Patent Publication Number: US-4317657-A

Title: Gasoline additive fluids to reduce hydrocarbon emissions

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation-in-part of Ser. No. 890,494 filed Mar. 27, 1978, now U.S. Pat. No. 4,175,927. 
    
    
     BACKGROUND OF THE INVENTION 
     Fuels used in today&#39;s automotive engine cause deposits to be formed during combustion. Such deposits collect on parts of the combustion chamber including valves, spark plugs, and cylinder heads and walls. Formation of these deposits can result in increased exhaust emissions. 
     Cyclopentadienyl manganese compounds are excellent antiknocks in gasolines used to operate internal combustion engines and have proven to be especially beneficial in solving some of the problems present when low-lead or lead-free gasolines are used with internal combustion engines. 
     Use of such compounds as antiknocks is described in U.S. Pat. Nos. 2,818,417, 2,839,552, and 3,127,351, all incorporated herein by reference. 
     SUMMARY OF THE INVENTION 
     According to the present invention, exhaust hydrocarbon emissions of internal combustion engines operating on gasoline containing a cyclopentadienyl manganese antiknock compound are reduced by gasoline compositions containing a dimer or trimer acid or a mixture of a dimer and trimer acid produced by the polymerization or condensation of an unsaturated aliphatic monocarboxylic acid having between 16 and 18 carbon atoms per molecule. 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The essence of the present invention resides in the reduction of exhaust emissions of internal combustion engines which burn gasoline containing an organomanganese compound. This reduction in exhaust emission is affected by addition to the gasoline of a dimer or a trimer acid or mixture of a dimer and a trimer acid produced by the polymerization or condensation of an unsaturated aliphatic monocarboxylic acid having between 16 and 18 carbon atoms per molecule to the gasoline. Accordingly, a preferred embodiment is a gasoline suitable for use in an internal combustion engine and containing an amount of organomanganese compound, preferably a cyclopentadienyl manganese tricarbonyl, sufficient to increase the gasoline&#39;s antiknock effectiveness, and also containing an exhaust emission reducing amount of a dimer or a trimer acid or a mixture thereof produced by the polymerization or condensation of an unsaturated aliphatic monocarboxylic acid having between 16 and 18 carbon atoms per molecule. 
     A further embodiment of the present invention is a method for reducing exhaust emissions of internal combustion engines which operate on a gasoline containing an organomanganese compound by the addition to the gasoline of an exhaust emission reducing amount of a dimer acid, a trimer acid or a mixture of a dimer and trimer acid produced by the polymerization or condensation of an unsaturated aliphatic monocarboxylic acid having between 16 and 18 carbon atoms per molecule. 
     Liquid hydrocarbon fuels of the gasoline boiling range are mixtures of hydrocarbons having a boiling range of from about 80° F. to about 430° F. Of course, these mixtures can contain individual constituents boiling above or below these figures. These hydrocarbon mixtures contain aromatic hydrocarbons, saturated hydrocarbons and olefinic hydrocarbons. The bulk of the hydrocarbon mixture is obtained by refining crude petroleum by either straight distillation or through the use of one of the many known refining processes, such as thermal cracking, catalytic cracking, catalytic hydroforming, catalytic reforming, and the like. Generally, the final gasoline is a blend of stocks obtained from several refinery processes. The final blend may also contain hydrocarbons made by other procedures such as alkylate made by the reaction of C 4  olefins and butanes using an acid catalyst such as sulfuric acid or hydrofluoric acid. 
     Preferred gasolines are those having a Research Octane Number of at least 85. A more preferred Research Octane Number is 90 or greater. It is also preferred to blend the gasoline such that it has a content or aromatic hydrocarbons ranging from 10 to about 60 volume percent, an olefinic hydrocarbon content ranging from 0 to about 30 volume percent, and a saturate hydrocarbon content ranging from about 40 to 80 volume percent, based on the whole gasoline. 
     In order to obtain fuels having properties required by modern automotive engines, a blending procedure is generally followed by selecting appropriate blending stocks and blending them in suitable proportions. The required octane level is most readily accomplished by employing aromatics (e.g. BTX, catalytic reformate or the like), alkylate (e.g., C 6-9  saturates made by reacting C 4  olefins with isobutane using a HF or H 2  SO 4  catalyst), or blends of different types. 
     The balance of the whole fuel may be made up of other components such as other saturates, olefins, or the like. The olefins are generally formed by using such procedures as thermal cracking, catalytic cracking and polymerization. Dehydrogenation of paraffins to olefins can supplement the gaseous olefins occurring in the refinery to produce feed material for either polymerization or alkylation processes. The saturated gasoline components comprise paraffins and naphthenates. These saturates are obtained from (1) virgin gasoline by distillation (straight run gasoline), (2) alkylation processes (alkylates) and (3) isomerization procedures (conversion of normal paraffins to branched chain paraffins of greater octane quality). Saturated gasoline components also occur in so-called natural gasolines. In addition to the foregoing, thermally cracked stocks, catalytically cracked stocks and catalytic reformates contain saturated components. 
     The classification of gasoline components into aromatics, olefins and saturates is well recognized in the art. Procedures for analyzing gasolines and gasoline components for hydrocarbon composition have long been known and used. Commonly used today is the FIA analytical method involving fluorescent indicator adsorption techiques. These are based on selective adsorption of gasoline components on an activated silica gel column. The components being concentrated by hydrocarbon type in different parts of the column. Special fluorescent dyes are added to the test sample and are also selectively separated with the sample fractions to make the boundaries of the aromatics, olefins and saturates clearly visible under ultraviolet light. Further details concerning this method can be found in &#34;1969 Book of ASTM Standards,&#34; January 1969 Edition, under ASTM Test Designation D 1319-66T. 
     The motor gasolines used in formulating the improved fuels of this invention generally have initial boiling points ranging from about 80° to about 105° F. and final boiling points ranging from about 380° to about 430° F. as measured by the standard ASTM distillation procedure (ASTM D-86). Intermediate gasoline fractions boil away at temperatures within these extremes. 
     From the standpoint of minimizing atmospheric pollution to the greatest extent possible, it is best to keep the olefin content of the fuel as low as can be economically achieved as olefins reportedly give rise to smogforming emissions, especially from improperly adjusted vehicular engines. Accordingly, in the preferred base stocks of this invention the olefin content will not exceed about 10 volume percent and the most particularly preferred fuels will not contain more than about 5 percent olefins. Table 1 illustrates the hydrocarbon type makeup of a number of particularly preferred fuels for use in this invention. 
     
