BACKGROUND

[0001] The present invention relates generally to polycyclic aromatic

compounds that have one or more bay regions and more specifically to a process for transforming such polycyclic aromatic compounds into safe aromatic oils that have a low mutagenicity (Ml) and good physical and chemical properties for safe industrial use including as rubber processing oils and inks.

[0002] Heavy Vacuum Gas Oils (HVGO's) that are not processed beyond distillation often contain a measurable proportion of polycyclic aromatic

compounds (PACs). A subset of these compounds are classified as carcinogens by Environmental Protection Agency (EPA). A common trait of these

carcinogenic PACs is that they contain bay regions: concave exterior regions formed by three or more phenyl rings that are in a nonlinear arrangement.

[0003] Figure 1 depicts examples of PACs that have one or more bay regions.

[0004] When carcinogenic PACs enter the body of humans or mammals, the bay regions of aromatic compounds form reactive epoxy-diol intermediates which react with the enzyme system responsible for oxidative metabolism. This reactive intermediate binds with DNA adducts and interrupts normal cell reproduction. A test developed to predict cell mutation is called the Modified Ames test and is used to determine the mutagenicity (Ml), i.e. the ability to cause mutation in genetic material.

[0005] Historically HVGO's have been relied upon for their ability to provide excellent solvency for the rubber and ink oil industry; however, the use of HVGO's is currently undesirable due to the high carcinogenicity and mutagenicity of the 4-6 member fused aromatics with bay regions.

[0006] Many countries require unprocessed HVGO's to include warning labels on Safety Data Sheets to make workers aware of the danger of these compounds due to workplace exposure. The petroleum industry responded to these labeling requirements by further processing of HVGO's to extract PAC's using solvent extraction or converting the PAC's to naphthenic compounds using hydrotreating above 800 psi. These hydrotreatments removed sulfur, nitrogen, and oxygen heterocycling of PAC's. Hydrotreating also saturates the aromatic fused rings with hydrogen making the oils non-carcinogenic and non-mutagenic. These hydrotreated naphthenic oils were deemed safe for worker exposure. However these hydrotreated naphthenic oils lost significant solvency that is required in many of the applications such as rubber processing oils and inks.

[0007] The resulting hydrotreated product is a naphthenic oil with low

aromaticity (10-25%) and a decrease in performance in the industry. The industry compensates for this decrease in performance by relying on the use of other additives.

[0008] In the European Union HVGO's are aggressively extracted with dimethyl sulfoxide (DMSO) to make a product called Treated Distillate Aromatic Extract (TDAE). This process results in an oil with -25% aromaticity. Several drawbacks to this process are an immediate yield loss of at least 15%, costly solvent usage and/or solvent recovery, extra processing and equipment costs, and the hazardous disposal of highly carcinogenic organic waste. [0009] The alkylation of HVGO compounds with t-butyl chloride/AIC or an olefin such as pentene with a zeolite catalyst can reduce the Ml to less that 1 is discussed in U.S. Patent Nos. 5,488,193 and 6,010,617 to Mackerer et al. This work was performed on a small scale (100 mg PAH) using carbon disulfide (CS2) as a reaction solvent with a suitable alkylation catalyst. No isolation route was investigated. This process was never developed for commercial use.

[0010] The alkylation of aromatics proceeds through the formation of the carbonium ion. Reaction of the carbonium with an aromatic forms the arenium ion which then loses a hydrogen as follows:

Olefin + Acid→ E ⁺ (Carbonium or Carbocation)

E ⁺ + Ar-H→ [E-Ar-H] ⁺ (Arenium)

[E-Ar-H] ⁺ - H→ E-Ar

BRIEF SUMMARY

[0011] According to various features, characteristics and embodiments of the present invention which will become apparent as the description thereof proceeds, the present invention provides method of reducing the mutagenicity of polycyclic aromatic compounds having one or more bay regions, which method comprises: obtaining a source of polycyclic aromatic compounds; contacting the polycyclic aromatic compounds with alkylating agent selected from styrene and hexene in the presence of a catalyst selected from Lewis acids or protonic acids such as AlC , sulfuric acid, and methyl sulfonic acid to alkylate the polycyclic aromatic compounds; and recovering the alkylated polycyclic aromatic compounds, wherein the mutagenicity of the alkylated polycyclic aromatic compounds is less than 1 .0.

[0012] The present invention further provides an alkylated polycyclic aromatic compound which is made by:

obtaining a polycyclic aromatic compound;

contacting the polycyclic aromatic compound with alkylating agent selected from olefins such as styrene and hexane or halogenated aromatic or aliphatics such as t-butyl chloride or chlorobenzene in the presence of a catalyst selected from AlC , sulfuric acid, and methyl sulfonic acid to alkylate the polycyclic aromatic compound; and

recovering the alkylated polycyclic aromatic compound.

