PROCEDURE FOR PRODUCING POLY-ALPHA-OLEFIN-TYPE LUBRICANT

Abstract: In producing lubricants by oligomerizing α-olefins with the aid of the catalyst of a BF₃ cocatalyst complex, e.g. a BF₃, alcohol or carboxylic acid complex, the used catalyst complex is recovered by distillation, and reused as catalyst in a similar oligomerization process.

Description: The present invention concerns a procedure for producing a poly-α-­ olefine-type lubrication by oligomerizing olefins with the aid of a BF₃ cocatalyst complex. The production methods known in the art of a poly-α-olefine lubrication consist in general of the following phases: oligomerizing the starting material olefine, removal of catalyst residues, fraction distillation of the product, and hydrogenation. The most commonly used oligomerization catalysts are of so-called Friedel-Crafts type, pri­ marily boron trifluoride, in addition to which various alcohols are used as so-called cocatalysts or promotor (see e.g. USP 3,780,128, USP 4,032,591, USP 4,376,222, USP 4,409,415 and USP 4,587,368), or aluminium halogenides (see e.g. USP 2,559,984, USP 3,637,503 and USP 3,652,706). Among said catalysts, specifically boron trifluoride, owing to high-level toxicity of fluorine compounds, involves considerable re­ moval and waste handling problems related to catalyst residues, thus resulting in remarkable economic expenses. Known procedures used for removing catalyst residues consist primari­ ly of washing of an oligomerizing mixture with a concentrated NaOH water solution, and precipitation of the fluorine compounds in the form of solid inorganic salts. In addition, procedures for circulating the BF₃ catalyst have been developed, either by binding it to a solid cocatalyst (silicon dioxide), whereby in the oligomerization product is left only the part of the BF₃ soluble therein, the separation of which from the product is accomplished with filler piece columns operating at reduced pressure (US. 4,263,467). Also liquid phase separation between the BF₃ alcohol catalyst complex and the oligomer product can be performed. Utilization of both said technologies leads, however, to the use of such a BF₃ cocatalyst system (BF₃*SiO₂ or a BF₃*alcohol) which does not allow an optimum oligomerization result and which causes problems in the production of a high-quality product. The present invention concerns a procedure for producing a lubricat­ ion of poly-α-olefine type, which is characterized in that the BF₃ cocatalyst complex is separated from the oligomerization product by distilling, and said separated complex is reused as catalyst in a similar oligomerizing reaction. With said procedure, remarkable savings are achieved both in the total catalyst consumption and in the expenses incurred in removing residues. In addition, it should be noted that the total reaction time is reduced compared with a standard batch process because the circulated catalyst already is in the form of a complex, and is able to start the reaction immediately. It is thus essential in view of the invention that the BF₃ complex circulated by distilling can be reused as such or after a minor BF₃ addition as an oligomerizing catalyst without essentially changing the quality of the end product. It should also be noted that circul­ ation can be continued innumerable times, thus allowing the maximum use of said catalyst. In addition, the invention particularly concerns the procedures in which the BF₃ catalyst complex is separated from the oligomerization product by distilling, preferably at a low, about 0.1 to 3 mbar pressure and at a low, about 20 to 100°C temperature. In order to enhance the separation efficiency, it is recommended to use distill­ ation columns. For cocatalyst are used compounds which form a stable, relatively low boiling complex with BF₃, such as C₁-C₁₅ alcohols or polyols, and C₁-C₇ carboxylic acids. Particularly suitable cocatalysts are C₁-C₁₀ alcohols. For starting material olefins, either straight chain or branched C₄-C₂₀ olefins, preferably however olefins with straight chains, are used, in which the double bond is located in the 1 position and the length of a chain portion is 8 to 12 carbon atoms, or mixtures of said olefins. The invention is suited for use in producing poly-α-olefin-type lub­ rications either in a batch or continous type of process. The invention can be described more in detail with the aid of the examples presented below. Examples 1-5 The reaction was accomplished in a 2 liter Parr autoclave provided with a mixer and an internal heating/cooling coil. Into the reactor were weighed a 1 decene and n butanol or a distilled catalyst complex. From the reactor was removed air with the aid of vacuum and N₂ flushing. The temperature was raised up to 30°C, and BF₃ gas was supplied at constant rate to obtain the quantity required in produc­ ing the BF₃-BuOH complex. The oligomerization process was performed in the BF₃ atmosphere and terminated by supplying nitrogen for about 30 mins. The catalyst complex was distilled as a batch distillation utilising the aid of a Vigreux column at 0.1 to 3 mbar pressure and at 20 to 100°C temperature of the bottom. During the collection, the temperature of the top of the distillation column was 40 to 70°C. The distillate was stored under an N₂ atmosphere and at room temperature prior to use. From the oligomerization product, the BF₃ residues were removed by washing with a 5% NaOH water solution, and the monomer (1 decene) boiling at low temperature and part of the dimer were removed by distilling. The end product was hydrogenated with the aid of the Raney-Ni catalyst. The experiments 1 to 5 were carried out in succession in that the catalyst distillate obtained in the preceding experiment was used as such for the oligomerization catalyst in the next experiment subsequent to a minor BF₃ addition. The product features, which are introduced in Table I, are determined using standard procedures. a) obtained from the preceding oligomerization experiment as distillate b) feeding at constant rate c) in the first experiment n-BuOH and equivalent molar quantity of BF₃ (fresh catalyst) is used, whereby the catalyst concentration re­ garding the decane is 10 mol%. Examples 6 and 7 The oligomerization reaction was accomplished using two mixer reactors connected in series, their reaction volumes being 2.15 l and 4.1 l. Both reactors were provided with a mixer and an inner cooling coil. Into the reactors was supplied in continuous action 0.7 l/h 1-decene, 12.3 g/h n butanol (Example 6), or 19.2 g/h circulated co­ catalyst complex (Example 7), this being obtained in the form of a product separated from an oligomerization product similar to the one presented in the previous example by distilling, and BF₃ gas so that both reactors had about 1.5 bar pressure. The temperature of the first reactors was 10°C and of the other, 30°C. The feeding of both the circulated and the fresh catalyst was so controlled that the con­ centration of the catalyst complex regarding the decene supply was about 4 mol%. In Fig. 1 is presented the distribution of various oligomers of a product oligomerized using continuous-action oligomerization equip­ ment with a fresh (Example 6) and a circulated (Example 7) catalyst, in which it is seen that a similar product is obtained with the cir­ culated catalyst as with the fresh catalyst. In Fig. 2, the changing of the cooling effect (endeavours were made to maintain the reaction mixture in isothermic form) of the batch oligomerization (Examples 1 to 5), in which is seen that with the distilled, or circulated catalyst, the oligomerization reaction starts at a far greater rate than with the fresh catalyst, with which a remarkably long induction time takes in forming the catalyst complex, and consequently, in starting the oligomerization reaction.

