/or where (ii) has a
TBN of 250 or greater.
[0011] In this specification, the following words and expressions, if and when used, have
the meanings ascribed below:
"active ingredients" or "(a.i.)" refers to additive material that is not diluent or
solvent;
"comprising" or any cognate word specifies the presence of stated features, steps,
or integers or components, but does not preclude the presence or addition of one or
more other features, steps, integers, components or groups thereof; the expressions
"consists of" or "consists essentially of" or cognates may be embraced within "comprises"
or cognates, wherein "consists essentially of" permits inclusion of substances not
materially affecting the characteristics of the composition to which it applies;
"major amount" means 50 mass % or more of a composition, preferably 40 mass % or more
of a composition, more preferably 30 mass % or more of a composition;
"minor amount" means less than 50 mass % of a composition, preferably less than 40
mass % of a composition, more preferably less than 30 mass % of a composition;
"TBN" means total base number as measured by ASTM D2896.
[0012] Furthermore in this specification, if and when used:
"calcium content" is as measured by ASTM 4951;
"phosphorus content" is as measured by ASTM D5185;
"sulphated ash content" is as measured by ASTM D874;
"sulphur content" is as measured by ASTM D2622;
"KV100" means kinematic viscosity at 100°C as measured by ASTM D445.
[0013] Also, it will be understood that various components used, essential as well as optimal
and customary, may react under conditions of formulation, storage or use and that
the invention also provides the product obtainable or obtained as a result of any
such reaction.
[0014] Further, it is understood that any upper and lower quantity, range and ratio limits
set forth herein may be independently combined.
DETAILED DESCRIPTION OF THE INVENTION
[0015] The features of the invention will now be discussed in more detail below.
OIL OF LUBRICATING VISCOSITY
[0016] The trunk piston marine lubricating oil composition of the invention comprises a
major amount of an oil of lubricating viscosity. That may range in viscosity from
light distillate mineral oils to heavy lubricating oils. Such oil may be referred
to as base oil. Generally, the viscosity of the oil ranges from 2 to 40 mm
2/sec, as measured at 100°C. The oil may be a natural or a synthetic oil.
[0017] Natural oils include animal oils and vegetable oils (e.g., castor oil, lard oil);
liquid petroleum oils and hydrorefined, solvent-treated or acid-treated mineral oils
of the paraffinic, naphthenic and mixed paraffinic-naphthenic types. Oils of lubricating
viscosity derived from coal or shale may also be used.
[0018] Synthetic lubricating oils include hydrocarbon oils and halo-substituted hydrocarbon
oils such as polymerized and interpolymerized olefins (e.g., polybutylenes, polypropylenes,
propylene-isobutylene copolymers, chlorinated polybutylenes, poly(1-hexenes), poly(1-octenes),
poly(1-decenes)); alkybenzenes (e.g., dodecylbenzenes, tetradecylbenzenes, dinonylbenzenes,
di(2-ethylhexyl)benzenes); polyphenyls (e.g., biphenyls, terphenyls, alkylated polyphenols);
and alkylated diphenyl ethers and alkylated diphenyl sulphides and derivative, analogues
and homologues thereof.
[0019] Alkylene oxide polymers and interpolymers and derivatives thereof where the terminal
hydroxyl groups have been modified by esterification, etherification, etc., constitute
another class of known synthetic lubricating oils. These may be exemplified by polyoxyalkylene
polymers prepared by polymerization of ethylene oxide or propylene oxide, and the
alkyl and aryl ethers of polyoxyalkylene polymers (e.g., methyl-polyiso-propylene
glycol ether having a molecular weight of 1000 or diphenyl ether of poly-ethylene
glycol having a molecular weight of 1000 to 1500); and mono- and polycarboxylic esters
thereof, for example, the acetic acid esters, mixed C
3-C
8 fatty acid esters and C
13 oxo acid diester of tetraethylene glycol.
