Synthetic polyolefin lubricant blends

Abstract

Synthetic lubricant blends exhibiting superior lubricant properties such as high viscosity index, including mixtures of oligomeric products of shape selective catalysis with other lubricants, such as high viscosity index poly-alpha-(.alpha.-)olefins lubricant basestock, conventional poly(.alpha.-olefin) and/or other liquid lubricant basestock material.Preferred lubricant mixtures comprise hydrogenated components:a) a low viscosity C.sub.20 -C.sub.60 lubricant range liquid comprising substantially linear hydrocarbon moietoes prepared by shape selective catalysis of lower olefin with medium pore acid zeolite catalyst to provide substantially linear liquid olefinic intermediates or C.sub.20.sup.+ lubricants, said lubricant range liquid having a kinematic viscosity of about 2-10 cS at 100.degree. C.; andb) at least one poly(.alpha.-olefin) having viscosity greater than 20 cS and viscosity index improvement properties.

Description

BACKGROUND OF THE INVENTION

This invention relates to synthetic lubricant compositions. In zeolite catalyzed oligomerization of propylene or other lower olefins to produce high viscosity index (HVI) lubricant range hydrocarbons in the C.sub.20 -C.sub.60 range by shape selective catalysis, it has been observed that the average molecular weights of the lube products that give viscosities greater than 6 cS at 100.degree. C. are not easily obtainable, due to diffusion limitation imposed by the medium pore catalyst structure. While these low cost lubricants can be made by the Mobil Olefins to Lubricants ("MOL") process, it may be necessary to add viscosity improvers to obtain acceptable lubricant formulations. Synthetic hydrocarbon fluids have found increasing use as lubricant basestocks, additives and functional fluids. Automotive lubricants based on .alpha.-olefin oligomers have been commercially available for over a decade, preceded by many years of research to develop economic synthetic oils with improved viscosity index (VI), volatility, oxidation stability and lower temperature fluidity than naturally occurring mineral oils or those produced from refining of petroleum. Particular attention has been directed to upgrading low cost refinery olefins, such as C.sub.3 -C.sub.4 byproducts of heavy oil cracking processes. Work by Garwood, Chen, Tabak and others has led to development of a useful process for producing lubricant range hydrocarbons by shape selective catalysis using medium pore ZSM-5 by the "MOL" process described herein.

Synthetic poly-alpha-(.alpha.-)olefins (PAO), such as 1-decene oligomers, have found wide acceptability and commercial success in the lubricant field for their superiority to mineral oil based lubricants. In terms of lubricant properties improvement, industrial research effort on synthetic lubricants has led to PAO fluids exhibiting useful viscosities over a wide range of temperature, i.e., improved viscosity index (VI), while also showing lubricity, thermal and oxidative stability and pore point equal to or better than mineral oil. These relatively new synthetic lubricants lower mechanical friction, enhancing mechanical efficiency over the full spectrum of mechanical loads from worm gears to friction drives and do so over a wider range of ambient operating conditions than mineral oil. The PAO's are prepared by the polymerization of 1-alkenes using typically Lewis acid or Ziegler-catalysts. Their preparation and properties are described by J. Brennan in Ind. Eng. Chem. Prod. Res. Dev. 1980, 19, pp 2-6, incorporated herein by reference in its entirety. PAO incorporating improved lubricant properties are also described by J. A. Brennan in U.S. Pat. Nos. 3,382,291, 3,742,082, and 3,769,363, incorporated herein by reference.

In accordance with customary practice in the lubricants art, PAO's have been blended with a variety of functional chemicals, oligomeric and high polymers and other synthetic and mineral oil based lubricants to confer or improve upon lubricant properties necessary for applications such as engine lubricants, hydraulic fluids, gear lubricants, etc. Blends and their components are described in Kirk-Othmer Encyclopedia of Chemical Technology, third edition, volume 14, pages 477-526, incorporated herein by reference. A particular goal in the formulation of blends is the enhancement of viscosity index (VI) by the addition of VI improvers which are typically high molecular weight synthetic organic molecules. While effective in improving viscosity index, these VI improvers have been found to be deficient in that their very property of high molecular weight that makes them useful as VI improvers also confers vulnerability in shear stability to the blended materials during actual use applications. This deficiency dramatically negates the range of application usefulness for many VI improvers. Their usefulness is further compromised by cost since they are relatively expensive polymeric substances that may constitute a significant proportion of the final lubricant blend. Accordingly, workers in the lubricant arts continue to search for lubricant blends with high viscosity index less vulnerable to degradation by shearing forces in actual use applications while maintaining other important properties such as thermal and oxidative stability.

Blending the conventional low viscosity PAO with MOL type oligomers, as described above, produces mixtures which have aggregative properties of the blended components.

Recently, a novel class of PAO lubricant liquid compositions, herein referred to as "HVI-PAO", exhibiting surprisingly high viscosity indices has been reported by M. M. Wu in U.S. Pat. Nos.4,827,064 and 4,827,073, incorporated herein by reference. These novel PAO lubricants are particularly characterized by low ratio of methyl to methylene groups, i.e., low branch ratios, as further described hereinafter. Their very unique structure provides new opportunities for the formulation of distinctly superior and novel lubricant blends. It has been found that these HVI-PAO type synthetic polymeric components, when admixed with relatively low viscosity MOL type oligomeric base stock oil, provides greatly enhanced VI of the blend of materials along with shear stability. This enhanced viscosity property is substantially greater than would be expected from a knowledge of the properties of the individual components. Accordingly, it is an object of the present invention to provide novel lubricant compositions having improved viscosity index and shear stability. It is a further object of the present invention to provide novel lubricant basestock blends from low viscosity synthetic MOL liquids and high viscosity PAO and HVI-PAO. In conjunction with a major amount of the MOL liquid hydrocarbons, the PAO additives provide excellent chemical and physical properties.

SUMMARY OF THE INVENTION

Novel compositions have been discovered for a lubricant mixture having enhanced viscosity index. The preferred lubricants comprise: (a) a major amount (typically about 50-95 wt %) of low viscosity C.sub.20 -C.sub.60 lubricant range liquid comprising substantially linear hydrocarbons prepared by shape selective catalysis of lower olefin with medium pore acid zeolite catalyst to provide substantially linear liquid olefinic intermediates or C.sub.20.sup.+ hydrogenated lubricants, said lubricant range liquid having a kinematic viscosity of about 2-10 centistokes (cS) at 100.degree. C.; and (b) a minor amount (typically about 5-20 wt % or between about 1 to 30 wt %) of at least one poly(o-olefin) having viscosity at least 20 cS at 100.degree. C. and viscosity index improvement properties.

