Production of shear-stable high viscosity PAO

Patent metadata

Field	Value
Publication number	US-9365663-B2
Application number	US-38879409-A
Country	US
Kind code	B2
Filing date	Feb 19, 2009
Priority date	Mar 31, 2008
Publication date	Jun 14, 2016
Grant date	Jun 14, 2016

Abstract

The invention is directed to a process for the preparation of high viscosity lubricant base stocks by contacting alphaolefin feedstocks with single-site metallocene catalysts in a mixed flow or continuous stirred tank reactors.

First claim

What is claimed is:

1. A process for preparing a high viscosity PAO base stock, comprising contacting a catalyst system comprising a single-site metallocene and a non-coordinating anion (NCA) with a feedstock consisting of linear alpha-olefins and optionally water at a concentration of less than 10 ppm by weight in a continuous stirred tank reactor (CSTR) operation to obtain a PAO crude product, wherein said feedstock is selected from the group consisting of:
(i) a mixed feedstock consisting essentially of C10 and C12 alpha-olefins comprising from about 1 wt % to 90 wt % of 1-decene; (ii) a mixed feedstock consisting essentially of C12 to C14 alpha-olefins; (iii) a mixed feedstock consisting essentially of C6, C10, and C14 alpha-olefins comprising from about 1 wt % to 90 wt % of 1-decene; and (iv) a mixed feedstock consisting essentially of C6, C10, C12, and C14 alpha-olefins comprising from about 1 wt % to 90 wt % of 1-decene, and
obtaining a high viscosity PAO base stock from the PAO crude product; wherein the high viscosity PAO base stock is characterized by a KV 100 of greater than 10 to about 10,000 cSt, and a MWD of 1.76 or less, where KV 100 is kinematic viscosity measured at 100° C. in cSt.

2. The process according to claim 1 , wherein obtaining the high viscosity PAO base stock from the crude product includes a step of hydrogenating the PAO crude product.

3. The process according to claim 1 , wherein the PAO crude product comprises particles having a mean diameter of >4 microns and at least one of Al, Zr, Si, and B, and the step of obtaining the high viscosity PAO base stock includes a step of filtering the PAO crude product and the high viscosity PAO base stock comprises less than 1000 ppm by weight of the particles having a mean diameter of >4 microns and less than 1 ppm by weight of said at least one of Al, Zr, Si, and B.

4. The process according to claim 1 , wherein the high viscosity PAO base stock is characterized by a KV 100 of greater than 10 to about 300 cSt, a MWD of 1.76 or less, and a Viscosity Index of 195-220.

5. The process according to claim 1 , wherein the high viscosity PAO base stock is characterized by a KV 100 of about 20 to about 250 cSt, and a MWD of 1.76 or less.

6. The process according to claim 1 , wherein the high viscosity PAO base stock is characterized by a KV 100 of about 90 to about 160 cSt, and a MWD of 1.76 or less.

7. The process according to claim 1 , wherein the high viscosity PAO base stock is characterized by a KV 100 of about 250 to about 900 cSt, and a MWD of 1.76 or less.

8. The process according to claim 1 , wherein the high viscosity PAO base stock is characterized by a KV 100 of about 300 to about 650 cSt, and a MWD of 1.76 or less.

9. The process according to claim 1 , including:
(a) a step of drying an olefin feedstock precursor over molecular sieves to obtain the feedstock wherein the feedstock has a water content of less than 10 ppm by weight;
(b) contacting the feedstock from step (a) with the catalyst system, wherein the catalyst system further comprises a trialkyl aluminum co-activator and the PAO crude product further comprises particles having a mean diameter of >4 microns and at least one of Al, Zr, Si, and B, wherein the step of obtaining the high viscosity PAO base stock includes:
(c) separating said PAO crude product from step (b) from said catalyst system;
(d) distilling said PAO crude product to obtain a crude lubricant range PAO;
(e) filtering said crude lubricant range PAO to obtain the high viscosity PAO base stock, wherein the high viscosity PAO base stock comprises less than 1000 ppm of the particles having a mean diameter of >4 microns and less than 1 ppm by weight of said at least one of Al, Zr, Si, and B.

10. The process according to claim 1 , wherein the high viscosity PAO base stock is characterized by a MWD that is at least 10 percent less than MWD=0.41667+[0.725*log KV 100 ].

11. A lubricant comprising a high viscosity PAO base stock made by the process of claim 1 , wherein the lubricant is a gear oil, bearing oil, circulating oil, compressor oil, hydraulic oil, turbine oil, or machinery grease.

12. The process according to claim 1 , wherein the high viscosity PAO base stock is characterized by a MWD that is at least 10 percent less than MWD=0.66017+[0.44922*log KV 100 ].

13. The process according to claim 2 , wherein after hydrogenation, the high viscosity PAO base stock has a bromine number below 1.

Assignees

• Hagemeister Mark Paul
• Jiang Peijun
• Wu Margaret M
• Yang Norman
• Exxonmobil Chem Patents Inc

Inventors

• Hagemeister Mark Paul
• Jiang Peijun
• Wu Margaret M
• Yang Norman

Classifications

• C08F10/08

  Butenes · CPC title

• C08F2500/03

  Narrow molecular weight distribution, i.e. Mw/Mn < 3 · CPC title

• C08F2/00

  Processes of polymerisation · CPC title

• C08F10/14 Primary

  Monomers containing five or more carbon atoms · CPC title

• C08F210/14

  Monomers containing five or more carbon atoms · CPC title