[0013] The present invention further provides rubber extender oil that comprises an alkylated polycyclic aromatic compound.

[0014] The present invention further provides a rubber article that comprise an alkylated polycyclic aromatic compound.

[0015] The present invention also provides an alkylated polycyclic aromatic compound which has been alkylated so as to have a freely rotating aromatic ring attached to a pre-alkylated bay region of the polycyclic aromatic compound.

BRIEF DESCRIPTION OF THE DRAWING

[0016] Figure 1 depicts examples of PAC's that have one or more bay regions.

DETAILED DESCRIPTION OF THE DRAWINGS AND THE PRESENTLY PREFERRED EMBODIMENTS [0017] The present invention relates generally to PAC's that have one or more bay regions and more specifically to a process for transforming such polycyclic aromatic compounds into safe aromatic oils that have a low mutagenicity (Ml) and good physical and chemical properties for safe industrial use including as rubber processing oils and inks.

[0018] The PAC's of the present invention have mutagenicity values as low as about 0.1 which provides a degree of safety greatly needed in the art.

[0019] During the course of the present invention, Heavy Vacuum Gas Oil, several HVGC distillation cuts from HVGO, Light Cycle Oil, and Cat Cracker Slurry, and several naphthenic oils with low aromatics were tested as the feedstock oils to be alkylated.

[0020] Catalysts tested for the alkylation included US-Y zeolite, Amberlite 15 and 36, AlC , sulfuric acid, methane and p-toluene sulfonic acids although other Lewis acids, protonic acids and superacids can be used to alkylate.

[0021] Alkylating reagents tested included butene, hexene, naphthalene, styrene, t-BuCI, and benzyl chloride. It was determined that other olefins and halogenated aromatics can be used in place of these alkylating reagents depending on the catalyst system used.

[0022] As the result of the alkylation testing styrene is the chosen olefin for alkylation. In this regard it was discovered that styrene is better at blocking the bay region than t-butyl chloride or hexene. It is believed that the reason styrene performed better was probably due to the freely rotating aromatic ring of the ethylbeneze side chain formed from the alkylation. Since the resulting oil retains its aromaticity (46%) it was anticipated that the product would have the desired high solvency with low mutagenicity. ASered Biological Activity

Examples

Features and characteristics of the present invention will be exemplified by the following examples which are provided as non-limiting examples only

Examples of alkylation:

[0023] In the following examples un-hydrotreated HVGO having a∑4-6 ring PAC content of 170 ppm and a mutagenicity index (Ml) of 7.5 was subjected to alkylation as described. The target Ml was <1 .

HVGO with t-butyl chloride and AlCb

[0024] In this example 100 grams of the HVGO was alkylated with 102 grams (1 .01 moles) of t-butyl chloride in the presence of 22 grams AlCb in hexane while being refluxed. After alkylation the catalyst was quenched with water and the product was distilled to remove unreacted t-butyl chloride. After alkylation the ∑4-6 ring PAC's in the product were reduced to 0 ppm and Ml was 0.89.

[0025] In this example 100 grams of HVGO was alkylated with 66 grams (0.72 moles) of t-butyl chloride in the presence of 7 grams of AlCb in hexane while being refluxed. After alkylation the catalyst was quenched with water and the product was distilled to remove unreacted t-butyl chloride. After alkylation the ∑4-6 ring PAC's in the product were reduced to 11.9 ppm and the Ml was 1.30.

HVGO with Styrene and H2SO4

[0026] In this example 100 grams of HVGO was alkylated with 75 grams (0.72 moles) of styrene in the presence of 20 grams of sulfuric acid at a temperature of less than 20°C. After alkylation the catalyst was quenched using either an aqueous solution of NaOH or NH ₄ OH and the product was distilled to remove unreacted styrene and light end materials. After alkylation the∑4-6 ring PAC's in the product were reduced to 12.7 ppm and the Ml was 0.14.

[0027] In this example 100 grams of HGO was alkylated with 45 grams (0.43 moles) of styrene in the presence of 30 ml_ methane sulfonic acid at a

temperature of less than 20°C. After alkylation the catalyst was phase separated and the product is distilled to remove unreacted styrene and light end materials. After alkylation the∑4-6 ring PAC's in the product were reduced to 13.1 ppm and the Ml was 0.60

[0028] In this example 100 grams of HVGO was distilled to remove 25% of the light ends and then alkylated with 30 grams (0.29 moles) styrene in 20 grams of sulfuric acid at a temperature of less than 20°C. After alkylation the catalyst was quenched using either an aqueous solution of NaOH or NH ₄ OH and the product was is distilled to remove unreacted styrene and light end materials. After alkylation the∑4-6 ring PAC's in the product were reduced to 22.8 ppm and the Ml was 0.77. The flash point for this product was 410°F.