Lubricant mixtures having surprisingly enhanced viscosity indices have been discovered comprising hydrogenated oligomeric liquid products of shape selective catalysis in combination with various other lubricant basestock liquids and additives. Unexpectedly, when a low viscosity lubricant is blended with a high viscosity, high VI lubricant produced from .alpha.-olefins containing C.sub.6 to C.sub.20 atoms, the resulting blends have high viscosity indices and low pour points. The blended materials may include HVI-PAO having a branch ratio of less than 0.19. The high viscosity index lubricant produced as a result of blending MOL liquids with HVI-PAO and/or PAO has much lower molecular weight than a conventional polymeric VI improver, thus offering the opportunity of greater shear stability.

The HVI-PAO having a branch ratio of less than 0.19 employed to prepare the blends of the present invention may be comprised of hydrogenated C.sub.30 H.sub.62 hydrocarbons.

DETAILED DESCRIPTION OF THE INVENTION

Preparation of MOL major basestock component

The MOL liquid lubricant range hydrocarbons may be prepared by the processes of Chen et al in U.S. Pat. Nos. 4,520,221 or 4,568,786, incorporated herein by reference. By upgrading propylene or butylenes to substantially linear hydrocarbon moieties in contact with a medium pore shape selective zeolite catalyst, a low cost basestock is produced, suitable for blending with higher viscosity synthetic oils. The shape-selective oligomerization/polymerization catalysts preferred for use herein include the crystalline aluminosilicate zeolites having a silica to alumina molar ratio of at least 12, a constraint index of about 1 to 12 and acid cracking activity of about 50-300. Representative of the ZSM-5 type zeolites are ZSM-5, ZSM-11, ZSM-12, ZSM-23, ZSM-35 and ZSM-48. ZSM-5 is disclosed and claimed in U.S. Pat. No. 3,702,886 and U.S. Pat. No. Re. 29,948; ZSM-11 is disclosed and claimed in U.S. Pat. No. 3,709,979. Also, see U.S. Pat. No. 3,832,449 for ZSM-12; U.S. Pat. No. 4,076,842 for ZSM-23; U.S. Pat. No. 4,016,245 for ZSM-35. The disclosures of these patents are incorporated herein by reference.. A suitable shape selective medium pore catalyst for fixed bed is a small crystal H-ZSM-5 zeolite (silica:alumina ratio=70:1) with alumina binder in the form of cylindrical extrudates of about 1-5 mm. Unless otherwise stated in this description, the catalyst shall consist essentially of ZSM-5, which has a crystallite size of about 0.02 to 0.05 micron. Other pentasil catalysts which may be used in one or more reactor stages include a variety of medium pore (ie-5 to 9A) siliceous materials such as gallosilicates, borosilicates, ferrosilicates, and/or aluminosilicates.

Optional secondary stage catalyst for upgrading linear intermediate oligomeric moities to higher molecular weight C30+components may comprise acid zeolites; however, other acid materials may be employed which catalyze ethylenic unsaturation reactions. Other desirable materials for the secondary reaction include HZSM-12, as disclosed in U.S. Pat. No. 4,254,295 (Tabak) or large-pore zeolites in U.S. Pat. No. 4,430,516 (LaPierre et al). Advantage may be obtained by selecting the same type of unmodified catalyst for both stages. Since the final stage is usually conducted at lower temperature than the initial reaction, higher activity may be maintained in the secondary reactor. However, the second stage catalyst can be any acid catalyst useful for polymerizing olefins. Particularly suitable are unmodified medium pore ZSM-5 type zeolites with a Constraint Index of 1-12, preferably of small crystal size (less than 1 micron). Also suitable are small pore zeolites, e.g., ZSM-34; large pore zeolites, e.g., mordenite, ZSM-4; synthetic faujasite; crystalline silica-aluminophosphates; amorphous silica-alumina; acid clays; organic cation exchange resins, such as cross linked sulfonated polystyrene; and Lewis acids, such as BF.sub.3 or AlCl.sub.3 containing suitable co-catalysts such as water, alcohols, carboxylic acids; or hydrogen halides.

Shape-selective oligomerization, as it applies to the conversion of C.sub.2 -C.sub.10 olefins over ZSM-5, is known to produce higher olefins up to C.sub.30 and higher. As reported by Garwood in Intrazeolite Chemistry 23, (Amer. Chem. Soc., 1983), reaction conditions favoring higher molecular weight product are low temperature (200.degree.-260.degree. C.), elevated pressure (about 2000 kPa or greater), and long contact time (less than 1 WHSV). The reaction under these conditions proceeds through the acid-catalyzed steps of (1) oligomerization, (2) isomerization-cracking to a mixture of intermediate carbon number olefins, and (3) interpolymerization to give a continuous boiling product containing all carbon numbers. The channel systems of ZSM-5 type catalysts impose shape-selective constraints on the configuration of the large molecules, accounting for the differences with other catalysts.

The desired oligomerization-polymerization products include C.sub.20.sup.+ substantially linear aliphatic hydrocarbon moities. The ZSM-5 catalytic path for propylene feed provides a long chain with approximately one lower alkyl (e.g., methyl) substituent per 8 or more carbon atoms in the straight chain.

The hydrogenated intermediate olefin or lubricant range basestock product can be depicted as a typical linear molecule having a sparingly substituted (saturated) long carbon chain. The final molecular conformation is influenced by the pore structure of the catalyst. For the higher carbon numbers, the structure is primarily a methyl-branched straight olefinic chain, with the maximum cross section of the chain limited by the 5.4.times.5.6 Angstrom dimension of the largest ZSM-5 pore. Although emphasis is placed on the normal 1-alkenes as feed stocks, other lower olefins such as 2-butene or isobutylene, are readily employed as starting materials due to rapid isomerization over the acidic zeolite catalyst. At conditions chosen to maximize heavy distillate and lubricant range products (C.sub.20.sup.+) the raw aliphatic product is essentially mono-olefinic. Overall branching is not extensive, with most branches being methyl at about one branch per eight or more atoms.