                       TABLE 1                                                     
______________________________________                                    
Hydrocarbon Blends of Particularly Preferred Base Fuels                   
                   Volume Percentage                                      
Fuel    Aromatics  Olefins        Saturates                               
______________________________________                                    
A       35.0       2.0            63.0                                    
B       40.0       1.5            58.5                                    
C       20.0       2.5            77.5                                    
D       33.5       1.0            65.5                                    
E       36.5       2.5            61.0                                    
F       43.5       1.5            55.0                                    
G       49.5       2.5            48.0                                    
______________________________________                                    
 
    
     It is also desirable to utilize base fuels having a low sulfur content as the oxides of sulfur tend to contribute an irritating and choking character to smog and other forms of atmospheric pollution. Therefore, to the extent it is economically feasible, the fuel will contain not more than about 0.1 weight percent of sulfur in the form of conventional sulfur-containing impurities. Fuels in which the sulfur content is no more than about 0.02 weight percent are especially preferred for use in this invention. 
     Normally the gasoline to which this invention is applied is lead-free or substantially lead-free, although small amounts of organolead additives usually employed to give fuels of improved performance quality such as tetraalkyllead antiknocks including tetramethyllead, tetraethyllead, physical or redistributed mixtures of tetramethyllead and tetraethyllead, and the like may be present therein. The gasoline may also contain antiknock quantities of other agents such cyclopentadienyl nickel nitrosyl, N-methyl aniline, and the like. Antiknock promoters such as tert-butyl acetate may be included. The gasoline may further contain blending agents or supplements such as methanol, isopropanol, t-butanol and the like. Antioxidants such as 2,6-di-tert-butylphenol, 2,6-di-tert-butyl-p-cresol, phenylenediamines such as N,N&#39;-di-sec-butyl-p-phenylenediamine, N-isopropylphenylenediamine, and the like, may be present. Likewise, the gasoline can contain dyes, metal deactivators, or other types of additives recognized to serve some useful purpose in improving the gasoline quality. 
     Cyclopentadienyl manganese tricarbonyls are known antiknocks and their preparation and use as described in U.S. Pat. Nos. 2,818,417, 2,839,552, and 3,127,351. An important antiknock of this type is methylcyclopentadienyl manganese tricarbonyl. The amount of the cyclopentadienyl manganese tricarbonyl added to the gasolines should be an amount adequate to increase its antiknock effectiveness. This has generally been found to be in the range of from about 0.005 to 10 grams per gallon of manganese as a cyclopentadienyl manganese tricarbonyl. A preferred range is from about 0.05 to 6 grams of manganese per gallon as a cyclopentadienyl manganese tricarbonyl. A more preferred range is from about 0.05 to about 0.25 grams of manganese per gallon, and a most preferred range is from about 0.05 to about 0.125 grams of manganese per gallon as methylcyclopentadienyl manganese tricarbonyl. 
     The dimerized and trimerized unsaturated fatty acid component of the present invention is preferably a dimer or trimer of a comparatively long chain unsaturated fatty acid, i.e., an acid having about 16 or 18 carbon atoms, such as linoleic acid. When two molecules of linoleic acid react with one another, the product is a dimer acid. Similarly, when three molecules interact, the product is a trimer. However, it is to be understood that for purposes of this invention, one may use a product derived by reacting one molecule of one unsaturated fatty acid with a molecule of another unsaturated fatty acid. Similarly, one can condense one molecule of three different acids, or 2 molecules of one acid with one molecule of another to produce a trimeric product suitable for this invention. It is also to be understood that mixtures of the above described materials can be used. The dimer and trimer or mixtures of these as described above can be made by such procedures as set forth in Landis et al, U.S. Pat. No. 2,632,695. The dimer of linoleic acid has been found to be particularly suitable for use in the present invention. Particularly preferred is a 40 percent mixture of a dimer of linoleic acid in kerosene. 
     Commercial dimer and trimer products are highly efficacious components of compositions of this invention. Commercial products that have been found to be paticularly effective include those dimer acid products prepared by the Humko Sheffiend Chemical Company and known to the trade as Hystrene 3695, Hystrene 3687, Hystrene 3680, and Hystrene 3675. These products have the following characteristics: 
     
