Mobil Oil Corporation

Mobile Oil Corporation

Bruce P Pelrine

Nai Y Chen

James C Vartuli

Margaret M Wu

Kirk D Schmitt

Clarence D Chang

Thomas F Degnan

Jeffrey S Beck

Sharon B McCullen

David C Calabro

Tsoung Y Yan

Emmerson Bowes

Thomas R Forbus, Jr

Scott S Han

Quang N Le

Dennis E Walsh

Stephen M Oleck

Richard F Socha

Michael E Landis

Suzzy C Ho

Joosup Shim

Andrew Jackson

Alice S Chu

Cynthis T Chu

Susan M Leiby

The invention includes a ZSM-5 composition and the preparation thereof which comprises treating ZSM-5 with solutions of salts of weak acids. The resulting ultrasmall crystal size ZSM-5 component has a sorption capacity for 2,2-dimethylbutane of at least 10 mg/g zeolite and a sorption time for 30% capacity zeolitic sorption at 60.degree. C. and P(2,2-dimethylbutane) of 60 torr, of less than about 4 minutes.

Activation of zeolites

A catalyst for oligomerizing alpha olefins to produce hydrocarbon oligomers useful as lubricants and lubricant additives comprises a supported reduced Group VIB metal, preferably chromium, in the form of its oxide. The support is a mesoporous, inorganic, crystalline solid of unique structure, of novel pore geometry. The preferred forms of these mesoporous materials are characterized by substantially uniform hexagonal honeycomb microstructure, with uniform pores having a cell diameter greater than 13 .ANG., preferably in the mesoporous range of about 20-100 .ANG.. The use of the catalysts made with the mesoporous support materials enables products of greater viscosity to be made as compared to the products from catalysts using amorphous supports. The catalyst is usually used under oligomerization conditions at a temperature of about 90.degree. to 250.degree. C. to produce liquid hydrocarbon oligomers in the lubricant range which have a branch ratio of less than 0.19 and high values of viscosity index.

Olefin oligomerization catalyst

A process is provided for separating at least one component from a mixture of components which comprises contacting the mixture with a composition comprising a functionalized inorganic, porous, non-layered crystalline phase having uniformly sized pores of at least about 13, e.g., at least about 15, Angstrom Units in diameter.

Sorption separation over modified synthetic mesoporous crystalline

A process is provided for effecting catalytic conversion of an organic compound-containing feedstock to conversion product which comprises contacting said feedstock under catalytic conversion conditions with a catalyst comprising an active form of a functionalized inorganic, porous, non-layered crystalline phase having uniformly sized pores of at least about 13, e.g., at least about 15, Angstrom Units in diameter.

Catalytic conversion over modified synthetic mesoporous crystalline

It is disclosed that aromatic compounds can be alkylated with mono-olefinic HVI-PAO dimer in contact with an acidic catalyst to produce novel alkylated aromatic compositions. It has been found that the novel HVI-PAO dimer alkylated aromatic compositions exhibit an extraordinary combination of properties relating to low viscosity with high viscosity index and low pour point which renders them very useful as lubricant basestock. Further, it has been found that the novel alkylaromatic compositions of the present invention show improved oxidative stability. Depending upon the substituent groups on the aromatic nucleus, useful lubricant additives can be prepared for improved antiwear, antioxidant and other properties. HVI-PAO dimer is prepared as a product or by-product from 1-alkene oligomerization using reduced chromium oxide on solid support.

Alkylaromatic lubricants from alpha-olefin dimer

A novel composition is disclosed that is particularly useful as a lubricant viscosity index improver. The composition comprises branched C.sub.30 -C.sub.10000 hydrocarbons that have a branch ratio of less than 0.19 and viscosity at 100.degree. C. between 725 cS and 15,000 cS. The novel compositions comprise the product of the oligomerization of C.sub.6 to C.sub.20 alpha-olefin feedstock, or mixtures thereof, under oligomerization conditions at a temperature between -20.degree. C. and +90.degree. C. in contact with a reduced valence state Group VIB metal catalyst on porous support. The compositions have viscosities at 100.degree. C. between 725 cS and 15,000 cS. Using the foregoing compositions in admixture with mineral oil and synthetic lubricants provides novel lubricant blends that show an elevated viscosity index. The mixtures also show an increased stability to shear stress at high temperature with all blends notable by exhibiting Newtonian flow.