The viscosity index of MOL hydrocarbon lube oil is related to its molecular conformation. Extensive branching in a molecule usually results in a low viscosity index. It is believed that two modes of oligomerization/polymerization of olefins can take place over acidic zeolites such as HZSM-5. One reaction sequence takes place at Brdnsted acid sites inside the channels or pores, producing essentially linear materials. The other reaction sequence occurs on the outer surface, producing highly branched material. By decreasing the surface acid activity of such zeolites, fewer highly branched products with low VI are obtained.

Several techniques may be used to increase the relative ratio of intra-crystalline acid sites to surface active sites. This ratio increases with crystal size due to geometric relationship between volume and superficial surface area. Deposition of carbonaceous materials by coke formation can also shift the effective ratio. However, enhanced effectiveness is observed where the surface acid sites of small crystal zeolites are reacted with a chemisorbed organic base or the like.

Catalysts of low surface activity can be obtained by using medium pore zeolites of small crystal size that have been deactivated by basic compounds, examples of which are amines, phosphines, phenols, polynuclear hydrocarbons, cationic dyes and others. These compounds have a minimum cross section diameter of 5 Angstroms or greater. Examples of suitable amines are described by Chen et al in U.S. Pat. No. 4,568,786.

The lower molecular weight C.sub.10 -C.sub.20 intermediate materials formed over the modified catalyst are relatively linear olefins. These olefins can be effectively converted to lube range materials by additional polymerization Accordingly, lube range materials can be obtained in accordance with the present invention in a two-stage process. Generally the first stage involves oligomerization of an inexpensive lower olefin of, e.g., propylene at about 200.degree. C. over a surface poisoned HZSM-5. The second stage involves further oligomerization/ interpolymerization of the product (or a fraction of the product) from the first stage over a second and/or different acid catalyst, which may be modified or unmodified as disclosed herein, at about 100.degree.-260.degree. C. The temperature of the second stage is usually lower than that of the first stage, i.e., about 25.degree.-75.degree. C. lower and preferably the catalyst is an unmodified ZSM-5 type catalyst. Both high yields and high VI are achieved by this two-stage process.

Conventional temperatures, pressures and equipment may be used in the novel process disclosed herein. Preferred temperatures may vary from about 100.degree. to about 350.degree. C., preferably 150.degree. to 250.degree. C. pressures from about atmospheric to 20,000 kPa (3000 psi) and WHSV from about 0.01 to about 2.0, preferably 0.2 to 1.0 are employed.

EXAMPLE A

Stage I Processing

Primary stage catalyst (HZSM-5) is pretreated by mixing the catalyst particles with a 10 wt % solution of 2,6-di(t-butyl)-pyridine deactivating agent in hexane, solvent washing and drying to obtain a surface-deactivated material. An olefinic feedstock consisting of 27 weight percent propene, 36.1 wt. % butene, 10.7 wt. % propane and 26.1 wt. % butane is cofed with gasoline recycle in a downflow fixed bed reactor system, as depicted, at 7000 kPa (1000 psig), about 0.4 WHSV and average reactor temperature of 205.degree. C. (400.degree. F.). The deactivating agent is injected with the olefinic feed at a concentration of about 50 weight parts per million, based on fresh feed. The results of the continuous run are shown below.

TABLE I______________________________________Primary Stage Production off Intermediate Hydrocarbon______________________________________Hours on Stream 42-54 114-126Olefin Conv., wt. % 98% 98%Yield, wt. %LPG 4 3Gasoline C.sub.5 -165.degree. C. 31 35Distillate (165-345.degree. C.) 58 57Lubricant range 345.degree. C. 7 5 100% 100%Lube PropertiesViscosity @40.degree. C., cS 14.68 11.97Viscosity @100.degree. C., cS 3.60 3.13V.I. 131 126______________________________________

Stage II Processing

The secondary reactor is charged with unmodified HZSM-5 catalyst having an acid cracking activity (.alpha.-value) of about 250. An enclosed stirred reactor is maintained at an average temperature of about 175.degree. C. under autogenou pressure. The secondary feed is the 165.degree.-345.degree. C. distillate cut from the primary effluent (Table I), which is contacted with catalyst at a 10:1 ratio based on active catalysts at a space velocity of about 0.1 to 0.4 WHSV. The results of this run are tabulated below:

TABLE II______________________________________Hours on Stream 32-54 114-126Yield 650.degree. F..sup.+ Lube 31.5 30.6Lube PropertiesViscosity, cS @40.degree. C. 22.49 21.75Viscosity, cS @100.degree. C. 4.50 4.48V.I. 113 119______________________________________

EXAMPLE B

Stage I

Ten parts by weight of 2,6-di-tert-butylpyridine modified small crystal (0.1 microns) HZSM-5 as prepared in Example A and 100 parts propylene are heated to 200.degree. C. in an autoclave under inert atmosphere with stirring. After 15 hours, the pressure decreases from 1240 to 33 psi, 100 parts propylene are charged and the temperature is adjusted to 200.degree. C. After 29.5 more hours, the pressure decreases from 1150 to 260 psi, 100 parts propylene are again charged and the temperature adjusted to 200.degree. C. After 66.3 hours from the second propylene addition, the reaction is stopped. An oil product, 167.8 gm, was obtained which contained only 2.8% 650.degree. F..sup.+ lube fraction.

Stage II

162 parts by weight of the product from Stage I and 15 parts of unmodified small crystal HZSM-5 zeolite are charged to an autoclave. After flushing the contents with nitrogen, the mixture is heated carefully to 100.degree. C., and maintained 4 days (96 hours). No significant change in the oil takes place as indicated by GC results of samples withdrawn from the reaction mixture. The temperature is raised to 150.degree. C. After 69 hours at 150.degree. C., the 650.degree. F..sup.+ lube yield is determined to be 11.2%; after 92.7 hours, 16.7%; after 116.7 hours, 19.3%; after 140.8 hours, 23%; after 164.7 hours, 26.4%; after 236.7 hours, 31%. The reaction is stopped at this point and 138 gm product were recovered. After distillation, the 650.degree. F..sup.+ lube has kinematic viscosities of 31.1 cS at 40.degree. C., 5.6 cS at 100.degree. C. and a VI of 120. The pour point is -20.degree. F.

