Patent Publication Number: US-7897034-B2

Title: Aviation gasoline formulation

Description:
FIELD OF THE INVENTION 
     The present invention relates to the field of the hydrocarbon compositions for use as fuels, more specifically, to unleaded aviation gasoline formulations for piston driven aircraft, which require high octane fuel. 
     BACKGROUND INFORMATION 
     In view of the increasing demand from environmental regulations, banning tetraethyl lead (TEL) from aviation gasoline (Avgas) formulations is a question of time. 
     Thus, several companies and research groups are presently involved in projects aiming at providing fuel formulations having a performance similar to those using TEL. 
     Such endeavor is not an easy task since such product should be endowed with special features among which high octane rating, stability and high performance are among the most important items required for the new product. 
     Alternative formulations described in the literature employ oxygenated compounds (ethyl tert-butyl ether—ETBE, ethyl alcohol) and aromatic amines, chiefly meta-toluidine (m-Tol) as components of the new fuels, all of them still being developed or tested and none of them being yet commercially available. 
     Aviation gasoline fuels are mainly used in small passenger aircraft for leisure activities and also in small piston driven helicopters. 
     Because of the limited consuming market, aviation gasoline is produced in few refineries where the required stringent specifications are met without affecting too much the overall refinery budget. 
     The development of a specific aviation gasoline fuel started in 1930. At that time the air sector of the US Army specified a combat gasoline fuel having a minimum octane number requirement of 87. This is believed to be the first time the anti-knocking properties of an aviation gasoline fuel were defined in terms of octane number. In the beginning of Second World War fuels were similar to those of present class 100. 
     Aviation gasoline attained its development peak during Second World War. In 1944, the US Army issued a specification for class 115/145. Such fuel had the highest anti-knocking evaluation among all commercial aviation gasoline and was used to obtain maximum response of high performance engines. 
     Useful streams for this kind of fuel should have a narrow distillation range and high octane numbers. C 5  and C 6  isoparaffin cuts—those being used in small concentrations due to their high volatility—or alkylates are generally sought for these formulations. 
     Suitable additives are frequently the same as those used in jet engine fuels. However, the use of tetraethyl lead (TEL) is specific for aviation gasoline fuels. The use of this additive is specified in ASTM Method D 910 and the amounts are a function of the fuel class. Maximum allowed levels are 0.14 g/L, 1.12 g/L, and 0.56 g/L, respectively for 80/87, 100/130, and 100/130 LL classes. The only difference between the last two gasoline fuels is color and lead amount, with LL having the meaning of low lead. 
     According to several fuel experts, for economic reasons the consumption of gasoline fuel for light aviation (100 LL gasoline fuel) can be suppressed in the next years. Without a substitute, many aircraft will no longer be able to fly. The main reason for this concern is the quick decline in other TEL applications and a corresponding drop in the supply. 
     A few years ago there were nearly 40-50 TEL suppliers while nowadays only two are left, one in the United Kingdom and another one in Russia. 
     In spite of the research under course, at this moment there is no unleaded additive for Avgas. 
     In spite of the rather modest contribution of Avgas for lead pollution, there is a huge concern of environmental agencies for banning such lead source from the atmosphere. 
     Lead-related additives constitute a further problem. 
     Ethylene dibromide, another cleaning additive used with TEL in 100 LL gasoline fuel, is highly toxic and should also be banned since it is a chemical product leading to the greenhouse effect. Without this cleaning additive, lead can block the engine in a few hours. 
     Low consumption, soaring prices, added to the pressure from environmental agencies are parameters that tend to cause the end of leaded Avgas around 2005-2010. The same reasons make the basis for the research of a new product for an unleaded gasoline fuel. 
     The patent literature teaches a few low lead or unleaded Avgas formulations. 
