# Patent

## Title
Hydrocarbon composition for use in compression-ignition engines

## Abstract

The invention provides a hydrocarbon composition for use in CI engines, said composition comprising a blend of hydrocarbons derived from a LTFT and from a HTFT process, said LTFT derived hydrocarbon being blended with said HTFT derived hydrocarbon in a volumetric ratio of from 1:20 to 20:1. The invention further provides a process for the production of the hydrocarbon composition and a the fuel composition including, in addition to the hydrocarbon composition, one or more component selected from the group including a crude oil derived diesel fuel, a crude oil derived naphtha, a lubricant or light cycle oil (LCO).

## Background
RELATED APPLICATIONS
This application is a continuation-in-part, under 35 U.S.C. §120, of International Patent Application No. PCT/ZA2004/000054, filed on May 19, 2004 under the Patent Cooperation Treaty (PCT), which was published by the International Bureau in English on Nov. 25, 2004, which designates the U.S. and claims the benefit of South African Provisional Patent Application No. 2003/3844, filed May 19, 2003, the disclosures of which are hereby incorporated by reference in their entireties and are made a portion of this application.


FIELD OF THE INVENTION
The invention relates to a hydrocarbon composition for use in Compression Ignition (CI) engines and to a process related to its preparation.
BACKGROUND TO THE INVENTION
There has been considerable discussion within the European Union (EU) since the late eighties on strategies and programmes to improve air quality. The EU motor vehicle emission regulations and fuel specifications subsequently became tighter with current EURO 3 emission limits for carbon monoxide (CO), hydrocarbons (HC)+nitrogen oxides (NOx) and particulate matter (PM) of 0.64 g/km, 0.56 g/km and 0.05 g/km respectively for passenger vehicles. Fuel with low sulphur and aromatic contents would improve PM emissions. Although fuel sulphur does not influence NOx emissions directly, its elimination from the fuel enables the use of NOx after-treatment methods in new vehicles. Californian Air Resources Board (CARB) diesel and Swedish Environmental Class 1 (EC1) diesel are examples of fuels with a low sulphur and low polycyclic aromatic hydrocarbon (PAH) content that are available in the market.
The highly paraffinic related properties of Sasol Slurry Phase DistillateTM (Sasol SPDTM) Low Temperature Fischer-Tropsch (LTFT) derived diesel, also known as Gas-to-Liquid (GTL) diesel, such as high H:C ratio, high cetane number and low density together with virtually zero-sulphur and very low aromatics content give Sasol SPDTM diesel its very good emission performance advantage over crude oil-derived diesel. Compared to CARB diesel and Swedish EC1 diesel, Sasol SPDTM diesel has the lowest regulated and unregulated exhaust emissions.
The LTFT process is a well known process in which synthesis gas, a mixture of gases including carbon monoxide and hydrogen, are reacted over an iron, cobalt, nickel or ruthenium containing catalyst to produce a mixture of straight and branched chain hydrocarbons ranging from methane to waxes with molecular masses above 1400 and smaller amounts of oxygenates. The LTFT process may be derived from coal, natural gas, biomass or heavy oil streams as feed. While the term Gas-to-Liquid (GTL) process refers to schemes based on natural gas, i.e. methane, to obtain the synthesis gas, the quality of the synthetic products is essentially the same once the synthesis conditions and the product work-up are defined. As a matter of reference, the Sasol SPDTM process is a well known LTFT scheme and is also one of the leading GTL conversion technologies.
Some reactors for the production of heavier hydrocarbons using the LTFT process are slurry bed or tubular fixed bed reactors, while operating conditions are generally in the range of 160-280° C., in some cases in the 210-260° C. range, and 18-50 bar, in some cases between 20-30 bar. The molar ratio of Hydrogen to Carbon Monoxide in the synthesis gas may be between 1.0 and 3.0, generally between 1.5 and 2.4.
The LTFT catalyst may comprise active metals such as iron, cobalt, nickel or ruthenium. While each catalyst will give its own unique product slate, in all cases it includes some waxy, highly paraffinic material which needs to be further upgraded into usable products. The FT products are typically hydroconverted into a range of final products, such as middle distillates, naphtha, solvents, lube oil bases, etc. Such hydroconversion, which usually consists of a range of processes such as hydrocracking, hydrotreatment and distillation, can be termed a FT products work-up process.
The complete process can include gas reforming which converts natural gas to synthesis gas (H2 and CO) using well-established reforming technology. Alternatively, synthesis gas can also be produced by gasification of coal or suitable hydrocarbonaceous feedstocks like petroleum based heavy fuel oils. Other products from this unit include a gas stream consisting of light hydrocarbons, a small amount of unconverted synthesis gas and a water stream. The waxy hydrocarbon stream is then upgraded in the third step to middle distillate fuels such as diesel, kerosene and naphtha. Heavy distillates are hydrocracked and olefins and oxygenates are hydrogenated to form a final product that is highly paraffinic.
As it is the case with the LTFT process, the High Temperature Fischer-Tropsch (HTFT) process also makes use of the FT reaction albeit at a higher process temperature. A typical catalyst for HTFT process, and the one considered herebelow, is iron based.