[0020] Another suitable class of synthetic lubricating oils comprises the esters of dicarboxylic
acids (e.g., phthalic acid, succinic acid, alkyl succinic acids and alkenyl succinic
acids, maleic acid, azelaic acid, suberic acid, sebacic acid, fumaric acid, adipic
acid, linoleic acid dimer, malonic acid, alkylmalonic acids, alkenyl malonic acids)
with a variety of alcohols (e.g., butyl alcohol, hexyl alcohol, dodecyl alcohol, 2-ethylhexyl
alcohol, ethylene glycol, diethylene glycol monoether, propylene glycol). Specific
examples of such esters includes dibutyl adipate, di(2-ethylhexyl) sebacate, di-n-hexyl
fumarate, dioctyl sebacate, diisooctyl azelate, diisodecyl azelate, dioctyl phthalate,
didecyl phthalate, dieicosyl sebacate, the 2-ethylhexyl diester of linoleic acid dimer,
and the complex ester formed by reacting one mole of sebacic acid with two moles of
tetraethylene glycol and two moles of 2-ethylhexanoic acid.
[0021] Esters useful as synthetic oils also include those made from C
5 to C
12 monocarboxylic acids and polyols such as neopentyl glycol, trimethylolpropane, pentaerythritol,
dipentaerythritol and tripentaerythritol.
[0022] Silicon-based oils such as polyalkyl-, polyaryl-, polyalkoxy- or polyaryloxysilicone
oils and silicate oils comprise another useful class of synthetic oils; such oils
include tetraethyl silicate, tetraisopropyl silicate, tetra-(2-ethylhexyl)silicate,
tetra-(4-methyl-2-ethylhexyl)silicate, tetra-(p-tert-butyl-phenyl) silicate, hexa-(4-methyl-2-ethylhexyl)disiloxane,
poly(methyl)siloxanes and poly(methylphenyl)siloxanes. Other synthetic lubricating
oils include liquid esters of phosphorus-containing acids (e.g., tricresyl phosphate,
trioctyl phosphate, diethyl ester of decylphosphonic acid) and polymeric tetrahydrofurans.
[0023] Unrefined, refined and re-refined oils can be used in lubricants of the present invention.
Unrefined oils are those obtained directly from a natural or synthetic source without
further purification treatment. For example, a shale oil obtained directly from retorting
operations; petroleum oil obtained directly from distillation; or ester oil obtained
directly from esterification and used without further treatment, are unrefined oils.
Refined oils are similar to unrefined oils except that the oil is further treated
in one or more purification steps to improve one or more properties. Many such purification
techniques, such as distillation, solvent extraction, acid or base extraction, filtration
and percolation, are known to those skilled in the art. Re-refined oils are obtained
by processes similar to those used to provide refined oils but begin with oil that
has already been used in service. Such re-refined oils are also known as reclaimed
or reprocessed oils and are often subjected to additional processing using techniques
for removing spent additives and oil breakdown products.
[0024] The American Petroleum Institute (API) publication "Engine Oil Licensing and Certification
System", Industry Services Department, Fourteenth Edition, December 1996, Addendum
1, December 1998 categorizes base stocks as follows:
- a) Group I base stocks contain less than 90 percent saturates and/or greater than
0.03 percent sulphur and have a viscosity index greater than or equal to 80 and less
than 120 using the test methods specified in Table E-1.
- b) Group II base stocks contain greater than or equal to 90 percent saturates and
less than or equal to 0.03 percent sulphur and have a viscosity index greater than
or equal to 80 and less than 120 using the test methods specified in Table E-1.
- c) Group III base stocks contain greater than or equal to 90 percent saturates and
less than or equal to 0.03 percent sulphur and have a viscosity index greater than
or equal to 120 using the test methods specified in Table E-1.
- d) Group IV base stocks are polyalphaolefins (PAO).
- e) Group V base stocks include all other base stocks not included in Group I, II,
III, or IV.
[0025] Analytical Methods for Base Stock are tabulated below (Table E-1):
PROPERTY |
TEST METHOD |
Saturates |
ASTM D 2007 |
Viscosity Index |
ASTM D 2270 |
Sulphur |
ASTM D 2622 |
|
ASTM D 4294 |
|
ASTM D 4927 |
|
ASTM D 3120 |
[0026] By way of example, the present invention embraces Group II, Group III and Group IV
basestocks and also basestocks derived from hydrocarbons synthesised by the Fischer-Tropsch
process. In the Fischer-Tropsch process, synthesis gas containing carbon monoxide
and hydrogen (or 'syngas') is first generated and then converted to hydrocarbons using
a Fischer-Tropsch catalyst. These hydrocarbons typically require further processing
in order to be useful as a base oil. For example, they may, by methods known in the
art, be hydroisomerized; hydrocracked and hydroisomerized; dewaxed; or hydroisomerized
and dewaxed. The syngas may, for example, be made from gas such as natural gas or
other gaseous hydrocarbons by steam reforming, when the resulting basestock may be
referred to as gas-to-liquid ("GTL") base oil; or from gasification of biomass, when
the resulting basestock may be referred to as biomass-to-liquid ("BTL" or "BMTL")
base oil; or from gasification of coal, when the resulting basestock may be referred
to as coal-to-liquid ("CTL") base oil.