     U.S. Pat. No. 6,767,372 discloses an aviation gasoline (Avgas) fuel composition possessing a high motor octane number containing reduced amounts of tetraethyl lead. The Avgas composition preferably comprises about 20 to about 80 vol % iso-octane, about 5 to about 18 vol % toluene, about 1 to about 20 vol % C 4  to C 5  paraffins, about 0 to about 1 mL/gallon tetraethyl lead (TEL) and the balance light alkylate. The Avgas composition may be economically produced utilizing spare methyl tertiary butyl ether plant capacity to produce iso-octane as one component of the composition. 
     U.S. Pat. No. 6,451,075 relates to a particularly useful low lead aviation gasoline fuel blend that complies with all requirements of ASTM D 910 and includes 67.0 volume % isooctane, 18.0 volume % xylene, 12.0 volume % isopentane, 3.0 volume % isobutane and 0.47 mL/gal of tetraethyl lead. Another useful low lead aviation gasoline fuel blend which complies with all requirements of ASTM D 910 except for oxygenate content includes 60.0 volume % isooctane, 15.0 volume % xylene, 14.0 volume % methyl t-butyl ether, 8.0 volume % isopentane, 3.0 volume % isobutane and 0.2 mL/gal tetraethyl lead. The isooctane used in either case is a purified isooctane prepared either by fractionating a crude DIB (diisobutylene) material and hydrogenating the fractionated material or hydrogenating the crude DIB material and fractionating the hydrogenated material. 
     U.S. Pat. No. 6,258,134 and U.S. Pat. No. 5,851,241 relate to aviation fuel compositions that contain a substantially positive or synergistic combination of an alkyl tertiary butyl ether, an aromatic amine and, optionally, a manganese component. The base fuel containing the additive combination may be a wide boiling range alkylate. MON is at least 91, and is raised to at least 94 by the addition of the cited components. 
     U.S. Pat. No. 6,238,446 teaches unleaded aviation gasoline having heats of combustion and octane rating deemed necessary for use under actual service conditions that are formed from blends of specific proportions of aviation alkylate, ether blending agent, a cyclopentadienyl manganese tricarbonyl and optionally other appropriate hydrocarbons falling in the gasoline boiling range. 
     U.S. Pat. No. 5,470,358 relates to an unleaded aviation gasoline fuel, containing additives such as aromatic amines substituted with C 1 -C 10  alkyl or halogen, where the alkyl substituent cannot occupy the 2- or 6-position in the phenyl ring. According to this document, Avgas, due to stringent requirements in terms of octane rating and stability, is a blend of isopentane, alkylate, toluene and TEL. A base fuel useful as Avgas without octane booster such as TEL has a MON rate of 90 to 93. MON, and not RON, is the accepted parameter for the Avgas octane and is measured using the ASTM Method 2700-92. The additive is used in amounts from 6 to 10 wt %, if necessary with the aid of a co-solvent. 
     However, in spite of the present developments, the technique still needs an alkylate-based unleaded Avgas formulation, which contains triptane (2,2,3-trimethyl butane) associated to toluidine and super-alkylate in suitable proportions to lead to an Avgas having suitable properties, such Avgas formulation being described and claimed in the present application. 
     SUMMARY OF THE INVENTION 
     Broadly, the invention relates to an unleaded Avgas formulation for piston driven aircraft, which comprises, by volume, between 0 and 65.2% base alkylate, between 0 and 50% super-alkylate, between 0 and 25% toluene, between 2 and 10% toluidine, between 0 and 5% ethyl alcohol, between 0 and 25% C 5  stream and between 0 and 10% triptane. 
     Therefore, the invention provides an unleaded Avgas formulation useful for piston driven aircraft. 
     The invention provides further an unleaded Avgas formulation where the octane boosters include super-alkylate, triptane and a blend of toluidine isomers. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  attached is a graph illustrating the volume proportion of the evaporated from an alkylate feed to obtain super-alkylate. 
         FIG. 2  attached is a bar chart showing the MON and RON values for several unleaded Avgas formulations. C is for Control, a state-of-the-art formulation. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED MODES 
     Therefore, the present invention deals with an unleaded Avgas formulation for piston driven aircraft. 
     By volume, the formulation includes between 0 and 65.2% base alkylate, between 0 and 50% super-alkylate, between 0 and 25% toluene, between 2 and 10% of a toluidine isomer blend, between 0 and 5% ethyl alcohol, between 0 and 25% C 5  and between 0 and 10% triptane. 
     Volume proportions of some preferred formulations are for example as in Table 1 below. 
     