Known reactors for the production of heavier hydrocarbons using the HTFT process are the circulating bed system or the fixed fluidized bed system, often referred in the literature as Synthol processes. These systems operate at temperatures in the range 290-360° C., and typically between 310-340° C., and at pressures between 18-50 bar, in some cases between 20-30 bar. The molar ratio of Hydrogen to Carbon Monoxide in the synthesis gas is essentially between 1.0 and 3.0, generally between 1.5 and 2.4.
Products from the HTFT process are somewhat lighter than those derived from the LTFT process and, as an additional distinction, contain a higher proportion of unsaturated species.
The HTFT process is completed through various steps which include natural gas reforming or gasification of coal or suitable hydrocarbonaceous feedstocks like petroleum based heavy fuel oils to produce synthesis gas (H2 and CO). This is followed by the HTFT conversion of synthesis gas in a reactor system like the Sasol Synthol or the Sasol Advanced Synthol. One of the products from this synthesis is an olefinic distillate, also known as Synthol Light Oil (SLO). This SLO is fractionated into naphtha and distillate fractions. The distillate fraction of SLO is further hydrotreated and distilled to produce at least two distillates boiling in the diesel range: a Light and a Heavy product. The former is also known as Hydrotreated Distillate (DHT) diesel and the latter as a Distillate Selective Cracked (DSC) heavy diesel.
The HTFT derived DHT diesel also contains ultra-low sulphur levels, has a cetane number greater than fifty and a density that meets current European National Specifications for Special Low Sulphur and Low Aromatics Grade Diesel Fuel with a mono-aromatic content of ±25 vol %.
Description of these two FT processes, LTFT and HTFT, may be found in Appl Ind Catalysis vol. 2 chapter 5 pp 167-213 (1983), amongst others.
Material compatibility in fuel systems is a concern whenever fuel composition changes. Exposure of an elastomer that has been exposed to high aromatic fuel and then to low aromatic, severely hydrotreated fuel, may cause leaching of absorbed aromatics, causing it to shrink. If the elastomer is still pliable, this shrinkage will not cause a leak, but an aged elastomer will loose its elasticity and a leak may occur. It is therefore not the low aromatic hydrocarbon diesel that causes fuel system leaks, but the combination of a change from higher to lower aromatics fuel. The above was confirmed with the ageing of nitrile rubber and Viton® in LTFT derived diesel and US No. 2-D diesel without pre-conditioning.
SUMMARY OF THE INVENTION
Thus, according to a first aspect of the invention, there is provided a hydrocarbon composition for use in CI engines, said composition comprising a blend of hydrocarbons derived from a LTFT and from a HTFT process, said LTFT derived hydrocarbon being blended with said HTFT derived hydrocarbon in a volumetric ratio of from 1:20 to 20:1.
The LTFT:HTFT ratio may be from 1:8 to 8:1.
The LTFT:HTFT ratio may be from 1:4 to 4:1.
The LTFT:HTFT ratio may be from 1:2 to 2:1.
The LTFT:HTFT ratio may be 1:1.
The hydrocarbon composition may have an aromatics content of above 1% by mass, typically above 3% by mass.
The hydrocarbon composition may have an aromatics content in excess of 9% by mass.
The aromatics content comprises mostly the least harmful mono-aromatics species which are derived primarily from the HTFT component of the blend.
The hydrocarbon composition may have a density of above 0.78 kg/m3@15° C.
The net heating value of the hydrocarbon composition may be between 43.0 and 44.0 MJ/kg on a mass basis or 33.5 to 35.0 MJ/l on a volume basis.
The hydrogen content may be from 13.5 mass % to 15 mass %
The hydrogen to carbon ratio of the hydrogen composition may be from 1.8 mol/mol to 2.2 mol/mol
The hydrocarbon composition may have an initial boiling point as measured according to the ASTM D86 method above 150° C. and T95 below 360° C.
The hydrocarbon composition may have a final boiling point as measured according to the ASTM D86 method of below 390° C.
The hydrocarbon composition may have a bromine number below 10.0 g Br/100 g.
The hydrocarbon composition may have an acid number below 0.006 mg KOH/g.
The hydrocarbon composition may have an Oxidation Stability below 0.7 mg/100 ml insolubles formed.
The hydrocarbon composition may be stable over two years with the total amount of insolubles formed being less than 1.35 mg/100 ml and an acid number less than 0.02 mgKOH/g.
The hydrocarbon composition may have a water content below 0.005% on a volume basis.
The hydrocarbon composition may be benign to elastomers used in CI engines and which have been exposed to crude oil derived diesel fuels.
The invention extends to a fuel composition including from 1% to 99% by volume of a hydrocarbon composition as described above.
The fuel composition may include 15% by volume of the hydrocarbon composition as described above.
The fuel composition may be a CI engine fuel composition.
According to another aspect of this invention, the fuel composition may include, in addition to the hydrocarbon composition, one or more component selected from the group including a crude oil derived diesel fuel, a crude oil derived naphtha, a lubricant or light cycle oil (LCO).
According to yet a further aspect of the invention there is provided a process for the production of a hydrocarbon composition for use in CI engines, said process including the steps of:—