Claims: 1. A process for producing a poly-α-olefin-type lubricant by oligomerizing one or more olefins with the aid of a BF₃ cocatalyst complex, characterised in that the BF₃ cocatalyst complex is separated from the oligomerization product by distillation, and the separated complex is reused as catalyst in a similar oligomerization reaction. 2. A process according to claim 1, characterized in that the olefin is a straight or branched C₄-C₂₀ olefin, advantageously a C₆-C₁₂ olefin-1. 3. A process according to claim 1 or claim 2 characterized in that the cocatalyst is a C₁-C₁₅ alcohol or a polyol or a C₁-C₇ carboxylic acid, advantageously a C₁-C₁₀ alcohol. 4. A process according to any one of claims 1-3, characterized in that the separation of the complex from the oligomerization product is performed in distillation columns, advantageously at low pressure and temperature. 5. A process according to any one of claims 1-4, characterized in that the oliogmerization is performed either as a batch or as a continuous process. 6. A process according to any one of claims 1-4, characterized in that the concentration of the catalyst complex relative the olefin feed is from 0.1 to 10 mol%, advantageously 0.5 to 4 mol%.

Inventors: IDELMANN PETER, KOSKIMIES, SALME, NISSFOLK, FREDRIK, NURMINEN, MATTI, RONI, SALLA
Applicants: NESTE OY
Application year: 1988
Main classification: C10M177
IPC codes: C10G50, B01J31, C07C67, C10M107, B01J38, C07C1, C07C2, C10M177, C07B61, C10N70