       
         
           
               
               
               
             
               
                 TABLE 1 
               
               
                   
               
               
                   
                 COMPONENTS 
                 % vol/vol 
               
               
                   
               
             
            
               
                   
                 Alkylate 
                 12-18 
               
               
                   
                 Super Alkylate 
                 28-42 
               
               
                   
                 Toluene 
                 20-30 
               
               
                   
                 Toluidines 
                 3-5 
               
               
                   
                 Ethyl alcohol 
                 0-5 
               
               
                   
                 C 5  stream 
                 10-20 
               
               
                   
                 Triptane 
                  0-10 
               
               
                   
               
            
           
         
       
     
     Base alkylate is a product obtained by the alkylation process of the petroleum industry whereby a stream, generally formed by isobutane and cis/trans 2-butene reacts under conditions of acidic catalysis, to yield poly branched hydrocarbons in the gasoline boiling range (alkylate) the major fractions of which contains 8 carbon atoms. Gasoline fuel obtained by this process has an excellent quality in terms of octane number and oxidation stability besides complying with several environmental requirements that are being progressively implemented aiming at modifying gasoline composition so that it is less harmful to man and environment. 
     Super-alkylate means, in the present invention, a distillation cut of the base alkylate containing between 75% and 78% by volume of isooctane. Such cut works as an octane booster for the Avgas formulation. The superalkylate is a stream obtained by the fractioning of the base alkylate. The range of interest is between 95° C. and 105° C. since the boiling point of isooctane is 99.4° C. The way to obtain super alkylate is depicted in  FIG. 1 . 
     Other physical properties of alkylate and super alkylate can be found in Table 2 below. 
     
       
         
           
               
               
             
               
                 TABLE 2 
               
             
            
               
                   
               
               
                   
                 Stream 
               
            
           
           
               
               
               
               
               
            
               
                 Feature 
                 Unit 
                 Method 
                 Alkylate 
                 Superalkylate 
               
               
                   
               
            
           
           
               
               
               
               
               
            
               
                 RON 
                 — 
                 ASTM D-2699 
                 94.4 
                 100.6 
               
               
                 MON 
                 — 
                 ASTM D-2700 
                 93.5 
                 96.5− 
               
               
                 Density@ 
                 — 
                 ASTM D-4052 
                 0.6919 
                 0.7008 
               
               
                 20/4° C. 
               
               
                   
               
            
           
         
       
     
     According to the invention, useful toluidines are a blend of toluidine isomers in any amount. Although the literature mentions chiefly m-toluidine as octane booster, the Applicant has experimentally determined that isomer blends can be used, this representing an economic advantage. 
     Triptane is an octane booster, 2,2,3-trimethyl butane. 
     Toluene is commercial toluene. 
     C 5  is a refinery cut having boiling point between 35.5° C. and 48° C. 
     As regards the method to prepare the formulations according to the invention, the order of blending the components should be from the denser to the less dense, except in the case of m-Tol, which in spite of being the denser product is the latest to be mixed to the other streams. This is due to homogenization problems experienced by m-Tol. 
     The bar chart of  FIG. 2  illustrates the formulations used in the Examples listed in Tables 3 and 4 below. In this chart, the symbol C in the abscissa means Control. 
     The invention will now be illustrated by the following non-limiting Examples according to Tables 3 and 4 below, 
     
       
         
           
               
               
               
               
               
               
               
               
             
               
                 TABLE 3 
               
             
            
               
                   
               
               
                   
                 Alky- 
                 Super 
                   
                 Tolu- 
                 Ethyl 
                 C 5   
                 Trip- 
               
               
                 Formu- 
                 late 
                 Alkylate 
                 Toluene 
                 idines 
                 alcohol 
                 Stream 
                 tane 
               
            
           
           
               
               
            
               
                 lation 
                 % vol/vol 
               
               
                   
               
            
           
           
               
               
               
               
               
               
               
               
            
               
                 Control 
                 65.0 
                 0.0 
                 15.0 
                 0.0 
                 0.0 
                 20.0 
                 0.0 
               