a. producing one or more synthesis gas products from solid, liquid or gaseous carbonaceous feedstock by one or more synthesis gas production process;
b. optionally, blending two or more synthesis gas products to produce a synthesis gas blend for a synthesis gas reaction process;
c. processing the synthesis gas product or synthesis gas blend by a High Temperature Fischer-Tropsch synthesis process to produce synthetic hydrocarbon and water;
d. processing synthesis gas or synthesis gas blend by a Low Temperature Fischer-Tropsch synthesis process to produce synthetic hydrocarbon and water;
e hydroconverting at least a fraction of the hydrocarbon of step c. to produce one or more HTFT process derived hydrocarbons in the boiling range 150° C. to 390° C. for blending to produce a hydrocarbon composition for use as a fuel in a CI engine;
f. hydroconverting at least a fraction of the hydrocarbon of step d. to produce one or more LTFT process derived hydrocarbons in the boiling range 150° C. to 390° C. for blending to produce a hydrocarbon composition for use as a fuel in a CI engine; and
g blending the hydrocarbons produced in steps e and f to form the hydrocarbon composition.
The hydrocarbon composition may be prepared by blending a LTFT process derived hydrocarbon with a HTFT derived hydrocarbon.
The process may include the step of blending two or more of the hydrocarbons in the boiling range 150° C. to 390° C. to produce the hydrocarbon composition for use in CI engines.
The synthesis gas may be produced by reforming natural gas.
The synthesis gas may be produced by gasification of suitable hydrocarbon feed stock, for example, coal.
The synthetic hydrocarbon may be an olefinic hydrocarbon.
The synthetic hydrocarbon may be a hydrocarbon suited for conversion to distillate range hydrocarbons.
Two of the hydrocarbons produced by the hydrocarbon processes may be a DHT diesel and a Sasol SPDTM diesel.
The DHT diesel is an example of HTFT derived hydrocarbons and GTL diesel is an example of LTFT derived hydrocarbons.
The DHT diesel and Sasol SPDTM diesel may be blended at a ratio from 1:100 to 100:1 on a volume basis.
The DHT diesel and Sasol SPDTM diesel may be blended at a ratio from 1:40 to 40:1 on a volume basis.
The DHT diesel and Sasol SPDTM diesel may be blended at a ratio from 1:20 to 20:1 on a volume basis.
The synthesis gas feeds produced from the reforming of natural gas and gasification may be blended prior to synthesis gas reaction process in a ratio of 1:100 to 100:1 on a volume basis.
The synthesis gas feeds produced from the reforming of natural gas and gasification may be blended prior to synthesis gas reaction process in a ratio of 1:40 to 40:1 on a volume basis.
The LTFT synthetic hydrocarbon and HTFT synthetic hydrocarbon produced from the LTFT synthesis gas reaction process and HTFT synthesis gas reaction process respectively may be blended prior to hydroconversion in a ratio of 1:100 to 100:1 on a volume basis.
The LTFT synthetic hydrocarbon and HTFT synthetic hydrocarbon produced from the LTFT synthesis gas reaction process and HTFT synthesis gas reaction process respectively may be blended prior to hydroconversion in a ratio of 1:40 to 40:1 on a volume basis.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a linear relationship of fuel density with various Sasol SPDTM diesel-DHT diesel blends.
FIG. 2 shows gravimetrical and volumetric net heating values of hydrocarbon compositions of the invention.
FIG. 3 shows a distillation profile of Sasol SPDTM diesel and DHT diesel.
FIG. 4 shows a linear cetane number relationship of hydrocarbon compositions of the invention.
FIG. 5 shows percentage change in mass and thickness of new nitrile rubber dumbbells, pre-conditioned in US No. 2-D and then further aged in a hydrocarbon composition comprising DHT/Sasol SPDTM diesel and US No. 2-D diesel.
FIG. 6 shows percentage change in tensile strength of nitrile rubber dumbbells, pre-conditioned in US No. 2-D and then further aged in a hydrocarbon composition of the invention and US No. 2-D diesel.
FIG. 7 shows: Percentage change in hardness of nitrile rubber dumbbells, pre-conditioned in US No. 2-D and then further aged in the hydrocarbon composition of the invention and US No. 2-D diesel.
FIG. 8 provides a schematic representation of a process for producing hydrocarbons according to the preferred embodiments.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The hydrocarbon composition of the invention was prepared by blending a LTFT process derived hydrocarbon with a HTFT derived hydrocarbon.
In the examples that follow the following abbreviations have been used:
DHT—refers to the hydroconversion process used primarily to upgrade the distillate contained in the HTFT SLO.
DHT Diesel—it refers to a HTFT process derived hydrocarbon which has been hydrotreated.
GTL—This is a LTFT process based on natural gas that optionally can also make use of alternative hydrocarbonaceous feeds to produce synthesis gas.
Sasol Slurry Phase DistillateTM (Sasol SPDTM) diesel or GTL diesel—it refers to a LTFT process derived hydrocarbon that is fully hydroconverted.
Two base fuels were used to prepare five hydrocarbon compositions including Sasol SPDTM diesel and DHT diesel for this investigation.
The experimental blends contained mixtures of 15%, 30%, 50%, 70% and 85% by volume Sasol SPDTM diesel with the DHT diesel. The properties of the neat Sasol SPDTM diesel and DHT diesel and blends thereof are summarised in Table 1, 2, 3 and 4. An example of the fuel properties of the Fischer-Tropsch hydrocarbon compositions of the invention and crude oil derived diesel (US 2-D diesel) blends are also tabulated as illustrated in Table 5.