EXAMPLE C

Stage I

Oligomers are prepared as described in Example B and fractionated. The fraction containing C.sub.9.sup.= -C.sub.18.sup.= is used in the second stage to yield lube.

Stage II

One hundred parts of the C.sub.9.sup.= -C.sub.18.sup.= fraction from the first stage are cooled to 0.degree.-5.degree. C. in a stirred reactor under dry nitrogen atmosphere. The oligomer mixture is saturated with BF.sub.3. To this BF.sub.3 -olefin mixture is added 10 ml of BF.sub.3 C.sub.4 H.sub.9 OH complex, keeping the temperature of the reaction mixture between 0.degree.-5.degree. C. Samples are withdrawn periodically and their product compositions determined by gas chromatography. The results are tabulated below:

______________________________________Total Time % Conversion to LubeHours 650.degree. F..sup.+ 750.degree. F..sup.+______________________________________0 0 00.5 20.6 12.11.0 28.0 17.52.0 32.5 20.93.0 35.8 23.64.0 36.9 24.45.0 39.2 26.3______________________________________ After 5 hours, the reaction mixture is neutralized with ammonia to form a white solid which is filtered off. The lube is obtained by distillation. The 650.degree. F..sup.+ lube has kinematic viscosities of 32.82 cS at 40.degree. C., 5.00 cS at 100.degree. C. and a VI of 63.

EXAMPLE D

Stage I

Follows the procedure of Example C above.

Stage II

The procedure of Example C is followed, except that the reaction is carried out for 0.5 hours. The 650.degree. F..sup.+ lube (12%) has kinematic viscosities of 12.6 at 40.degree. C., 3.2 cS at 100.degree. C. and a VI of 127.

Examples C and D illustrate that lubes of high viscosities and of high viscosity index can be obtained when adequate reaction conditions are employed, such as by varying the total reaction time.

EXAMPLE E

Stage I

Fifteen parts by weight of large crystal HZSM-5 (1 micron) of relatively low surface acidity and 300 parts propylene are heated to 200.degree. C. in autoclave under inert atmosphere with stirring. After 46 hours the chraged propylene is converted to C.sub.6.sup.= (22.5%), C.sub.9.sup.= (46.5%), C.sub.12.sup.= (12.5), C.sub.15.sup.= (5.5%), C.sub.18.sup.= (4.0%), C.sub.21.sup.= (3 5%) and C.sub.21.sup.= (5.5%). This product mixture is used in the second stage reaction.

Stage II

Seventy parts of the total product from the first stage are heated over 7 parts of small crystal HZSM-5 (0.1 micron) under inert atmosphere at 150.degree. C. The lube conversion is monitored periodically by GC. A conversion of 42% to 650.degree. F..sup.+ lube is accomplished in 180 hours. This lube has kinematic viscosities of 34.25 cS at 40.degree. C., 5.85 cS at 100.degree. C. and a VI of 113.

Various modifications can be made to the system, especially in the choice of equipment and non-critical processing steps.

EXAMPLE F

F.1 Preparation of MOL Lube From Propylene Using Two-Stage Process

Two fixed-bed reactors are used in series with a scrubber between. The first reactor, which has its own outlet and can be isolated from the rest of the system, is loaded with HZSM-5B extrudate catalyst, surface deactivated with 2,6-di(tert-butyl)pyridine (2,6-DTBP). The scrubber contains zeolite beta to remove any eluted 2,6-DTBP. The second reactor contains unmodified HZSM-5B extrudate. Propylene feed containing 100 ppm 2,6-DTBP is injected into the primary reactor, maintained at 800 psig and 230.degree. C. to produce liquid product. Following scrubbing, the liquid is introduced to the second-stage reactor, maintained at 175.degree. C. After reaching equilibrium the liquid products contain 35-40% 650.degree. F..sup.+ lube having a VI range of 115 to 135. After distillation and hydrogenation the lube products are useful for blending with high viscosity PAO basestock A.

F.2 Improvement of Viscosity and Viscosity Index (VI) of a Two-Stage Synthetic Propylene Lube by Blending With High Viscosity High VI Stock A

Stock A is a commercial PAO synthetic oil base stock prepared by acid oligomerization of 1-decene with AlCl.sub.3 type Lewis acid catalyst having a branch ratio greater than 0.19. Blends of different ratios of F.1 two-stage MOL propylene lube and Stock A are prepared by carefully weighing and admixing the two components; and viscosities and VI's well as the pour points are determined by standard methods. The results are summarized in Table F.2.

TABLE F.2______________________________________Properties of Blends of a Two-Stage MOL Propylene Lubeand Stock AComposition, % Viscosity, cSTwo-Stage Lube Stock A 40.degree. C. 100.degree. C. VI Pour, .degree.C.______________________________________100 0 25.55 4.95 119.7 -45.795 5 31.51 5.84 130.296.66 3.34 -47.090 10 -48.30 100 1242.75 100.75 170.2______________________________________

It is clearly shown that the viscosity, VI and pour point of the two-stage propylene lube have been improved by blending with minor amounts of Stock A.

F.3. Improvement of Viscosity and Viscosity Index (VI) of Two-Stage Synthetic Propylene Lubes by Blending With HVI-PAO

Blends of different ratios of two different MOL two-stage propylene lubes and a HVI-PAO are prepared by admixing the two components. The viscosities and VI's are summarized in Table F.3.1 for one propylene lube and Table F.3.2 for the other.

F.3.1.The HVI-PAO is prepared by oligomerizing 1-decene with CrII catalyst as described herein to provide VI improver blending stock. The catalyst used for this synthesis is activated by calcining a 1% Cr on silica precursor (surface area=330 m.sup.2 /g and pore volume=2.3 cc/g) at 700.degree. C. with air for 16 hours and reduced with CO at 350.degree. C. for one hour. The activated catalyst is stored and handled under nitrogen atmosphere.

The catalyst, 10 grams, is added to purified 1-decene, 2000 g, at 125.degree. C. in a 4-liter flask blanked under N2. The reaction mixture is stirred for 16 hours. The lube product is isolated at 90% yield by filtration to remove the solid catalyst and distillation to remove dimer at 120 C/0.1 mmHg. The lube product, after hydrogenation with Ni on Kieselguhr at 180.degree. C. and 450 psi, have Viscosity at 100.degree. C. of 131.5 cS and VI=213.