[0027] Preferably, the oil of lubricating viscosity in this invention contains 50 mass %
or more of a basestock containing 50 mass % or more of a basestock containing greater
than or equal to 90 % saturates and less than or equal to 0.03 % sulphur or a mixture
thereof. Preferably, it contains 60, such as 70, 80 or 90, mass % or more of the defined
basestock or a mixture thereof. The oil of lubricating viscosity may be substantially
all of the defined basestock or a mixture thereof.
[0028] Most preferably, the oil of lubricating viscosity in this invention contains 50 mass
% or more of a basestock containing 50 mass % or more of a basestock containing less
than 90% saturates and greater than 0.03 % sulphur or a mixture thereof. Preferably,
it contains 60, such as 70, 80 or 90, mass % or more of the defined basestock or a
mixture thereof. The oil of lubricating viscosity may be substantially all of the
defined basestock or a mixture thereof.
[0029] The composition may have a TBN in the range of 20-60, preferably 25-55.
DETERGENT SYSTEM
[0030] A metal detergent is an additive based on so-called metal "soaps", that is metal
salts of acidic organic compounds, sometimes referred to as surfactants. They generally
comprise a polar head with a long hydrophobic tail. Overbased metal detergents, which
comprise neutralized metal detergents as the outer layer of a metal base (e.g. carbonate)
micelle, may be provided by including large amounts of metal base by reacting an excess
of a metal base, such as an oxide or hydroxide, with an acidic gas such as carbon
dioxide.
[0031] In the present invention, detergents (i) and (ii) of the invention are overbased
alkyl-substituted hydroxybenzoate calcium salts, preferably alkyl-substituted salicylate
calcium salts.
[0032] A salicylate detergent of such a system typically has the structure shown:
wherein R is a linear alkyl group. There may be more than one R group attached to
the benzene ring. The COO
- group can be in the ortho, meta or para position with respect to the hydroxyl group;
the ortho position is preferred. The R group can be in the ortho, meta or para position
with respect to the hydroxyl group.
[0033] In (i), R has 20-28, preferably 20-24, carbon atoms. In (ii), R has 14-18 carbon
atoms. Each of (i) and (ii) may be mixtures.
[0034] Salicylic acids are typically prepared by the carboxylation, by the Kolbe-Schmitt
process, of phenoxides, and in that case, will generally be obtained (normally in
a diluent) in admixture with uncarboxylated phenol. Salicylic acids may be non-sulphurized
or sulphurized, and may be chemically modified and/or contain additional substituents.
Processes for sulphurizing an alkyl salicylic acid are well known to those skilled
in the art and are described, for example, in
US 2007/0027057.
[0035] The term "overbased" is generally used to describe metal detergents in which the
ratio of the number of equivalents of the metal moiety to the number of equivalents
of the acid moiety is greater than one. The term 'low-based' is used to describe metal
detergents in which the equivalent ratio of metal moiety to acid moiety is greater
than 1, and up to about 2.
[0036] The basicity of the detergents may be expressed as a total base number (TBN). A total
base number is the amount of acid needed to neutralize all of the basicity of the
overbased material. The TBN may be measured using ASTM standard D2896 or an equivalent
procedure. The detergents, as stated, each have a TBN of below 250; for example the
TBN is in the range of 60 to 250, preferably 150 to 250.
[0037] The wt % Ca ratio of (ii) to (i) is as stated greater than one, for example in the
range of 1 to 50, preferably 1 to 3.
[0038] The treat rate of the detergent system contained in the lubricating oil composition
may for example be in the range of 1 to 25, preferably 2 to 20, more preferably 5
to 18, mass %.
CO-ADDITIVES
[0039] The lubricating oil composition of the invention may comprise further additives,
different from and additional to the detergent system. Such additional additives may,
for example include ashless dispersants, other metal detergents, antiwear agents such
as zinc dihydrocarbyl dithiophosphates, anti-oxidants and demulsifiers. In some cases,
an ashless dispersant need not be provided.
