Data processing: generic control systems or specific application – Specific application – apparatus or process – Chemical process control or monitoring system
Reexamination Certificate
1999-01-29
2001-11-13
Grant, William (Department: 2121)
Data processing: generic control systems or specific application
Specific application, apparatus or process
Chemical process control or monitoring system
C700S273000, C700S270000, C208S058000
Reexamination Certificate
active
06317654
ABSTRACT:
FIELD OF THE INVENTION
The present invention is directed to petroleum-based lubricants. More specifically, the present invention relates to a method for controlling lubricant production by predicting the quality of the final lubricant product in view of product performance tests and specific compositional parameters.
BACKGROUND OF THE INVENTION
Lubricating oils are, for the most part, based on petroleum fractions that boil above about 232 degree C (450 degrees F). The molecular weight of the hydrocarbon constituents is high and these constituents display almost all conceivable structures and structure types depending in
The rationale in lubricant refining is that a suitable crude oil, as shown by experience or by assay, can be refined into lubricant base stock having a predetermined set of properties such as, for example, appropriate viscosity, oxidation stability, and maintenance of fluidity at low temperatures. The refining process employed to isolate the lubricant base stock currently consists of a set of subtractive unit operations which remove the unwanted components. These unit operations include distillation, solvent refining, hydroprocessing, and dewaxing, each of which is basically a separation process.
A lubricant base stock (i.e. from a refined crude oil) may be used as a lubricant component, or it may be blended with another lubricant base stock having somewhat different properties. A particular base stock, prior to use as a lubricant, is conventionally compounded with one or more additives such as antioxidants, extreme pressure additives, and viscosity index (V.I.) improvers. As used herein, the term “stock,” regardless of whether the term is further qualified, refers only to a hydrocarbon oil without additives. The term “solvent-refined stock” or “raffinate” refers to an oil that has been solvent extracted, for example with furfural. The term “dewaxed stock” refers to an oil which has been treated by any method to remove or otherwise convert the wax contained therein and thereby reduce its pour point. The term “waxy” as used herein refers to an oil of sufficient wax content to result in a pour point greater than 4 degrees C. (+25 degrees F.). The term “base stock” refers to an oil refined to a point suitable for some particular end use, such as for preparing an automotive oil, marine oil, hydraulic oil, etc.
The current practice for the preparation of high grade lubricating oil base stocks is illustrated in FIG.
1
. The overall process is designated as
10
. The first step is to vacuum distill an atmospheric tower residuum from an appropriate crude oil (step
100
). This step provides one or more raw stocks within the boiling range of about 700 degrees F to about 1000 degrees F designated as light
15
(from about 700 to about 810 degrees F), medium
20
(from about 810 to about 890 degrees F), and heavy
30
neutrals (from about 890 to about 1000 degrees F), and a vacuum residuum
40
. Each stock is characterized by a different viscosity range, e.g., light neutral stocks have the lowest viscosity range (from about 3.5 to about 5.5 Kv at 100 degrees C) and heavy neutral stocks have the highest viscosity range (from about 10.0 to about 15.3 Kv at 100 degrees C). After preparation, each raw stock is extracted with a solvent, e.g., furfural, phenol or chlorex, which is selective for aromatic hydrocarbons, and which removes undesirable components (step
140
). The vacuum residuum
140
usually requires an additional step to remove asphaltic material prior to solvent extraction (step
120
). The raffinate from the solvent refining is generally very waxy and typically requires a dewaxing operation (step
160
). Dewaxing raffinates is generally carried out by solvent dewaxing or catalytic dewaxing under conditions which produce a predetermined or target pour point for the base stock.
The art of lube base stock production may further require an additional step of hydroprocessing the dewaxed stock (step
180
). Hydroprocessing is the addition of hydrogen to the stock for the purpose of removing certain impurities that may be detrimental to lubricant performance, depending upon the final lubricant product specifications. Hydroprocessing is especially useful for removing sulfur as the hydrogen combines with sulfur to form hydrogen sulfide. Either the dewaxing step (step
160
) or the hydroprocessing step (step
180
), or both, can yield a stock of sufficient quality to be used as a base stock for final lubricant formulation.
Suitable materials, or additives, are then added to the base stock to augment the base stock's lubricating properties and to meet the required specifications, such as viscosity index (VI) (shown in FIG.
6
).
Historically, lubricant manufacturing has been inflexible. Base stock produced from new crude sources is considered to be a “new” base stock and must be approved for use as a lubricant. The lube base stock approval system requires that a base stock produced from a new crude undergoes a costly and time-consuming approval process before it can be used as a lubricant oil. Full approval for samples produced from a new crude or base stock requires extensive bench and engine testing which generally takes 5 to 10 months to complete. Changes in process conditions also require re-approval with additional bench and engine testing. The high cost of bench and engine testing discourages optimization of process conditions on all but the most frequently run crudes. In addition, the need to streamline this system has become increasingly important as a result of the rapid changes in crude mixes from at least some geographic locations, quality concerns over purchased base stocks, and the drive for economic benefits from increased lube flexibility. Therefore, there is a need in the art for increased flexibility in lubricant production and to streamline the approval system for lube crudes, base stocks, and blends thereof.
SUMMARY OF THE INVENTION
In one embodiment of the present invention, a method for selecting a lubricant base stock for use in manufacturing a lubricant for a particular application is provided. Each lubricant base stock is characterized according to a plurality of compositional components common to all lubricant base stocks and each compositional component varies in amount with respect to each base stock. A model predicting the performance of a lubricant base stock in a final lubricant product is formed by identifying particular ones of the plurality of compositional components in a lubricant base stock that are probative of lubricant performance for a plurality of applications, in combination.
An acceptable range is next determined for a combination of identified compositional components from a plurality of performance tests required of a plurality of lubricant products where each lubricant product has a viscosity and the plurality of lubricant products each have a different viscosity. After the acceptable region is determined, adjustments are made for viscosity variations of each lubricant base stock by predicting the amounts of the compositional components from at least one other acceptable range for a base stock of a different viscosity wherein the acceptable range is determined for a combination of the identified compositional components from the plurality of performance tests, each lubricant product having a viscosity, the plurality of lubricant base stocks having a plurality of different viscosities.
A candidate base stock is then analyzed to determine the amounts of the identified components. It is then determined whether the amount of each identified component, in combination, in the candidate base stock is within the acceptable performance range.
In another embodiment of the present invention, a method is provided for making a lubricant base stock to be used in manufacturing a lubricant for a particular application from a refinery stream wherein the lubricant base stock and the refinery stream are characterizable according to a plurality of compositional components common to the base stock and to the refinery stream. This method
Gleeson James William
Heaney William Francis
Sanchez Eugenio
Visweswaran Viswanathan
Bahta Kidest
Grant William
LandOfFree
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