TABLE 1







Selected properties of Sasol SPD TM - DHT Hydrocarbon Compositions




















15%
30%
50%
70%
85%
Sasol





DHT
Sasol
Sasol
Sasol
Sasol
Sasol
SPD TM


Analysis
Units
Method
diesel
SPD TM
SPD TM
SPD TM
SPD TM
SPD TM
diesel



















Colour

ASTM
1
1
1
1
1
<1
<1




D1500


Appearance

Caltex
1
1
1
1
1
1
1




CMM76


Density @
kg/l
ASTM
0.809
0.803
0.797
0.789
0.781
0.775
0.769


15° C.

D4052


Distillation

ASTM




D86


IBP
° C.

184
180
166
159
153
152
151


T10
° C.

208
205
200
195
189
184
182


T50
° C.

239
242
242
243
245
246
249


T95
° C.

363
359
351
343
336
330
325


FBP
° C.

385
385
379
367
358
345
334


Flash point
° C.
ASTM
78
74
72
66
63
60
58




D93


Viscosity @
cSt
ASTM
2.14
2.11
2.10
2.07
2.03
2.01
1.97


40° C.

D445


CFPP
° C.
IP 309
0
−1
−3
−6
−11
−20
−19


Water
vol %
ASTM
0.003
0.003
0.004
0.003
0.003
0.003
0.003




D1744


Sulphur
mass %
ASTM
0.0003
0.0002
0.0002
<0.0001
<0.0001
<0.0001
<0.0001




D5453


Acid
mgKOH/g
ASTM
0.004
0.005
0.003
0.004
0.002
0.002
0.001


number

D664


Total
Mass %

23.88
20.32
16.76
12.01
7.26
3.70
0.14


Aromatics


(HPLC)


Cetane

ASTM
57
59
61
66
67
69
73


Number

D613


Oxidation
mg/100 ml
ASTM
0.5
0.5
0.5
0.4
0.3
0.3
0.6


Stability

D2274


Bromine
gBr/100 g
IP 129
9.4
8.2
6.7
5.4
3.2
1.9
0.6


Number


Long term
mgKOH/g
ASTM
0.008
0.007
0.008
0.008
0.006
0.009
0.013


Storage

D4625


stability


Acid


number


Total
mg/100 ml

0.68
0.63
0.45
0.96
1.31
0.53
0.35


insolubles
















TABLE 2







Heating values of DHT-Sasol SPD TM Hydrocarbon Compositions
















15%
30%
50%
70%
85%
Sasol



DHT
Sasol
Sasol
Sasol
Sasol
Sasol
SPD TM



diesel
SPD TM
SPD TM
SPD TM
SPD TM
SPD TM
diesel


















Gross heating value (MJ/kg)
46.037
46.248
46.331
46.816
46.845
46.954
46.964


Net Heating Value (MJ/kg)
43.164
43.368
43.422
43.775
43.774
43.818
43.787


Hydrogen content (mass %)
13.54
13.57
13.71
14.33
14.47
14.78
14.97


Density @ 15° C. (kg/l)
0.8092
0.8031
0.7971
0.7888
0.7806
0.7747
0.7685


Net heating value (MJ/l)
34.928
34.829
34.611
34.530
34.170
33.946
33.651


H:C ratio (mol/mol)
1.87
1.87
1.90
1.98
2.01
2.06
2.10
















TABLE 3







High-frequency reciprocating rig (HFRR)


and scuffing load ball-on-cylinder


(SL BOCLE) lubricity evaluation of Sasol


SPD TM - DHT Hydrocarbon Compositions
















15%
30%
50%
70%
85%
Sasol



DHT
Sasol
Sasol
Sasol
Sasol
Sasol
SPD TM



diesel
SPD TM
SPD TM
SPD TM
SPD TM
SPD TM
diesel


















HFRR
547
549
552
556
560
612
617


(WSD


μm)


SL
4400
2800
2800
2800
2500
1700
1500


BOCLE


load


(g)









Another property which was considered was the heating value of the hydrocarbon compositions. There are two values, Gross (or High) and Net (or Low) commonly quoted which vary according to whether the water content in the products of combustion is considered to be in liquid or gaseous form. The gross heating values (Qgross) of the Sasol SPDTM diesel—DHT diesel blends were determined according to the American Society for Testing and Material (ASTM) D240 test method. The net heating value (Qnett) per mass was calculated using the following equation:

Qnett25° C.=Qgross25° C.−0.2122×H(mass%)

where the difference between the two values is a function of the latent heat of condensation of water and hydrogen content of the composition. Table 2 shows these results.