               
                 2 
                 65.2 
                 0.0 
                 15.0 
                 3.0 
                 0.0 
                 16.8 
                 0.0 
               
               
                 3 
                 17.3 
                 33.1 
                 25.0 
                 3.0 
                 5.0 
                 16.6 
                 0.0 
               
               
                 4 
                 17.0 
                 40.0 
                 23.5 
                 3.0 
                 0.0 
                 16.5 
                 0.0 
               
               
                 5 
                 0.0 
                 50.0 
                 25.0 
                 4.0 
                 0.0 
                 21.0 
                 0.0 
               
               
                 6 
                 40.0 
                 50.0 
                 0.0 
                 10.0 
                 0.0 
                 0.0 
                 0.0 
               
               
                 7 
                 8.0 
                 47.0 
                 20.0 
                 3.0 
                 0.0 
                 22.0 
                 0.0 
               
               
                 8 
                 15.0 
                 35.0 
                 25.0 
                 4.0 
                 0.0 
                 21.0 
                 0.0 
               
               
                 9 
                 16.0 
                 50.0 
                 15.0 
                 4.0 
                 0.0 
                 15.0 
                 0.0 
               
               
                 10 
                 24.2 
                 50.0 
                 10.0 
                 6.0 
                 0.0 
                 9.8 
                 0.0 
               
               
                 11 
                 15.0 
                 35.5 
                 25.0 
                 3.5 
                 0.0 
                 21.0 
                 0.0 
               
               
                 12 
                 16.0 
                 40.0 
                 15.0 
                 4.0 
                 0.0 
                 25.0 
                 0.0 
               
               
                 13 
                 0.0 
                 45.0 
                 25.0 
                 4.0 
                 0.0 
                 21.0 
                 5.0 
               
               
                 14 
                 0.0 
                 40.0 
                 25.0 
                 4.0 
                 0.0 
                 21.0 
                 10.0 
               
               
                 15 
                 10.0 
                 35.0 
                 23.0 
                 4.0 
                 0.0 
                 21.0 
                 7.0 
               
               
                   
               
            
           
         
       
     
     
       
         
           
               
               
               
             
               
                 TABLE 4 
               
               
                   
               
               
                 Formulation 
                 MON 
                 RON 
               
               
                   
               
             
            
               
                   
               
            
           
           
               
               
               
            
               
                 Control 
                 89.7 
                 94.6 
               
               
                 2 
                 95.4 
                 102 
               
               
                 3 
                 95.2 
                 100 
               
               
                 4 
                 96.5 
                 103.6 
               
               
                 5 
                 96.8 
                 104 
               
               
                 6 
                 102.4 
                 107 
               
               
                 7 
                 94.4 
                 102.4 
               
               
                 8 
                 96 
                 105 
               
               
                 9 
                 97.7 
                 105 
               
               
                 10 
                 101.4 
                 108 
               
               
                 11 
                 97.6 
                 105 
               
               
                 12 
                 97.4 
                 104 
               
               
                 13 
                 98 
                 106 
               
               
                 14 
                 101 
                 108.8 
               
               
                 15 
                 99.5 
                 107 
               
               
                   
               
            
           
         
       
     
     As illustrated by the bar chart of  FIG. 2  and Tables 3 and 4 above, it should be pointed out that:
         As expected, the addition of toluidines (isomer blend) neatly increases values for a certain formulation;   Formulations containing triptane and super alkylate attain high MON values even for reduced amounts of toluidines;   The presence of ethyl alcohol in a formulation does not seem to have any effect at least in the amount used. The use of ethyl alcohol can be considered in alternative/optional formulations since this compound is attractive under environmental considerations besides being an octane booster. However employing ethyl alcohol in a formulation designed for an aircraft should be cautiously thought of since such fuel can show phase separation, water absorption and freeze at the altitude level of aircraft fly.       

     In conclusion, the proposed formulations state that it is possible to obtain high MON levels for an unleaded Avgas, the booster effect being obtained by including specified amounts of a high isooctane cut such as super-alkylate, besides triptane and relatively reduced contents of toluidine isomer blends.