[0040] It may be desirable, although not essential, to prepare one or more additive packages
or concentrates comprising the additives, whereby the detergent system can be added
simultaneously to the base oil to form the lubricating oil composition. Dissolution
of the additive package(s) into the lubricating oil may be facilitated by solvents
and by mixing accompanied with mild heating, but this is not essential. The additive
package(s) will typically be formulated to contain the additive(s) in proper amounts
to provide the desired concentration, and/or to carry out the intended function in
the final formulation when the additive package(s) is/are combined with a predetermined
amount of base oil. Thus, the detergent system, in accordance with the present invention,
may be admixed with small amounts of base oil or other compatible solvents together
with other desirable additives to form additive packages containing active ingredients
in an amount, based on the additive package, of, for example, from 2.5 to 90, preferably
from 5 to 75, most preferably from 8 to 60, mass % of additives in the appropriate
proportions, the remainder being base oil.
[0041] The final formulations as a trunk piston engine oil may typically contain 30, preferably
10 to 28, more preferably 12 to 24, mass % of the additive package(s), the remainder
being base oil.
[0042] The present invention is illustrated by but in no way limited to the following examples.
EXAMPLES
COMPONENTS
[0043] The following components were used:
Detergent (ii):
[0044]
A: |
a calcium alkylsalicylate detergent of TBN 225 and whose alkyl group has 14-18 carbon
atoms. |
B: |
a calcium alkylsalicylate detergent of TBN 350 whose alkyl group has 14-18 carbon
atoms. |
C: |
a calcium alkylsalicylate detergent of TBN 64 and whose alkyl group has 14-18 carbon
atoms. |
Detergent (i): |
a calcium alkylsalicylate detergent of TBN 223 whose alkyl group has 20-24 carbon
atoms |
Base oil I: |
solvent-extracted API Group I base oil |
HFO: |
a heavy fuel oil (ISO-F-RMK 380) |
LUBRICANTS
[0045] Selections of the above components were blended to give a range of trunk piston marine
engine lubricants. Some of the lubricants are examples of the invention; others are
reference examples for comparison purposes. The compositions of the lubricants tested
are shown in the tables below under the "Results" heading. Each lubricant had a TBN
of about 40. Each lubricant also contained the same amount of HFO.
TESTING
Light Scattering
[0046] Test lubricants were evaluated for asphaltene dispersancy using light scattering
according to the Focused Beam Reflectance Method ("FBRM"), which predicts asphaltene
agglomeration and hence 'black sludge' formation.
[0048] The FBRM probe contains fibre optic cables through which laser light travels to reach
the probe tip. At the tip, an optic focuses the laser light to a small spot. The optic
is rotated so that the focussed beam scans a circular path between the window of the
probe and the sample. As particles flow past the window, they intersect the scanning
path, giving backscattered light from the individual particles.
[0049] The scanning laser beam travels much faster than the particles; this means that the
particles are effectively stationary. As the focussed beam reaches one edge of the
particle the amount of backscattered light increases; the amount will decrease when
the focussed beam reaches the other edge of the particle.
[0050] The instrument measures the time of the increased backscatter. The time period of
backscatter from one particle is multiplied by the scan speed and the result is a
distance or chord length. A chord length is a straight line between any two points
on the edge of a particle. This is represented as a chord length distribution, a graph
of numbers of chord lengths (particles) measured as a function of the chord length
dimensions in microns. As the measurements are performed in real time, the statistics
of a distribution can be calculated and tracked. FBRM typically measures tens of thousands
of chords per second, resulting in a robust number-by-chord length distribution. The
method gives an absolute measure of the particle size distribution of the asphaltene
particles.
[0051] The Focused beam Reflectance Probe (FBRM), model Lasentec D600L, was supplied by
Mettler Toledo, Leicester, UK. The instrument was used in a configuration to give
a particle size resolution of 1 µm to 1mm. Data from FBRM can be presented in several
ways. Studies have suggested that the average counts per second can be used as a quantitative
determination of asphaltene dispersancy. This value is a function of both the average
size and level of agglomerate. In this application, the average count rate (over the
entire size range) was monitored using a measurement time of 1 second per sample.