The issue of lubricity is pertinent in the case of severely hydrotreated low-sulphur diesel. There are two common methods of assessing lubricity; namely the Scuffing Load Ball-On-Cylinder (SL BOCLE) method and the HFRR. Lubricity evaluation tests of the various hydrocarbon compositions are shown in Table 3 and conducted according to both the ASTM D6078 and ASTM D6079 test methods.
Finally, the long-term storage stability of the neat Sasol SPDTM diesel and DHT diesel and hydrocarbon compositions comprising blends thereof was investigated according to the standard ASTM D4625 test method. The acid number and total insolubles formed over a period of 24 weeks at 43° C. were measured and reported to be smaller than 0.02 mgKOH/g and 1.35 mg/100 ml respectively.
The Bromine number (IP 129 Procedure), the Acid number (ASTM D694 test method), Oxidation Stability (ASTM D2274) and the water content (ASTM D1744 test method) of the fuel and the proposed blends were also measured and the results are shown in Table 1. It is evident that in all blends of DHT diesel and Sasol SPDTM diesel, the following measured quality characteristics apply:
1—Bromine number below 10.0 g Br/100 g. This is an indication of the residual olefin in the product. Olefinic compounds are susceptible to gum formation and are less stable.
2—Acid number below 0.004 mg KOH/g. This is an indication of, mostly, the residual organic acids and alcohols in the product and the tendency of the fuel to corrode.
3—Oxidation Stability below 0.6 mg/100 ml. Oxygen stability is tested through the calculation of the amount of insolubles formed in the presence of oxygen. This is an indication of the behaviour of the fuel when exposed to atmospheric oxygen under standard storage conditions and measures the fuel's resistance to degradation.

4—Water content below 0.004% on a volume basis. This is an indication of the quality of the final fractionated product. Entrained water can form stable emulsions and suspended matter, which cloud plug filters.

Characterisation and quantification of the composition of the neat Sasol SPDTM diesel and DHT diesel was obtained through Fluorescent Indicator Adsorption (FIA) and High Performance Liquid Chromatography (HPLC) (see Table 4).







TABLE 4







Sasol SPD TM diesel and DHT diesel hydrocarbon components












Sasol




Component
SPD TM
DHT















Total Aromatics (vol %)
<1
24



Mono-aromatics (mass %)
0.1439
23.658



Dicyclic-aromatics (mass %)
<0.0001
0.118



Polycyclic-aromatics (mass %)
<0.0001
0.104



Olefins (vol %)
2
1



Paraffins (vol %)
98
75










The diesel properties that are most important to ensure good engine performance and which influence emissions include cetane number, aromatics, density, heat content, distillation profile, sulphur, viscosity, and cold flow characteristics. These properties, among others, will be discussed below for the hydrocarbon compositions.
DENSITY—Diesel density specifications are tending to become tighter. This is due to the conflicting requirements of a lower density fuel to reduce particulate matter emissions, whilst retaining a minimum density to ensure adequate heat content, which relates to fuel economy. Increasing ratios of DHT to Sasol SPDTM diesel would increase the hydrocarbon composition density, even beyond the minimum requirement of 0.800 kg/l, but not higher than its upper specified limit of 0.845 kg/l@ 15° C. (see FIG. 1).
FIG. 1 shows a linear relationship of fuel density with various Sasol SPDTM diesel—DHT diesel blends.
HEATING VALUES—Fischer-Tropsch synthetic fuels have much higher gravimetrical heating values than severely hydrotreated crude derived diesel and lower net volumetric heating values. Aromatic compounds have a much higher density and volumetric heating value than naphthenes or paraffins with the same carbon number. The net volumetric heating value of the hydrocarbon composition increases with increasing DHT diesel content. The net volumetric heating value of the composition containing equal amounts of Sasol SPDTM and DHT is 34.5 MJ/l (see FIG. 2).
FIG. 2 shows gravimetrical and volumetric net heating values of hydrocarbon compositions of the invention
VISCOSITY—A fuel viscosity that is excessively low causes the injection spray not to penetrate far enough into the cylinder and could cause idling and hot start problems whereas high viscosity reduces fuel flow rates. All the hydrocarbon compositions described above are within the EN 590:1999 Diesel Specification viscosity requirement.
DISTILLATION PROFILE—DHT diesel has a much higher initial boiling point (IBP) than Sasol SPDTM diesel (see DHT diesel distillation profile in FIG. 3) and therefore a higher flash point than that of Sasol SPDTM diesel. The hydrocarbon compositions of the invention comply with the EN 590:1999 T95 Diesel Specification. Fuels with higher end points tend to have worse cold flow properties than fuels with lower final boiling points and therefore the low maximum T95 limit for arctic grade diesel. Sasol SPDTM diesel on the other hand has good cold flow properties as well as a high cetane number because of the predominately mono- and to a lesser extent di-methyl branching of the paraffins. Sasol SPDTM diesel improves the cold flow properties of DHT diesel with its higher T95 to meet the European Summer Climate Grade CFPP values of −5° C. and −10° C.
FIG. 3 shows a distillation profile of Sasol SPDTM diesel and DHT diesel.
CETANE NUMBER—Sasol SPDTM diesel, with a cetane number rating of 72, improves the 57 cetane number of DHT diesel linearly (see FIG. 4). Fuels with a high cetane number ignite quicker and hence exhibit a milder uncontrolled combustion because the quantity of fuel involved is less. A reduction of the uncontrolled combustion implies an extension of the controlled combustion, which results in better air/fuel mixing and more complete combustion with lower NOx emissions and better cold start ability. The shorter ignition delay implies lower rates of pressure rise and lower peak temperatures and less mechanical stress. The cetane numbers of the hydrocarbon compositions of the present invention are far beyond all specification requirements.
FIG. 4 shows a linear cetane number relationship of hydrocarbon compositions of the invention.
Other excellent properties of hydrocarbon compositions of the invention include their ultra-low sulphur content (less, than 5 ppm), no unsaturates or polycyclic aromatic hydrocarbons, low bromine number. According to the very low acid number and water content observed, the likelihood of the hydrocarbon compositions of the invention to corrode are very slim.







