PROCESS ECONOMICS PROGRAM

Transcription

1 PROCESS ECONOMICS PROGRAM STANFORD RESEARCH INSTITUTE Menlo Park. California Abstract Process Economics Program Report No. 125 SYNTHETIC LUBRICANTS This first PEP report on the subject presents technical and econanic information on three of the synthetic lubricants that show the greatest promise for growth over the next decade by displacing petroleum lubricants in automotive and industrial applications. They are: Linear Alpha Olefin Oligomers Neopolyol Esters Dibasic Acid Esters Technology and econanics are presented for making a typical product from each of the above three general types, as follows: Hydrogenated Decene-1 Oligomer Technical Pentaerythritol Esters Di-Tridecyl Adipate

2 Report No. 125 SYNTHETIC LUBRICANTS MAX SACKS May 1979 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii

4 CONTENTS 1 INTRODUCTION SUMMARY... Technical and Economic Comparisons of Base Stock Production Processes Hydrogenated Decene-1 Oligomer (LAOO) Technical Pentaerythritol Esters (Neopolyol Esters).... Di-Tridecyl Adipate (Dibasic Acid Ester) INDUSTRY STATUS Automotive Synthetic Lubricants for Additives Jet Aircraft Engine Lubricants.. Arctic Engine Lubricants..... Industrial Applications Production Capacity Industry Status--Japan Industry Status--Europe Gasoline Engines LINEAR ALPHA OLEFIN OLIGOMERS... Chemistry... Definition... RawMaterials... Oligomerization Reaction; Heat of Oligomerization... Hydrogenation Reaction; Heat of Hydrogenation... Physical Properties... Review of Patents... Production of Hydrogenated Decene-1 Oligomer... Process Description... Section loo--0ligomerization... Section 200--Recovery and Purification... Section 300--Hydrogenation... Process Discussion... Selection of Processing Scheme... Oligomerization Section... Recovery and Purification Section... Rydrogenation Section... Thermophysical Data... Waste Streams... Cost Estimates ix

5 CONTENTS 4 LINEAR ALPHA OLEFIN OLIGOMERS (Continued) Capital Investment Production Costs Discussion of Costs Raw Materials NEOPOLYOL ESTERS Chemistry Definition Raw Materials Neopolyols Acids Esterification I&action Effect of Ester Composition on Physical Properties Lubricant Base Stock Formulation Equilibrium Compositions Empirical Model Viscosity Considerations Other Properties Review of Patents Production of Mixed Short-Chain Fatty Acid Esters of Technical Pentaerythritol Process Description Process Discussion Selection of Processing Scheme Reactants Esterification Reaction; Heats of Reaction Thermophysical Data Design Philosophy Waste Streams Cost Estimates Capital Investment Production Costs Discussion of Costs RawMaterials DIBASIC ACID ESTERS Chemistry Definition RawMaterials Dibasic Acids Alcohols X

6 CONTENTS 6 DIBASIC ACID ESTERS (Continued) Esterification Reaction Physical Properties Review of Patents Production of Di-tridecyl Adipate Process Description Process Discussion Selection of Processing Scheme Reactants Esterification Reaction; Heat of Reaction Thermophysical Data Design Philosophy Waste Streams Cost Estimates Capital Investment Production Costs Discussion of Costs Raw Materials APPENDIX A DESIGN AND COSTS BASES APPENDIX B PROPERTIES OF RAW MATERIALS AND SYNTHETIC LUBRICANT BASE STOCKS APPENDIX C HANDLING AND SAFETY CITED REFERENCES PATENT REFERENCES BY COMPANY Xi

7 ILLUSTRATIONS 4.1 Linear Alpha Olefin Oligomers Viscosity/Oligomer Composition Relationships PRODUCTION OF HYDROGENATION DECENE-1 OLIGOMER 4.2 Flow Diagram Effect of Plant Capacity on Total Fixed Capital Effect of Operating Level and Plant Capacity on Production Cost Effect of Acid-Chain Branching on Viscosity on Pentaerythritol Esters PRODUCTION OF MIXED SHORT-CHAIN FATTY ACID ESTERS OF TRCHNICAL PENTAERYTRRITOL 5.2 Flow Diagram Effect of Plant Capacity on Total Fixed Capital Effect of Operating Level and Plant Capacity on Production Cost PRODUCTION OF DI-TRIDECYL ADIPATE 6.1 Flow Diagram Effect of Plant Capacity on Total Fixed Capital Effect of Operating Level and Plant Capacity on Production Cost xiii

8 TABLES Relative Performance of Synthetic Lubricant Base Stocks Versus Petroleum Oils... Summary of Synthetic Lubricant Base Stocb Economics... Synthetic Lubricant Base Stocks Production Capacities in the United States... Synthetic Lubricant Base Stocks Production Capacities in Japan... Linear Alpha Olefin Oligomers PatentSummary... PRODUCTION OF HYDROGENATED DECEDE-1 OLIGOhEK Design Bases and Assumptions... Major Equipment... Utilities Summary... StreamFlows... Total Capital Investment... Production Costs... Excerpts from Specifications for Aircraft Turbine Engine Lubricants... Products Resulting from Reaction of Pentaerythritol and an Acid Mixture... Neopolyol Esters Patent Summary... PRODUCTION OF HIXED SRORT-CHAIN FATTY ACID ESTERS OF TECHNICAL PENTAERYThRITOL Design Bases and Assumptions Major Equipment Utilities Summary StreamFlows Waste Streams Summary Total Capital Investment Production Costs is xv

9 TABLES 6.1 Dibasic Acid Esters PatentSummary PRODUCTION OF DI-TRIDECYL ADIPATE B.l B.2 B.3 B.4 B.5 B.6 B.7 B.8 B.9 Design Bases and Assumptions Major Equipment Utilities Summary StreamFlows Waste Streams Summary Total Capital Investment Production Costs Effect of Alcohol and Acid Prices on Production Costs of Dibasic Acid Esters Properties of Linear Alpha Olefins Properties of llydrogenated Linear Alpha Olefin Oligomer Synthetic Lubricant Base Stocks Properties of Neopolyols Properties of Technical Pentaerythritol Properties of Short-Chain Fatty Acids Properties of Pentaerythritol Fatty Acid Ester Synthetic Lubricant Base Stock Properties of Straight-Chain Dibasic Acids Properties of 0x0 Alcohols Properties of Dibasic Acid Ester Synthetic Base Stocks xvi