VI enhancing compositions and newtonian lube blends

A method is described for modifying an ultra-large pore crystalline material by contacting with a treatment composition M'X'Y'.sub.n wherein M' is an element of Groups IIA, IVA, VA, VIA, VIIA, IB, IIB, IVB, VB or VIB; X' is halide, hydride, alkoxide of C.sub.1-6', or acetate; Y' is X or phosphine, sulfide, carbonyl or cyano; and N=1-5. The contacted crystalline material becomes functionalized. The functionalized material is also described and can be used as a sorbent or catalyst component.

Method for functionalizing synthetic mesoporous crystalline material

A novel composition is disclosed that is particularly useful as a lubricant viscosity index improver. The composition comprises branched C.sub.30 -C.sub.10000 hydrocarbons that have a branch ratio of less than 0.19 and viscosity at 100.degree. C. between 725 cS and 15,000 cS. The novel compositions comprise the product of the oligomerization of C.sub.6 to C.sub.20 alpha-olefin feedstock, or mixtures thereof, under oligomerization conditions at a temperature between -20.degree. C. and +90.degree. C. in contact with a reduced valence state Group VIB metal catalyst on porous support. The compositions have viscosities at 100.degree. C. between 725 cS and 15,000 cS. Using the foregoing compositions in admixture with mineral oil and synthetic lubricants provides novel lubricant blends that show an elevated viscosity index. The mixtures also show an increased stability to shear stress at high temperture with all blends notable by exhibiting Newtonian flow.

VI enhancing compositions and Newtonian lube blends

It is disclosed that aromatic compounds can be alkylated with mono-olefinic HVI-PAO dimer in contact with an acidic catalyst to produce novel alkylated aromatic compositions. It has been found that the novel HVI-PAO dimer alkylated aromatic compositions exhibit an extraordinary combination of properties relating to low viscosity with high viscosity index and low pour point which renders them very useful as lubricant basestock. Further, it has been found that the novel alkylaromatic compositions of the present invention show improved oxidative stability. Depending upon the substituent groups on the aromatic nucleus, useful lubricant additives can be prepared for improved antiwear, antioxidant and other properties. HVI-PAO dimer is prepared as a product or by-product from 1-alkene oligomerization using reduced chromium oxide on solid support. Particularly disclosed are the alkylphenols prepared by the process of alkylation a phenol at the aromatic nucleus with the novel oligomer.

Alkylphenol lubricants from alpha-olefin dimer

The thermal and oxidative stability of HVI-PAO olefin oligomers is improved by reaction of the oligomerization mixture containing the olefin oligomer, dimer and isomerized but unoligomerized olefin with an aromatic compound such as toluene, xylene or naphthalene. The reaction is carried out in the presence of an acidic catalyst, which may be heterogeneous solid catalyst such as an acidic clay or a crystalline zeolite such as MCM-22, a homogeneous Friedel-Crafts catalyst such as AlCl.sub.3, BF.sub.3 or their complexes or a supported catalyst such as AlCl.sub.3 on graphite or silica. The reaction improves the yield and thermal stability of the lube range products. The olefinic oligomer mixture which is reacted with the aromatic compound is prepared from 1-alkene oligomerization in contact with a reduced metal oxide, preferably reduced chromium oxide, catalyst on support such as silica.

Process for producing alkylaromatic lubricant fluids

The stability of HVI-PAO olefin oligomers is improved by reaction of the oligomer over an acidic function catalyst which introduces aromatic groups into the oligomer by cracking a portion of the oligomer to form cracking fragments which are then aromatized to aromatics which are subsequently alkylated by the oligomer. This reaction incorporates an aromatic function into the oligomer to produce a modified oligomer product of improved stability. The olefinic oligomers are prepared from 1-alkene by oligomerization in contact with a reduced metal oxide, preferably reduced chromium oxide, catalyst on support such as silica. The products retain the unique features of the olefin oligomer and exhibit high viscosity index and low pour point as well as improved thermal and oxidative stability and additive solvency characteristics resulting from the introduction of aromatic moieties into the structure of the oligomer by the intramolecular dehydrocyclization reaction.