[0052] The test lubricant formulations were heated to 60°C and stirred at 400rpm; when the
temperature reached 60°C the FBRM probe was inserted into the sample. An aliquot of
heavy fuel oil (10% w/w) was introduced into the lubricant formulation under stirring
using a four-blade stirrer (at 400 rpm). A value for the average counts per second
was taken when the count rate had reached an equilibrium value (typically after 30
minutes).
RESULTS
Light Scattering
[0053] The results of the FBRM tests are summarized in TABLE 1 below, where lower particle
count indicates better performance.
[0054] Example 1 is an example of the invention and Examples A-F are comparison examples.
RESULTS
[0055]
Example |
C14-18 alkyl salicylate (225) (ii) A |
C14-18 alkyl salicylate (350) (ii) B |
C14-18 alkyl salicylate (64) (ii) C |
C20-24 alkyl salicylate (223) (i) |
|
Ca ratio (ii) to (i) |
Lasentec Count |
1 |
10.00 |
- |
- |
7.90 |
|
1.28 |
40.1 |
A |
- |
8.40 |
- |
5.00 |
|
2.65 |
377.7 |
B |
- |
6.00 |
- |
8.50 |
|
1.11 |
333.8 |
C |
- |
3.00 |
- |
13.00 |
|
0.36 |
700.2 |
D |
- |
- |
- |
17.94 |
|
- |
243.4 |
E |
5.00 |
8.30 |
- |
- |
|
- |
1037.6 |
F |
- |
9.80 |
10.00 |
- |
|
- |
187.8 |
Numbers in parentheses after the salicylate are TBN's. |
[0056] As shown above, the lowest Lasentec count is achieved by the use of Example 1 which
falls within the invention. (Lower particle count indicates better performance.)
1. A method for improving asphaltene dispersancy in a trunk piston marine engine, the
method comprising lubricating the engine with a lubricating oil composition comprising
a detergent system that includes (i) an overbased alkyl-substituted hydroxybenzoate
calcium salt of TBN less than 250, which alkyl group has 20-28 carbon atoms, and (ii)
an overbased alkyl-substituted hydroxybenzoate calcium salt of TBN less than 250,
which alkyl group has 14-18 carbon atoms; the wt% Ca ratio of (ii) to (i) being greater
than one.
2. The method of claim 1, where the hydroxybenzoates, (i) and (ii), are each salicylates.
3. The method of claims 1 or 2, where the alkyl group(s) of (i) has 20-24 carbon atoms.
4. The method of any claims 1-3, where the composition has a TBN in the range of 20-60,
preferably 25-55.
5. The method of any one of claims 1-4, where the wt% Ca ratio is in the range 1 to 50,
preferably 1 to 3.
6. The method of any one of claims 1-5, where the composition comprises an oil of a lubricating
viscosity, in a major amount, containing 50 mass% or more of a basestock containing
less than 90% saturates and/or greater than 0.03 percent sulphur.
7. The method of any one of claims 1-5, where the composition comprises an oil of a lubricating
viscosity, in a major amount, containing 50 mass% or more of a basestock containing
greater than or equal to 90% saturates and less than or equal to 0.03% sulphur.
8. The use of a detergent system that includes (i) an overbased alkyl-substituted hydroxybenzoate
calcium salt of TBN less than 250, which alkyl group has 20-28 carbon atoms, in a
trunk piston marine lubricating oil composition for a medium-speed compression-ignited
marine engine during operation of the engine, where the detergent system further comprises
(ii) an overbased alkyl-substituted hydroxybenzoate calcium salt of TBN less than
250, which alkyl group has 14-18 carbon atoms, the wt% Ca ratio of (ii) to (i) being
greater than one, said use being to improve the asphaltene dispersancy performance
of the composition.
9. The use of a detergent system that includes (i) an overbased alkyl-substituted hydroxybenzoate
calcium salt of TBN less than 250, which alkyl group has 20-28 carbon atoms, in a
trunk piston marine lubricating oil composition for a medium-speed compression-ignited
marine engine during operation of the engine, fueled by a heavy fuel oil, and its
lubrication by the composition, where the detergent system further comprises (ii)
an overbased alkyl-substituted hydroxybenzoate calcium salt of TBN less than 250,
which alkyl group has 14-18 carbon atoms, the wt% Ca ratio of (ii) to (i) being greater
than one, said use being to improve the asphaltene dispersancy performance of the
composition in comparison with that of analogous operation using a detergent system
whose wt% Ca ratio is one or less and/or where (ii) has a TBN of 250 or greater.