TABLE F.3.1______________________________________Properties of Blends of Two-Stage Propylene Lubeand a HVI-PAOComposition, % Viscosity, cS Pour,Two-Stage Lube HVI-PAO 40.degree. C. 100.degree. C. VI .degree.C.______________________________________100 0 25.89 4.92 114.4 --98.0 2.0 28.16 5.28 121.5 --94.8 5.2 30.87 5.73 129.0 --89.8 10.2 36.96 6.74 141.3 --80.0 20.0 52.82 9.23 157.8 --60.0 40.0 225.89 32.73 190.5 --40.0 60.0 228.04 32.48 187.6 --0 100.0 1243.2 131.5 213.0 -37______________________________________

F.3.2.The HVI-PAO used in this example is prepared using a catalyst prepared similarly as previously described. The catalyst, 5 grams, is added to purified 1-decene heated to 100.degree. C. After 16 hours reaction, the lube product isolated has viscosity at 100.degree. C. of 324.86cS and VI of 249. It is used in the blending experiment.

TABLE F.3.2______________________________________Composition, % Viscosity, cSTwo-Stage Lube HVI-PAO 40.degree. C. 100.degree. C. VI Pour, .degree.C.______________________________________100 0.0 32.19 5.83 125.3 -4797.6 2.4 34.81 6.25 129.9 -4294.6 5.4 38.16 6.69 132.2 -4492.4 7.6 41.63 7.16 134.4 -4389.8 10.2 45.32 7.65 136.7 -4579.9 20.1 62.10 10.33 154.8 -44______________________________________

It is clearly shown that once two lubes of different viscosities and VI's are synthesized, a wide range of lube viscosities and VI's can be obtained simply by blending.

EXAMPLE G

G.1 Preparation of Lube From Propylene Using Single-Stage Process

This process is a modified MOL systhesis procedure. Milder conditions are used to form products essentially free of aromatics so as not to impart oxidative instability. A single fixed-bed tubular isothermal reactor and unmodified HZSM-5B are used. The temperature is maintained at 200.degree. C. to 220.degree. C. and the weight hourly space velocity is 0.25 to 0.5 WHSV, based on parts by weight of feed olefin per part of total catalyst. The 650.degree. F..sup.+ lube yield is 15-40%, with VI of about 90-105. All lube products are essentially free of aromatics as shown by NMR.

G.2 Blending of Single-Stage Propylene Lubes With HVI-PAO

The blending results are shown in Tables G.2 and G.3.

The HVI-PAO used in Table G.2 is the same as that used in Example F.3.1.

The HVI-PAO used in Table G.3 is the same as that in Example F.3.2.

TABLE G.2______________________________________Properties of Blends of a Single-Stage Propylene Lubeand a HVI-PAOComposition, % Viscosity, cSSingle-Stage Lube HVI-PAO 40.degree. C. 100.degree. C. VI______________________________________100 0 39.16 5.93 91.275.0 25.0 90.99 12.83 138.262.5 37.5 136.53 18.57 153.250.0 50.0 254.35 26.04 132.325.0 75.0 505.11 57.16 181.60 100.0 -- 131.5 213.0______________________________________ TABLE G.3______________________________________Properties of Blends of a Single-Stage Propylene Lubeand a HVI-PAOComposition, % Viscosity, cSSingle-Stage Lube HVI-PAO 100.degree. C. VI______________________________________100 0 4.01 9387 13 7.9 14374 26 13.8 165______________________________________

EXAMPLE H.1

A commercial Cr on silica catalyst which contains 1% Cr on a large pore volume synthetic silica gel is used. The catalyst is first calcined with air at 700.degree. C. for 16 hours and reduced with CO at 350.degree. C. for one to two hours. 1.0 part by weight of the activated catalyst is added to 1-decene of 200 parts by weight in a suitable reactor and heated to 185.degree. C. 1-Decene is continuously fed to the reactor at 2-3.5 parts/minute and 0.5 parts by weight of catalyst is added for every 100 parts of 1-decene feed. After 1200 parts of 1-decene and 6 parts of catalyst are charged, the slurry is stirred for 8 hours. The catalyst is filtered and light product boiled below 150.degree. C. @0.1 mm Hg is stripped. The residual product is hydrogenated with a Ni on Kieselguhr catalyst at 200.degree. C. The finished product has a viscosity at I00.degree. C. of 18.5 cs, VI of 165 and pour point of -55.degree. C.

EXAMPLE H.2

The proceduce of Example H.1 is followed, except reaction temperature is 185.degree. C. The finished product has a viscosity at 100.degree. C. of 145 cs, VI of 214, pour point of -40.degree. C.

EXAMPLE H.3

The procedure of Example H.1 is followed, except reaction temperature is 100 C. The finished product has a viscosity at 100.degree. C. of 298 cs, VI of 246 and pour point of -32.degree. C.

The final lube products in Examples H.1-H.3 contain the following amounts of dimer and trimer and isomeric distribution (distr.).

TABLE H______________________________________ Example H.1 H.2 H.3______________________________________Vcs @100.degree. C. 18.5 145 298VI 165 214 246Pour Point, .degree.C. -55.degree. C. -40.degree. C. -32wt % dimer 0.01 0.01 0.027wt % isomeric distr. dimern-eicosane 51% 28% 73%9-methylnonacosane 49% 72% 27%wt % trimer 5.53 0.79 0.27wt % isomeric distr. trimer11-octyldocosane 55 48 449-methyl,11-octyl- 35 49 40heneicosaneothers 10 13 16______________________________________

These three examples demonstrate that the new HVI-PAO of wide viscosities contain the dimer and trimer of unique structures in various proportions. The molecular weights and molecular weight distributions are analyzed by a high pressure liquid chromatography, composed of a Constametric II high pressure, dual piston pump from Milton Roy Co. and a Tracor 945 LC detector. During analysis, the system pressure is 650 psi and THF solvent (HPLC grade) deliver rate is 1 cc per minute. The detector block temperature is set at 145.degree. C. 50 microliter of sample, prepared by dissolving 1 gram PAO sample in 100 cc THF solvent, is injected into the chromatograph. The sample is eluted over the following columns in series,all from Waters Associates: Utrastyragel 10.sup.5 A, P/N 10574, Utrastyragel 10.sup.4 A, P/N 10573, Utrastyragel 10.sup.3 A, P/N 10572, Utrastyragel 500 A, P/N 10571. The molecular weights are calibrated against commercially available PAO from Mobil Chemical Co, Mobil SHF-61 and SHF-81 and SHF-401.