Process for producing lubricant fluids of improved stability

A process for oligomerizing alpha olefins to produce hydrocarbon oligomers useful as lubricants and lubricant additives uses a catalyst comprising a supported reduced group VIB metal, preferably chromium, in the form of its oxide. The support is a mesoporous, inorganic, crystalline solid of unique structure, of novel pore geometry. The preferred forms of these mesoporous materials are characterized by substantially uniform hexagonal honeycomb microstructure, with uniform pores having a cell diameter greater than 13 .ANG., preferably in the mesoporous range of about 20-100 .ANG.. The use of the catalysts made with the mesoporous support materials enables products of greater viscosity to be made as compared to the products from catalysts using amorphous supports. The catalyst is usually used under oligomerization conditions at a temperature of about 90.degree. to 250.degree. C. to produce liquid hydrocarbon oligomers in the lubricant range which have a branch ratio of less than 0.19 and high values of viscosity index.

Production of olefin oligomer lubricants

The disclosure reveals that aromatic structures can be introduced into the molecular structure of polyalpha-olefin lubricant oligomers by subjecting the polyalpha-olefin to a dehydrocyclization reaction which converts a portion of the pendant or branching alkyl groups in the recurring polymeric unit of PAO to aromatic structures. When the starting material for dehydrocyclization is PAO prepared by oligomerization of C.sub.6 -C.sub.20 alpha-olefins in contact with reduced chromium oxide catalyst on porous support the dehydrocyclization reaction produces a lubricant oligomer with increased aromaticity without significantly degrading the viscometric properties of the feedstock lubricant, particularly the high VI of the starting material. The aromatic structures introduced lend increased thermal stability, wear resistance and solubilizing characteristics to the liquid lubricant oligomers so modified. The polyalpha-olefins produced by the dehydrocyclization process comprise novel compositions of matter containing up to five weight percent of aromatic structure attached as pendant groups to the backbone of the polyalpha-olefin structure.

Dehydrocyclization of polyalpha-olefin lubricants

The thermal and oxidative stability of HVI-PAO olefin oligomers is improved by alkylation in the presence of a solid, porous, acidic alkylation catalyst defined by a specific X-ray diffraction pattern. A preferred catalyst is the synthetic zeolite MCM-22. The olefinic oligomers used as alkylating agents are prepared from 1-alkene oligomerization in contact with a reduced metal oxide, preferably reduced chromium oxide, catalyst on support such as silica. Aromatics which may be used in the reaction include monocyclic aromatics such as benzene and toluene as well as bicyclic aromatics such as naphthalene. Substituted aromatics may be used in order to introduce functional groups such as hydroxyl groups into the products, for example by the use of hydroxyaromtics such as phenol or naphthaol. The alkylated aromatic hydrocarbon products retain the unique features of the alkylating olefinic oligomer and exhibit high viscosity index and low pour point as well as improved thermal and oxidative stability and additive solvency characteristics.

The thermal stability of synthetic lubricants composed of alpha-olefin oligomers is improved by reaction with an olefin such as decene or the lower molecular weight, non-lubricant range olefins produced in the course of the oligomerization of 1-alkenes. The alkylation of the lube range oligomer is carried out using acidic alkylation catalyst such as solid, open-pore catalyst, e.g., fluorided alumina. The improved lubricant compositions of the present invention comprise a high viscosity index liquid lubricant oligomer composition containing C.sub.30 -C.sub.1300 hydrocarbons with at least one higher alkyl branch per oligomer molecule, said alkyl branch containing between 12 and 40 carbon atoms. In a preferred embodiment the novel alkylated lubricant composition has a methyl to methylene branch ratio of less than 0.19 and pour point below -15.degree. C.

Growing community of inventors

Trenton, NJ, United States of America

Bruce P Pelrine