         __________________________________________________________________________
                Hystrene                                                  
                      Hystrene                                            
                           Hystrene                                       
                                Hystrene                                  
PRODUCT         3695  3687 3680 3675                                      
__________________________________________________________________________
SPECIFICATIONS                                                            
Neut. Eq.       283-289                                                   
                      284-295                                             
                           287-299                                        
                                285-297                                   
Acid Value      194-198                                                   
                      190-198                                             
                           190-197                                        
                                189-197                                   
Sap Value       198-202                                                   
                      195-201                                             
                           192-200                                        
                                191-199                                   
Color, Gard., Max.                                                        
                5     7    8    9                                         
% Monomer, Max. 1.5 max.                                                  
                      1.0 max.                                            
                           1.0 max.                                       
                                1.0 max.                                  
TYPICAL                                                                   
% Dimer         95    87   83   75                                        
% Trimer        4     13   17   25                                        
% Monomer       1     trace                                               
                           trace                                          
                                trace                                     
Dimer/Trimer Ratio                                                        
                36:1  10:1 7.3:1                                          
                                4.5:1                                     
Refrac. Index @ 25° C.                                             
                1.4830                                                    
                      1.4842                                              
                           1.4839                                         
                                1.4853                                    
Spec. Grav. @ 25/25° C.                                            
                0.952 0.953                                               
                           0.954                                          
                                0.955                                     
Spec. Grav. @ 100/25° C.                                           
                0.905 0.907                                               
                           0.908                                          
                                0.908                                     
Lbs./Gal. @ 25° C.                                                 
                7.94  7.95 7.96 7.96                                      
Pour Pt., °F.                                                      
                17    13   24   25                                        
Flash Pt., °F., C.O.C.                                             
                550   580  580  600                                       
Fire Pt., °F.                                                      
                625   620  625  625                                       
Visc. @ 25° C. Cstks.                                              
                6800  7600 8000 9000                                      
Visc. @ 60° C. Cstks.                                              
                550   570  630  660                                       
Unsap           0.5   0.5  1.0  1.0                                       
Surf. Tens. @ 25°  C. Dynes/cm                                     
                26.5  26.3 26.0 26.3                                      
__________________________________________________________________________
 Humko can supply versions of Hystrene 3675 with varying monomer contents.
 They are designated by a letter suffix: A = 1-2% monomer, B = 2-3%       
 monomer, C = 3-4% monomer, and D = 4-5% monomer. The variation in the    
 percent monomer will, of course, change the above physical characteristic
 of our Hystrene 3675.                                                    
 