TABLE 6







Percentage physical property change of new nitrile


rubber, pre-conditioned in US 2-D diesel and further


exposed to hydrocarbon composition samples.














Sasol SPD TM



Fuel
US No. 2-D
DHT diesel
diesel
FT blend














Mass
10.01
0.60
−4.12
−1.50


Thickness
6.98
1.89
1.24
0.75


Tensile
−38.81
−35.88
−25.80
−26.04


strength


Hardness
−10.20
−5.77
−2.68
−4.70









MASS AND DIMENSION CHANGE—Ageing of nitrile rubber in the Sasol SPDTM diesel caused the swollen pre-conditioned dumbbells to shrink and to loose weight (see FIG. 5). This effect was reduced with the blend of DHT and Sasol SPDTM causing the nitrile rubber to return to its original thickness and within 1.5% of its original mass. Exposure of the pre-conditioned nitrile rubber for another 166 hours to US No. 2-D diesel causes a total increase of 10% in the mass of new dumbbells. According to Chemical Resistance Guide for Elastomers II, if loss in dimensions are smaller than 15% from 30 days to one year, the description of attack can still be seen as excellent and little surface deterioration.
FIG. 5 shows percentage change in mass and thickness of new nitrile rubber dumbbells, pre-conditioned in US No. 2-D and then further aged in a hydrocarbon composition comprising DHT/Sasol SPDTM diesel and US No. 2-D diesel.
TENSILE STRENGTH—All the diesel samples softens new elastomers. The Sasol SPDTM diesel hardens the pre-conditioned nitrile rubber dumbbells and therefore increases its tensile strength (see FIG. 6). The mono-aromatic hydrocarbon content of the DHT diesel reduces the tensile strength of the nitrile rubber to a lesser extent than that of US No. 2-D diesel.







TABLE 5







Selected properties of Sasol SPD TM - DHT


Hydrocarbon Compositions blends with US 2-D diesel









Sasol SPD TM:DHT:US 2-D



volumetric blend ratio














Analysis
Units
Method
US2-D
0.3:0.7:1
0.7:0.3:1
1:1:1
2:2:1

















Density @
kg/l
ASTM D4052
0.861
0.8293
0.8210
0.813
0.8033


15° C.


Distillation

ASTM D86


IBP
° C.

147
167
155
156
154


T10
° C.

215
206
200
200
198


T50
° C.

268
256
257
252
249


T95
° C.

340
344
339
342
343


FBP
° C.

353
372
355
362
363


Flash point
° C.
ASTM D93
69
66
60
67
59


Viscosity @
cSt
ASTM D445
2.60
2.34
2.30
2.24
2.17


40° C.


CFPP
° C.
IP 309
−14
−7
−12
−8
−7


Sulphur
mass %
ASTM D5453
0.04
0.021
0.021
0.014
0.0086


Cetane no.

ASTM D613
41
52
56
59
62


Lubricity
(WSD μm)
ASTM D6079
293
423
427
468
503


(HFRR)