The following table summarizes the molecular weights and distributions of Examples H.1 to H.3.

______________________________________ Example H.1 H.2 H.3______________________________________V @100.degree. C., cs 18.5 145 298VI 165 214 246number-averaged 1670 2062 5990molecular weights, MW.sub.nweight-averaged 2420 4411 13290molecular weights, MW.sub.wmolecular weight 1.45 2.14 2.22distribution, MWD______________________________________

Under similar conditions, HVI-PAO product with viscosity as low as 3cs and as high as 750 cs, with VI between 130 and 280, can be produced. The use of supported Group VIB oxides as a catalyst to oligomerize olefins to produce low branch ratio lube products with low pour points was heretofore unknown. The catalytic production of oligomers with structures having a low branch ratio which does not use a corrosive co-catalyst and produces a lube with a wide range of viscosities and good V.I.'s was also heretofore unknown and more specifically the preparation of lube oils having a branch ratio of less than about 0.19 was also unknown heretofore.

Pour point and cloud point data for the above examples H.1 and H.3 respectively are given in Table H.4 and H.5 below:

TABLE H.4______________________________________Properties of Blends of a Single-StagePropylene Lube and a HVI-PAOComposition, % Pour, CloudSingle-Stage HVI- Viscosity, cS .degree.C. .degree.C.Lube PAO 40.degree. C. 100.degree. C. VI Point Point______________________________________100 0 28.08 4.88 93.0 -43.4 -28.995 5 35.50 6.05 116.2 -44.5 --90 10 48.02 7.95 136.3 -45.0 -55.080 20 70.39 11.26 152.6 -45.0 -54.8 0 100 3120.0 295.0 245.0 -32.0 --______________________________________ TABLE H.5______________________________________Properties of Blends of a Single-StagePropylene Lube and a HVI-PAOComposition, % Pour, CloudSingle-Stage HVI- Viscosity, cS .degree.C. .degree.C.Lube PAO 40.degree. C. 100.degree. C. VI Point Point______________________________________100 0 28.08 4.88 93.0 -43.4 -28.995 5 34.11 5.79 110.9 -45.0 --90 10 40.97 6.71 118.7 -45.0 --84.5 15.5 47.6 7.80 132.5 -45.4 -55.080 20 59.45 9.51 142.5 -44.5 --0 100 1418.0 145.0 215.0 -40 --______________________________________

Blending Techniques

The synthetic lubricant blending basestocks of the instant invention are obtained by mixing a major amount of low viscosity MOL lubricant basestock, optionally with conventional higher viscosity PAO materials such as BF.sub.3 Lewis acid catalyzed oligomers, and a minor amount (ie--at a weight ratio of about 1:20 to 1:2 based on the major oligomer component) of HVI-PAO having a very high viscosity index. The low viscosity lubricant basestock, typically with a viscosity of about 2 to 10 cS at 100.degree. C., can be predominantly synthetic MOL in mixture with other synthetic lube stock. The high viscosity PAO lubricant basestock, typically with a viscosity of 20 to 1000 cS at 100.degree. C. are produced from .alpha.-olefins, 1-alkenes, of C.sub.6 to C.sub.20, either alone or in mixture. The high viscosity, high VI basestock, HVI-PAO, is further characterized by having a branch ratio of less than 0.19. When the high viscosity PAO basestock is blended with MOL lubricant basestock of low viscostiy, the resultant lubricant has an unexpectedly high viscosity index and low pour points. The PAO is oxidatively and hydrolytically stable, as compared to other V.I. improvers.

The HVI-PAO lubricant blending stock of the present invention may be prepared by the oligomerization of 1-alkenes as described hereinafter, wherein the 1-alkenes have 6 to 20 carbon atoms to give a viscosity range of 20-1000 cS at 100.degree. C. The oligomers may be homopolymers or copolymers of such C.sub.6 -C.sub.20 1-alkenes, or physical mixtures of homopolymers and copolymers. They are preferably homopolymers of 1-decene or mixtures of 1-alkenes having 8 to 12 carbon atoms, characterized by their branch ratio of less than 0.19 and are further characterized as having a number average molecular weight range from 300 to 30,000.

Other useful minor blending components include hydrogenated polyolefins as polyisobutylene and polypropylene and the like, as disclosed in U.S. Pat. No. 4,912,272 (Wu), incorporated by reference. Such polymers may include compositions exhibiting useful lubricant properties or conferring dispersant, anticorrosive or other properties on the blend.

Compositions according to the present invention may be formulated according to known lube blending techniques to combine HVI-PAO components with various phenates, sulphonates, succinamides, esters, polymeric VI improvers, ashless dispersants, ashless and metallic detergents, extreme pressure and antiwear additives, antioxidants, corrosion inhibitors, anti-rust inhibitors, emulsifiers, pour point depressants, defoamants, biocides, friction reducers, anti-stain compounds, etc.

Unless otherwise noted, MOL, PAO and other lubricants discussed herein refer to hydrogenated materials in keeping with the practice of lubricant preparation well known to those skilled in the art.

Sometimes, the oligomeric MOL and PAO, obtained from the individual oligomerization reactions, can be blended together first and then hydrogenate the blend to produce a finished basestock useful for engine oil or industrial oil basestocks.

The following examples illustrate the application of the instant invention in the preparation of HVI-PAO viscosity index improver suitable for mixing with MOL. Blending experiment have the following viscometric properties:

EXAMPLE J

A Cr (1 wt %) on silica catalyst, 4 grams, calcined at 600.degree. C. with air and reduced with CO at 350.degree. C., is mixed with 1-decene, 63 grams in a flask. The mixture is heated in an 100.degree. C. oil bath under N.sub.2 atmosphere for 16 hours. The lube product is obtained by filtration to remove catalyst and distilled to remove components boiling below 120.degree. C. at 0.1 mmHg. The C.sub.30.sup.+ lube product yield is 92%.