    
     The amounts of hydrocarbon emission control additive compound, as for example, the dimer of linoleic acid, sufficient to reduce the hydrocarbon emission level is at least to some extent dependent upon the amount of manganese present in the gasoline. Generally, the greater the concentration of manganese, the greater the amount of additive compound needed to reduce deposit related hydrocarbon emission levels. A typical concentration range is from about 0.25 grams per gallon, to about 10 grams per gallon. It is to be understood that concentrations somewhat outside this range can be used if desired. The particularly preferred amount of compound is about 0.5-1.5 grams per gallon. There is no real known upper limit on the concentration of the hydrocarbon emission reducing compound. In general, one uses an additive quantity having adequate exhaust reducing properties. 
     The following examples, in which all parts are by weight, illustrate the preparation of the products of this invention. 
    
    
     EXAMPLE 1 
     To a blending vessel was added 30 gallons of a reformate gasoline having the following properties: 
     
         ______________________________________                                    
Boiling range          87-408° F.                                  
Research octane number 93                                                 
Aromatics (volume percent)                                                
                       28.5                                               
Olefinics (volume percent)                                                
                        8.0                                               
Aliphatics (volume percent)                                               
                       63.5                                               
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     To this gasoline was added an amount of methylcyclopentadienyl manganese tricarbonyl sufficient to provide 0.125 grams of manganese per gallon of fuel. There was then added to the gasoline a sufficient amount of the aforedescribed dimer of linoleic acid--40 percent mixture of dimer acid--in kerosene to give a concentration of 0.4 grams per gallon of fuel. The mixture was then agitated until thoroughly mixed. The result was a gasoline having reduced emission increasing properties. 
     EXAMPLE 2 
     The preparation of Example 1 was repeated and a product obtained having an amount of methylcyclopentadienyl manganese tricarbonyl sufficient to provide 0.125 grams of manganese per gallon of fuel and sufficient dimer acid to give a concentration of 0.4 grams of dimer acid per gallon of fuel. 
     EXAMPLE 3 
     The preparation of Example 1 was repeated except that a commercially prepared 95 percent pure dimer acid mixed with 4 percent trimer and one percent monomer acid product previously identified as Hystrene 3695 was substituted for the dimer acid (40 percent mixture in kerosene) of Example 1. An amount of Hystrene 3695 was added to the gasoline composition to give a concentration of 1.0 gram of the 95 percent pure dimer acid to each one gallon of fuel. 
     EXAMPLE 4 
     The preparation of Example 1 was repeated except that a commercially prepared trimer acid mixture prepared by Humko Sheffield Chemical Company and designated Hystrene 5460, was substituted for the dimer acid (40 percent mixture in kerosene) in Example 1. The trimer acid was 60 percent pure mixed with 39 percent dimer acid and one percent monomer acid. 
     Tests were run to illustrate the unusual and beneficial effects of the products of this invention on reducing exhaust emissions. In such tests, an Oldsmobile type single cyclinder engine with a 9.5:1 compression ratio is used, using Shell lOW-40 multigrade oil and a 28.5 percent aromatic fuel produced by Amoco and designated Amoco 91 containing 0.125 grams per gallon of fuel of methylcyclopentadienyl manganese tricarbonyl antiknock. 
     Engine Preparation.--Before each test, the combustion chamber, valves and valve parts are cleaned of deposits and the valves are reseated. The old oil is drained, the oil pan is flushed with new oil and then filled with new oil. A new AC-45 spark plug is installed and the fuel lines are flushed with test fuel. 
     Start of Test Procedure.--The engine is started on the aforementioned Amoco 91 fuel from a fuel burette, at 50 percent wide open throttle, at a speed of 1370 r.p.m., an air/fuel ratio of about 14.7:1 and with an ignition timing of 10 BTC. These conditions are maintained until the water and oil sump are at 160°±5° F. and the carburetor air is at 110°±5° F. At this condition exhaust measurements are made for hydrocarbon and carbon monoxide so as to detect any engine changes compared to other tests in the same engine. Hydrocarbon measurements are made with a Beckman 400 Flame Ionization Hydrocarbon Detector. Carbon monoxide is measured with a Beckman 315A Non-Dispersive Infrared Analyzer. Measurements are taken at two sampling points, one at the engine exhaust port and the other several inches from the engine after a mixing element. 
     The engine is then switched to the test fuel and the air/fuel ratio is adjusted to the stoichiometric air/fuel ratio required by the test fuel. At this time exhaust hydrocarbon emission measurements are made, giving a start-of-test-result, whereupon the engine is shut down and the oil level zeroed. 
     Time Accumulation Schedule.--The engine is restarted with test fuel on a cycling schedule alternating between the following conditions: 
     