Total
mass %

34.44
25.93
21.48
19.88
16.77


aromatics









ELASTOMER COMPATIBILITY—The effect of mono-aromatics in Sasol SPDTM diesel on the physical properties of seals was studied with a hydrocarbon composition comprising 50 vol % DHT with 50 vol % Sasol SPDTM (FT blend). The physical properties of the untreated elastomers were taken as baseline. The overall change in mass, thickness, tensile strength and hardness of pre-conditioned standard nitrile rubber being exposed to the composition was compared with nitrile rubber being exposed to the base fuels. The nitrile rubber, an acrylonitrile butadiene copolymer, was pre-conditioned in highly aromatic US No. 2-D diesel for 166 hours according to the ASTM test method for Rubber Property—Effect of Liquids (ASTM D471), Vulcanised Rubber and Thermoplastic Elastomers—Tension (ASTM D412) and Durometer Hardness (ASTM D 2240) respectively. Average mass change, change in thickness, tensile strength and hardness of five new dumbbells, pre-conditioned and thereafter exposed to US No. 2-D, Fischer-Tropsch diesel and a blend thereof are tabulated in Table 6.
FIG. 6 shows percentage change in tensile strength of nitrile rubber dumbbells, pre-conditioned in US No. 2-D and then further aged in a hydrocarbon composition of the invention and US No. 2-D diesel.
HARDNESS—Exposure of nitrile rubber to the hydrocarbon composition of the invention makes indentation more difficult and hardens the pre-conditioned dumbbells. Continuous exposure of the pre-conditioned dumbbells with US No. 2-D diesel softens it further. The presence of DHT diesel in the Sasol SPDTM diesel reduces its hardening effect on the dumbbells.
FIG. 7 shows: Percentage change in hardness of nitrile rubber dumbbells, pre-conditioned in US No. 2-D and then further aged in the hydrocarbon composition of the invention and US No. 2-D diesel.
The hydrocarbon compositions of the invention have a very high consistent quality with an ultra-low sulphur content and a high cetane number. These compositions provide future fuel characteristics in a form that is compatible with current infrastructure and technology.
Process Scheme
This process is illustrated in FIG. 8.
Synthesis gas can be produced either using reforming 4 of natural gas or gasification 1 of a suitable hydrocarbonaceous feedstock. The first process option results in synthesis gas 10a and the latter 10b, two streams possible of being interchangeable and/or manipulated to a required primary composition. This is illustrated by means of the dotted line linking 10a and 10b in said FIG. 8.
Either synthesis gas or a blend thereof is sent to a HTFT synthesis process 2, resulting in a mixture of synthetic hydrocarbons and water. This is separated into at least two streams: stream 11 is an olefinic distillate and stream 17 which for illustration groups all non-distillate range hydrocarbons which might undergo further processing not shown in this description. Stream 11 is sent to hydroconversion unit 3 to obtain the DHT diesel 12 along with other by-products 16 not specifically defined in this invention but know to a person skilled in the art.
In parallel, another portion of either synthesis gas or a blend thereof is sent to a LTFT synthesis process 5, also resulting in a mixture of synthetic hydrocarbons and water. This is separated into at least two streams. Stream 13 comprises synthetic hydrocarbon species suitable to be hydroconverted in hydroconversion unit 6 to a distillate range Sasol SPDTM diesel 14 and other products that for the purpose of this illustration are lumped as stream 18. Stream 19 from LTFT unit 5 comprises all synthesis products not sent to the hydroconversion unit 6. It will be apparent to a person skilled in the art that this product might be further processed beyond the scope of this invention.
Streams 12—DHT diesel—and 14—Sasol SPDTM diesel—can then be blended resulting in the CI fuel matter of this invention, stream 15. The blending ratio for the two synthetic fuels might be between 1:100 to 100:1, preferably 1:40 to 40:1, and even more preferably 1:20 to 20:1 on a volume basis.
Hydroprocessing to obtain the synthetic distillates can be done in parallel units—as described before—or in a single one to optimize the process. In the latter case, illustrated by the dotted line linking streams 11 and 13 in FIG. 8, the blending ratio for the two synthetic feeds might be between 1:100 to 100:1, preferably 1:40 to 40:1, and even more preferably 1:20 to 20:1 on a volume basis.
It is noted that while the two FT processes can be operated at separate locations respectively, there might be some significant synergy effects in running them together at the same location. These effects include better utilisation of the synthesis gas and integration of process utilities, as well as those derived from the product blend matter of this invention.

## Claims

1. A process for the production of a hydrocarbon composition for use in a fuel for compression ignition engines, said process consisting essentially of the steps of:
a. producing two or more synthesis gas products from a solid, liquid or gaseous carbonaceous feedstock by at least one synthesis gas production process, wherein the two or more synthesis gas products are blended;
b. subjecting the two or more synthesis gas products to a High Temperature Fischer-Tropsch synthesis to obtain a first synthetic hydrocarbon and water, wherein the first synthetic hydrocarbon has a sulphur content of below 5 ppm and a density of from 0.800 to 0.845 kg/l at 15° C.;
c. subjecting the two or more synthesis gas products to a Low Temperature Fischer-Tropsch synthesis to obtain a second synthetic hydrocarbon and water, wherein the second synthetic hydrocarbon has a sulphur content of below 5 ppm;
d. hydroconverting at least a fraction of the first synthetic hydrocarbon to produce one or more High Temperature Fischer-Tropsch process-derived hydrocarbons in the boiling range of from 150° C. to 390° C.;
e. hydroconverting at least a fraction of the second synthetic hydrocarbon to produce one or more Low Temperature Fischer-Tropsch process-derived hydrocarbons in the boiling range of from 150° C. to 390° C.; and
f. blending the hydrocarbons produced in steps d. and e. to form a hydrocarbon composition for use in a fuel for compression ignition engines, wherein the hydrocarbon composition has a sulphur content of below 5 ppm, a paraffin content of at least 75 vol. %, and an aromatics content above 9 mass %.

2. A process as claimed in claim 1, wherein the High Temperature Fischer-Tropsch process-derived hydrocarbon comprises hydrotreated distillate diesel and the Low Temperature Fischer-Tropsch process-derived hydrocarbon comprises gas-to-liquid diesel, and wherein the hydrotreated distillate diesel and the gas-to-liquid diesel are blended at a ratio of from 1:100 to 100:1 on a volume basis.

3. A process as claimed in claim 2, wherein the hydrotreated distillate diesel and the gas-to-liquid diesel are blended at a ratio from 1:40 to 40:1 on a volume basis.

4. A process as claimed in claim 3, wherein the hydrotreated distillate diesel and the gas-to-liquid diesel are blended at a ratio from 1:20 to 20:1 on a volume basis.