EXAMPLE K

Example J is repeated except 1.7 grams of catalyst and 76 grams of 1-decene are heated to 125.degree. C. The lube yield is 86%.

EXAMPLE L

Activated Cr (1 wt %) on silica catalyst, 3 grams, calcined at 500.degree. C. with air and reduced with CO at 350.degree. C., is packed in a stainless steel tubular reactor and heated to 119.degree..+-.3.degree. C. 1-Decene is fed through this reactor at 15.3 grams per hour at 200 psig. After about 2 hours on stream, 27.3 grams of crude product is collected. After distillation, 19 grams of lube product is obtained.

EXAMPLE M

In the same run as the previous example, 108 grams of crude product is obtained after 15.5 hours on stream. After distillation, 86 grams of lube product is obtained.

EXAMPLE N

N.1 Catalyst Preparation and Activation Procedure

1.9 grams of chromium (II) acetate (Cr.sub.2 (OCOCH.sub.3).sub.4.2H.sub.2 O) 5.58 mmole) (commercially obtained) is dissolved in 50 cc of hot acetic acid. Then 50 grams of a silica gel of 8-12 mesh size, a surface area of 300 m.sub.2 /g, and a pore volume of 1 cc/g, also is added. Most of the solution is absorbed by the silica gel. The final mixture is mixed for half an hour on a rotavap at 1 room temperature and dried in an open-dish at room temperature. First, the dry solid (20 g) is purged with N.sub.2 at 250.degree. C. in a tube furnace. The furnace temperature is then raised to 400.degree. C. for 2 hours. The temperature was then set at 600.degree. C. with dry air purging for 16 hours. At this time the catalyst is cooled under N.sub.2 to a temperature of 300.degree. C., and a stream of pure CO (99.99% from Matheson) is introduced for one hour. Finally, the catalyst is cooled down to room temperature under N.sub.2 and ready for use.

EXAMPLE N.2

The catalyst prepared in Example N.1 (3.2 g ) is packed in a stainless steel tubular reactor inside an N.sub.2 blanketed dry box. The reactor under N.sub.2 atmosphere is then heated to 150.degree. C. by a single-zone Lindberg furnace. Pre-purified 1-hexene is pumped into the reactor at 140 psi and 20 cc/hr. The liquid effluent is collected and stripped of the unreacted starting material and the low boiling material at 0.05 mm Hg. The residual clear, colorless liquid has viscosities and VI's suitable as a lubricant base stock.

______________________________________ Sample Prerun N.2.1 N.2.2 N.3______________________________________Time, hr. 2 3.5 5.5 21.5Lube Yield, wt % 10 41 74 31Viscosity, cS, at40.degree. C. 208.5 123.3 104.4 166.2100.degree. C. 26.1 17.1 14.5 20.4VI 159 151 142 143______________________________________

EXAMPLE O

Similar to Example N, a fresh catalyst sample is charged into the reactor and 1-hexene is pumped to the reactor at 1 atm and 10 cc per hour. As shown below, a lube of high viscosities and high VI's was obtained. These runs show that at different reaction conditions, a lube produce of high viscosities can be obtained.

______________________________________ Sample 0.1 0.2______________________________________T.0.S., hrs. 20 44Temp., .degree.C. 100 50Lube Yield, % 8.2 8.0Viscosities, cS at40.degree. C. 13170 19011100.degree. C. 620 1048VI 217 263______________________________________

Example P

A commercially available standard chromium/silica catalyst which contains 1% Cr on a large-pore volume synthetic silica gel is first calcined with air at 800.degree. C. for 16 hours and reduced with CO at 300.degree. C. for 1.5 hours. Then 3.5 g of the catalyst is packed into a tubular reactor and heated to 100.degree. C. under the N.sub.2 atmosphere. 1-Hexane is pumped through at 28 cc per hour at 1 atmosphere. The products were collected and analyzed as follows:

______________________________________ Sample P.1 P.2 P.3 P.4______________________________________Time, hrs. 3.5 4.5 6.5 22.5Lube Yield, % 73 64 59 21Viscosity, cS, at40.degree. C. 2548 2429 3315 9031100.degree. C. 102 151 197 437VI 108 164 174 199______________________________________

These runs show that different Cr on a silica catalyst were also effective for oligomerizing olefins to lube products.

EXAMPLE O

As in Example P, purified 1-decene is pumped through the reactor at 250 to 320 psi. The product is collected periodically and stripped of light products boiling points below 650.degree. F. High quality lubes with high VI are obtained (see following table).

______________________________________ Lube Product PropertiesReaction WHSV V at 40.degree. C. V at 100.degree. C.Temp. .degree.C. g/g/hr cS cS VI______________________________________120 2.5 1555.4 157.6 217135 0.6 389.4 53.0 202150 1.2 266.8 36.2 185166 0.6 67.7 12.3 181197 0.5 21.6 5.1 172______________________________________

EXAMPLE R

Similar catalyst is used in testing 1-hexene oligomerization at different temperature. 1-Hexene is fed at 28 cc/hr and at 1 atmosphere.

______________________________________ Sample R.1 R.2______________________________________Temperature, .degree.C. 110 200Lube Yield, wt. % 46 3Viscosities, cS at40.degree. C. 3512 3760100.degree. C. 206 47VI 174 185______________________________________

EXAMPLE S

1.5 grams of a similar catalyst as prepared in Example Q is added to a two-neck flask under N.sub.2 atmosphere. Then 25 g of 1-hexene is added. The slurry is heated to 55.degree. C. under N.sub.2 atmosphere for 2 hours. Then some heptane solvent is added and the catalyst was removed by filtration. The solvent and unreacted starting material was stripped off to give a viscous liquid with a 61% yield. This viscous liquid had viscosities of 1536 and 51821 cS at 100.degree. C. and 40.degree. C., respectively. This example demonstrates that the reaction can be carried out in a batch operation.