         ______________________________________                                    
Time, seconds 45         135                                              
Speed, r.p.m. 750-850    1,370                                            
Load          None       50 percent W.O.T..sup.1                          
Air/Fuel Ratio                                                            
              14.2       Stoichiometric                                   
Ignition Timing          10° BTC                                   
Oil Sump, °F.     165 ± 5                                       
Water, °F.        165 ± 5                                       
Carburetor Air, °F.                                                
                         110 ± 5                                       
______________________________________                                    
 .sup.1 Wide Open Throttle                                                
 
    
     The test is run for 100 hours with emission measurements made every 24 hours. 
     Periodic Emission Ratings.--After about each 24 hours of test time, hydrocarbon emission measurements are taken at 50 percent W.O.T. after which the engine is returned to the cycling schedule. 
     End of Test Procedure.--At the end of 100 hours of test, hydrocarbon emission measurements are taken at 50 percent W.O.T. and the engine is returned to a cycling schedule for a 1-2 hour period and then shut down. Oil consumption is then measured in ml/hr. 
     Using this procedure, the following results in terms of the percent of reduction in exhaust hydrocarbon emission were obtained using the emission reducing products of Examples 1, 2, 3 and 4. 
     
                       TABLE I                                                     
______________________________________                                    
               Reduction of                                               
                                 Emission                                 
                     Emission    Increase %                               
                     Increase    Measured 8-10                            
                     % Measured at                                        
                                 inches Down-                             
        Concentration, g.                                                 
                     Engine Exhaust                                       
                                 stream from                              
Additive                                                                  
        Mn/gal. fuel Port        Exhaust Port                             
______________________________________                                    
Product of                                                                
        0.4          79          93                                       
Example 1                                                                 
Product of                                                                
        0.4          45          35                                       
Example 2                                                                 
Product of                                                                
        1.0          23          ...*                                     
Example 3                                                                 
Product of                                                                
        1.0          35          ...*                                     
Example 4             48**       ...*                                     
______________________________________                                    
 *Measurements taken only at exhaust port.                                
 **Reduction of emission increase percent at the end of 102 hours.        
 
    
     As these results show, the emission reducing additives of the present invention effectively reduce exhaust emissions from engines operating on gasoline containing a cyclopentadienyl manganese antiknock. 
     It is convenient to utilize additive fluid mixtures composed of cyclopentadienyl manganese tricarbonyl antiknock agents and a dimer acid or a trimer acid or a mixture of a dimer and trimer acid produced by the polymerization or condensation of an unsaturated aliphatic monocarboxylic acid having between 16 and 18 carbon atoms per molecule. These additive fluid mixtures are added to low-head or unleaded gasoline. In other words, part of the present invention is exhaust emission-reducing fluids which comprise cyclopentadienyl manganese tricarbonyl antiknock agents and the exhaust emission-reducing agents of the type described hereinabove. 
     Use of such exhaust emission-reducing fluids in addition to resulting in great convenience in storage, handling, transportation, blending with fuels and so forth, also are potent concentrates which serve the multi-purpose functions of being useful as antiknocks and exhaust emission reducers. Thus, another embodiment of the invention is an additive fluid for low lead or essentially lead-free gasoline comprising an organomanganese compound and an exhaust-reducing amount of a compound selected from a dimer acid, a trimer acid or a mixture of a dimer and trimer acid produced by the polymerization or condensation of an unsaturated aliphatic monocarboxylic acid having between 16 and 18  carbon atoms. 
     In these fluid compositions the weight ratio of exhaust-emission-reducing agent to manganese can vary from about 1 to 35 grams of emission-reducing agent, such as the dimer and/or trimer of an unsaturated fatty acid having 16 or 18 carbon atoms to 1.0 grams of manganese. A preferred weight ratio of exhaust-emission-reducing agent to manganese is from about 2 to 15 grams of emission-reducing agent to 1.0 grams of manganese. 
     These fluids may optionally contain other additives such as antioxidants, anti-rust agent, detergents, etc., as well as solvents, e.g. a hydrocarbon to facilitate handling.