5. A process as claimed in claim 1, wherein the first synthetic hydrocarbon and the second synthetic hydrocarbon are blended, prior to hydroconversion, in a ratio of 1:100 to 100:1 on a volume basis.

6. A process as claimed in claim 5, wherein the first synthetic hydrocarbon and the second synthetic hydrocarbon are blended, prior to hydroconversion, in a ratio of 1:40 to 40:1 on a volume basis.

7. A process as claimed in claim 1, wherein the Low Temperature Fischer-Tropsch process-derived hydrocarbons comprise less than 1 vol. % total aromatics.

8. A process as claimed in claim 7, wherein the one or more High Temperature Fischer-Tropsch process-derived hydrocarbons comprise about 25 vol. % monoaromatics.

9. A process for the production of a hydrocarbon composition for use in a fuel for compression ignition engines as claimed in claim 1, said process consisting of steps a. through f.

10. A process as claimed in claim 1, wherein the hydrocarbon composition has a paraffin content between 75 vol. % and 98 vol. %.

11. A process as claimed in claim 1, wherein the fuel is configured to produce less than 0.05 g/km of particulate matter when combusted in a passenger vehicle.

12. A process for the production of a hydrocarbon composition for use in a fuel for compression ignition engines, said process consisting essentially of the steps of:
a. producing two or more synthesis gas products from a solid, liquid or gaseous carbonaceous feedstock by at least one synthesis gas production process, wherein the two or more synthesis gas products are blended;
b. subjecting the blended two or more synthesis gas products to a High Temperature Fischer-Tropsch synthesis to produce a first synthetic hydrocarbon composition and water, wherein the first synthetic hydrocarbon has a sulphur content of 0.0003 mass % and a density of from 0.800 to 0.845 kg/l at 15° C.;
c. subjecting at least a fraction of the first synthetic hydrocarbon to hydrocracking, hydrotreatment and distillation to produce one or more High Temperature Fischer-Tropsch process-derived hydrocarbons in a boiling range of from 150° C. to 390° C.;
d. subjecting the blended two or more synthesis gas products to a Low Temperature Fischer-Tropsch synthesis to produce a second synthetic hydrocarbon and water, wherein the second synthetic hydrocarbon has a sulphur content of <0.0001 mass %;
e. subjecting at least a fraction of the second synthetic hydrocarbon to hydrocracking, hydrotreatment and distillation to produce one or more Low Temperature Fischer-Tropsch process-derived hydrocarbons in the boiling range of from 150° C. to 390° C.; and
f. blending at least one of the one or more High Temperature Fischer-Tropsch process-derived hydrocarbons and at least one of the one or more Low Temperature Fischer-Tropsch process-derived hydrocarbons to form a hydrocarbon composition for use in a fuel for compression ignition engines, wherein the hydrocarbon composition has a sulphur content of below 5 ppm, a paraffin content of at least 75 vol. %, and an aromatics content above 9 mass %.

13. A process as claimed in claim 12, wherein the hydrocarbon composition has a density of at least 0.78 kg/l at 15° C., a Long Term Storage Stability below 1.35 mg/100 ml total insolubles formed, an initial boiling point as measured according to ASTM D86 method of above 150° C. and a T95 below 360° C., a final boiling point as measured according to ASTM D86 method of below 390° C., an oxidation stability below 0.7 mg/100 ml total insolubles formed, and a bromine number below 10 gBr/100 g.

14. A process for the production of a hydrocarbon composition for use in a fuel for compression ignition engines, said process consisting essentially of the steps of:
a. producing two or more synthesis gas products from a solid, liquid or gaseous carbonaceous feedstock by at least one synthesis gas production process, wherein the two or more synthesis gas products are blended;
b. subjecting the blended two or more synthesis gas products to a High Temperature Fischer-Tropsch synthesis to produce a first synthetic hydrocarbon and water, wherein the first synthetic hydrocarbon has a sulphur content of 0.0003 mass % and a density of from 0.800 to 0.845 kg/l at 15° C.,
c. subjecting the blended two or more synthesis gas products to a Low Temperature Fischer-Tropsch synthesis to produce a second synthetic hydrocarbon and water, wherein the second synthetic hydrocarbon composition has a sulphur content of <0.0001 mass %;
d. blending at least a fraction of the first synthetic hydrocarbon and at least a fraction of the second synthetic hydrocarbon to obtain a synthetic hydrocarbon blend; and
e. subjecting at least a fraction of the synthetic hydrocarbon blend to hydrocracking, hydrotreatment and distillation to produce a hydrocarbon composition for use in a fuel for compression ignition engines, wherein the hydrocarbon composition has a sulphur content of below 5 ppm, a paraffin content of at least 75 vol. %, and an aromatics content above 9 mass %.

15. A process as claimed in claim 14, wherein the hydrocarbon composition has a density of at least 0.78 kg/l at 15° C., a Long Term Storage Stability below 1.35 mg/100 ml total insolubles formed, an initial boiling point as measured according to ASTM D86 method of above 150° C. and a T95 below 360° C., a final boiling point as measured according to ASTM D86 method of below 390° C., an oxidation stability below 0.7 mg/100 ml total insolubles formed, and a bromine number below 10 gBr/100 g.