The MOL approach to synthetic lubricant preparation involves upgrading low cost C.sub.3 /C.sub.4 olefins by shape selective zeolite catalysis in one or more steps. The preferred PAO viscosity improvers are prepared by oligomerization of 1-decene with Cr(II). It may be desirable to combine aspects or processes for preparing the MOL liquids (e.g., C.sub.30.sup.+ hydrocarbons) and further upgrading these by acid or Cr catalyst, for instance with addition of small amounts (0-10%) of 1-decene to a reaction mixture containing a portion of MOL liquids having terminal unsaturation. This approach can prove valuable in producing low cost mixtures of C.sub.30.sup.+ oligomers by combination of two or more sequential catalytic process steps.

EXAMPLE T

Olefinic MOL liquid having an initial viscosity (V.sub.40) of 3.16 cS, is further upgraded a series of runs by contacting the liquid material with the CrII/silica catalyst described above at 125.degree. C.

Run T.1 is conducted for 44 hours at a feed:catalyst weight ratio of 20:1 to yield a product visosity increase to 3.15. Run T.2 repeats T.1 for 116 hours, yielding product upgraded to V.sub.40 of 3.85, V.sub.100 of 1.41 and VI=90. Run T.3 repeats T.2 to yield product viscosity V.sub.40 =4.34, V.sub.100 =1.53 and VI=92. It is believed that increasing terminal olefin concentation by metathesis can further upgrade MOL liquids in situ by CrII catalysis.

While the invention has been described by preferred examples, there is no intent to limit the inventive concept except as set forth in the following claims.

Claims

1. A lubricant mixture having enhanced viscosity index comprising:

a) a major amount of low viscosity C.sub.20.sup.+ lubricant range liquid comprising hydrocarbons prepared by shape selective catalysis of lower olefin with medium pore acid zeolite catalyst to provide substantially linear liquid olefinic intermediates or C.sub.20.sup.+ hydrogenated lubricants, said lubricant range liquid having a kinematic viscosity of about 2-10 cS at 100.degree. C.; and

b) a minor amount of at least one poly(.alpha.-olefin) having viscosity of at least about 20 centistokes and viscosity index improvement properties.

2. The lubricant mixture of claim 1 wherein said poly(.alpha.-olefin) has a number average molecular weight of about 300 to 30,000, weight average molecular weight between 300 and 150,000, molecular weight distribution between 1.00 and 5, viscosity index greater than 130 and pour point below -15.degree. C.

3. The lubricant mixture of claim 2 wherein said number average molecular weight is preferably between 300 and 20,000, said weight average molecular weight is between 330 and 60,000 and said molecular weight distribution is between 1.01 and 3.

4. The lubricant mixture of claim 1 wherein said poly(.alpha.-olefin) comprises the hydrogenated polymeric or copolymeric residue of 1-alkenes taken from the group consisting of C.sub.6 to C.sub.20 1 -alkenes.

5. The lubricant mixture of claim 1 wherein said poly(.alpha.-olefin) comprises poly(o-decene).

6. The lubricant mixture of claim 5 wherein said poly(.alpha.-decene) has a VI greater than 130 and a pour point below -15.degree. C.

7. A lubricant mixture according to claim 1 wherein said mixture comprises about 1 to 30 weight percent of said poly(.alpha.-olefin) with a kinematic viscosity at 100.degree. C. of between 20 and 1000 centistokes.

8. An automotive lubricant mixture according to claim 7 wherein said poly(.alpha.-olefin) has a kinematic viscosity of at least 20 cS and comprises about 5 to 20 weight percent of said mixture.

9. A lubricant mixture having enhanced viscosity index comprising:

low viscosity C.sub.20 -C.sub.60 lubricant range liquid comprising substantially linear hydrocarbons prepared in at least one process step by shape selective catalysis of lower olefin with medium pore acid zeolite catalyst to provrde C.sub.20.sup.+ hydrocarbon lubricant range basestock, said lubricant range liquid having a kinematic viscosity of about 2-10 at 100.degree. C.; and

a viscosity improver comprising at least one poly(.alpha.-olefin) having viscosity of at least about 20 cS and viscosity index improvement properties.

10. The lubricant mixture of claim 9 wherein said poly(.alpha.-olefin) comprises poly(.alpha.-olefin) having a branch ratio of greater than 0.19.

11. The lubricant mixture of claim 10 wherein said poly(.alpha.-olefin) having a branch ratio greater than 0.19 comprises polydecene, and wherein said polydecene provides increased blend viscosity index and lower pour point.

12. The mixture of claim 10 wherein said poly(.alpha.-olefin) having a branch ratio greater than 0.19 comprises oligomerization product of 1-alkene catalysed by acid catalyst.

13. The mixture of claim 12 wherein said oligomerization product of 1-alkene is catalysted by the acid catalyst of BF.sub.3 or AlCl.sub.3.

14. The mixture of claim 12 wherein said 1-alkene is 1-decene and said oligomerization product is poly(.alpha.-decene).

15. A lubricant mixture according to claim 1 wherein said hydrogenated poly(.alpha.-olefin) is the oligomerization product of the oligomerization of 1-alkene in contact with reduced chromium oxide catalyst supported on silica.

16. The lubricant mixture of claim 15 wherein said oligomerization product is from the oligomerization of 1-decene in contact with reduced chromium oxide catalyst supported silica.

17. A lubricant mixture having enhanced viscosity index comprising:

a) a major amount of low viscosit C.sub.20.sup.+ lubricant range liquid comprising hydrocarbon moieties prepared by shape selective catalysis of lower olefin with medium pore acid zeolite catalyst to provide C.sub.20.sup.+ hydrogenated lubricant basestock, said lubricant basestock liquid having a kinematic viscosity of about 2-10 cS at 100.degree. C.; and

b) a minor amount of hydrogenated poly(o-olefin) having viscosity of at least about 20 cS and viscosity index improvement properties, said poly(o-olefin) having a number average molecular weight of about 300 to 30,000, weight average molecular weight between 300 and 150,000, molecular weight distribution between 1.00 and 5, viscosity index greater than 130 and pour point below -15.degree. C., wherein the weight ratio of components b:a is about 1:20 to 1:2.

18. The lubricant mixture of claim 17 wherein said poly(.alpha.-olefin) comprises poly(.alpha.-olefin) having a branch ratio of less than 0.19.

19. The lubricant mixture of claim 18 wherein said poly(o-olefin) having a branch ratio less than 0.19 comprises polydecene, and wherein said polydecene provides increased blend viscosity index, lower pour point, and enhances shear stibility.