METHOD AND USE FOR THE PREVENTION OF FUEL INJECTOR DEPOSITS

Abstract
A method of substantially removing, or reducing the occurrence of, injector deposits in a diesel engine operated using a diesel fuel containing a minor amount of a metal-containing species is disclosed. The method comprises adding to the diesel fuel a salt formed by the reaction of a carboxylic acid with di-n-butylamine or tri-n-butylamine, wherein the diesel engine is equipped with fuel injectors having a plurality of spray-holes, each spray-hole having an inlet and an outlet, and wherein the fuel injectors have one or more of the following characteristics: (i) spray-holes which are tapered such that the inlet diameter of the spray-holes is eater than the outlet diameter; (ii) spray-holes having an outlet diameter of 0.10 mm or less; (iii) spray-holes where an inner edge of the inlet is rounded; (iv) 6 or more spray-holes; (v) an operating tip temperature in excess of 250° C.
Description
EXAMPLE

Rape seed oil fatty acid (ROFA) (50.0 g, 173 mmoles) was added to a beaker with stirring. Di-n-butylamine (22.36 g, 173 mmoles) was then added to the beaker. An exotherm of was measured indicating that the two components reacted. FTIR analysis of the reaction product showed a reduction in the strong carboxylic acid peak at 1710 cm−1 compared to the starting acid, and a corresponding appearance of carboxylate antisymmetric and symmetric stretches at 1553 and 1399 cm−1 as well as the appearance of a broad range of peaks 2300-2600 cm−1 assignable to ammonium species. This was a clear indication of the formation of a salt.


Test Protocol


The protocol used is described by Graupner et al. “Injector deposit test for modern diesel engines”, Technische Akademie Esslingen, 5th International Colloquium, 12-13 Jan. 2005, 3.10, p157, Edited by Wilfried J Bartz. Briefly, the protocol aims to replicate the operating conditions in a modern diesel engine with an emphasis on the fuel injector tip. The test is split into five stages:

    • a) an iso-speed measurement of engine power output
    • b) an 8 hour endurance run
    • c) an extended soaking period (3 to 8 hours) during which the engine is stopped and allowed to cool
    • d) a second 8 hour endurance run
    • e) an iso-speed measurement of engine power output.


For the data presented herein, the five stages above were used however, stages b), c) and d) can be repeated any number of times to suit the testing programme being undertaken. Also, stages a) and e) may be omitted but are useful to improve understanding of the results. Results are reported as the difference between the average torque at the start of the test during stage a) and the average torque at the end of the test during stage e). Alternatively, if the isospeed procedure is not run, the measured difference between starting torque at full load/full speed and final load/speed can be used. Differences in smoke production are also noted. The formation of injector deposits will have a negative influence on the final power output and will increase the amount of smoke observed. The injectors used had the physical characteristics (i)-(v) described above.


To replicate the conditions expected in a modern diesel engine, a small amount of metal contamination in the form of zinc neodecanoate is added to the fuel used to ran the engine.


The fuel used was a low-sulphur content diesel fuel with the characteristics shown in Table 1 below.













TABLE 1







Test description
Value
Units




















sulphur content
0.0005
mass %



cetane number
55.4




density @ 15° C.
844.9
kgm−3







distillation characteristics











D5%
204.8
° C.



D10%
211.6
° C.



D20%
222.2
° C.



D30%
232.2
° C.



D40%
242.1
° C.



D50%
252.3
° C.



D60%
262.8
° C.



D70%
275.1
° C.



D80%
290.5
° C.



D90%
315.1
° C.



D95%
337.1
° C.



FBP
353.6
° C.



IBP
179.7
° C.



kinematic viscosity @ 20° C.
3.935
cSt



kinematic viscosity @ 40° C. - D445



cloud point
−14.0
° C.



CFPP
−33.0
° C.










The species were tested using the test protocol described above. Results are given in Table 2 below. A conventional PIBS-PAM detergent was also tested by way of comparison 0.3 ppm of Zn in the form of zinc neodecanoate was added to the fuel for all tests (except for the untreated fuel alone).













TABLE 2








Treat rate wppm




Species
(active ingredient)
Torque loss




















Untreated fuel

4.3%



Untreated fuel + 3 ppm Zn

15.3%



PIBSA-PAM
100
14.0%



PIBSA-PAM
200
8.2%



Salt of Example 1
60
12.5%



Salt of Example 1
180
7.1%










The results show that the addition of zinc to the untreated fuel gives rise to a large increase in torque loss. The commercial PIBSA-PAM detergent only gave a marginal improvement at a treat rate of 100 ppm. The PIBSA-PAM detergent was effective at high treat rate. The salt provided a greater improvement than the commercial detergent, and importantly at a lower treat rate.

Claims
  • 1. A method of substantially removing, or reducing the occurrence of, injector deposits in a diesel engine operated using a diesel fuel containing a minor amount of a metal-containing species, the method comprising adding to the diesel fuel a salt formed by the reaction of a carboxylic acid with di-n-butylamine or tri-n-butylamine, wherein the diesel engine is equipped with fuel injectors having a plurality of spray-holes, each spray-hole having an inlet and an outlet, and wherein the fuel injectors have one or more of the following characteristics: (i) spray-holes which are tapered such that the inlet diameter of the spray-holes is greater than the outlet diameter;(ii) spray-holes having an outlet diameter of 0.10 mm or less;(iii) spray-holes where an inner edge of the inlet is rounded;(iv) 6 or more spray-holes;(v) an operating tip temperature in excess of 250° C.
  • 2. A method according to claim 1, wherein the fuel injectors have at least two, of characteristics (i) to (v).
  • 3. A method according to claim 2 wherein the fuel injectors have at least characteristics (i) and (ii).
  • 4. A method according to claim 1, wherein the carboxylic acid comprises a fatty acid or a mixture of fatty acids, preferably tall oil fatty acid, rape seed oil fatty acid, soy bean fatty acid or sunflower oil fatty acid.
  • 5. A method according to claim 1 wherein the salt is added to the diesel fuel in an amount of between 20 and 400 ppm by weight, based on the weight of the fuel.
  • 6. A method according to claim 1 wherein the metal-containing species comprises zinc, copper, iron, lead, cerium a Group I or II metal, platinum or manganese.
  • 7. A method according to claim 6 wherein the metal-containing species comprises zinc.
  • 8. A method according to claim 1 wherein the metal-containing species comprises a fuel-borne catalyst.
  • 9. A method according to claim 1 wherein the amount of metal-containing species in the diesel fuel, expressed in terms of the total weight of metal in the species, is between 0.1 and 50 ppm by weight, based on the weight of the diesel Fuel.
  • 10. A method according to claim 1, wherein the diesel fuel does not contain an alcohol component.
Priority Claims (1)
Number Date Country Kind
06120323.8 Sep 2006 EP regional