Mutagenicity based on blocking groups:

[0029] Based on the above examples styrene was determine to be more effective at blocking the bay regions and reducing the Ml (see Table 1). Using t- BuCI, the Ml at 0 ppm of∑4-6 ring PAC's is 0.89. The presence of as little as 11.9 ppm of these species increase the Ml above the target to 1.3 (Run numbers 2 and 1 , respectively)

Table 1. Comparison of Ml for t-BuCI and Styrene Alkylations

[0030] Using the same moles of styrene (0.72 moles) used to achieve 0 ppm with t-BuCI reduces the∑4-6 ring PAC's to 12.7 ppm; however, the Ml is reduced to 0.14 compared to 0.89 (Run 3 vs. Run 2). This indicates on a mole-to-mole basis, the styrene is more efficient at blocking the bay regions.

[0031] Reducing the moles of styrene by 60% to 0.43 moles still results in a passing Ml . Distilling 25% of the light end of the oil to increase flash point of the product and reducing the moles of styrene further to 0.29 results in a passing Ml

Other Tested Systems:

[0032] From the results of the examples above it was determined that the method for alkylation shows potential for other carcinogenic oil streams including light cycle oil, reclamite B, and cat cracker slurry. These oil streams alkylated as summarized in Table 2 below

[0033] Table 2: Alternative Oils and Alkylating Reagents

[0034] From the test results presented in Table 2 it can be seen that alkylation shows significant reductions in PAC's for all the different oils tested as well as reduction using hexene with HVGO.

Comparison of Analytical of Alkylated HVGO to other Rubber Extender Oils

[0035] In addition to lowering Ml (and∑4-6 ring PAC's) the physical and chemical properties of the alkylated oils were tested during the course of the present invention to determine if the functionality of the alkylation of the oils where adversely effected.

[0036] Currently, Sundex 790N aromatic oil is used in the US market to

compatibilize rubber for processing tires and other rubber products. Sundex oil is a carcinogen due to the high level of PAC's. Sundex oil will eventually be phased out of the U.S. market as it was in the EU and likely will be in the Canadian

market. In the EU, these oils are aggressively solvent extracted to product a passing oil, TDAE. The treatment of this oil results in a loss of the aromaticity and yield loss. In addition there is a high cost associated with disposal of the byproduct solvent stream that is high in PAC's.

[0037] During the course of the present invention it was discovered that HVGO that has 25% of the lights removed and is alkylated according to the present invention results in an aromatic oil that is not only non-carcinogenic, but also has physical and chemical properties similar to that of the Sundex 790 (See Table 3).

Table 3: Physical and Chemical Properties of Alkylated HVGO and other Rubber Extender Oils

Sample

Sundex DAE ³ TDAE ³ Oil Treated Method by

Invention

∑4-6 PAC's - ppm 138.4 - <10 22.84 GC-TOF

Mutagenicity Index Fail Fail Pass 0.77 AMES test for Ml

API Gravity (60°F) 13.8 14.1 D4052

Specific Gravity g/cm-3 0.9738 0.9722 D4052

Pound/Gallon 8.1 1 8.10 Calculation

Flash Point F 473 410 COC

Sulfur 0.93 1 .2 0.8 2.2 D4294/D2622

Viscosity (40°C) cSt 432 1240 410 410.5 D445

Viscosity (100°C) cSt 16.1 28 20 13.5 D445

VGC 0.938 0.937 Calculation Refractive Index 1 .0604 1 .0529 D1747

Caromatic 41 35 30 46

Calculation from Rl

Cparaffinic 42 35 45 24

and VCG

Cnaphthenic 17 40 25 30

³ Petroleum-Based Safe Process Oils in NR and NR/SBR Blends: Effects of Oil Types and Contents on the

Properties on Carbon Black Filled Compounds - J.W.M Noodermeer, University of Twente, Netherlands

[0038] As seen from the data in Table 3 alkylation of HVGO containing PAC's using styrene under acid conditions has higher aromatic content than either

Sundex 790N or TDAE with a mutagenicity index comparable to TDAE and much lower than Sundex. In addition, the viscosity and specific gravity are comparable to the two oils. Flash point of the alkylated HVGO is high enough to be used in the vulcanization process.

[0039] The work conducted during the course of the present invention

demonstrates that safe aromatic oils with low Ml and good physical and chemical properties can be prepared by alkylation. Such safe aromatic oils can be used to compatibilize rubber for processing tires and other rubber products and in other processes in which PCA's have been used.

[0040] Although the present invention has been described with reference to particular means, materials and embodiments, from the foregoing description, one skilled in the art can easily ascertain the essential characteristics of the

present invention and various changes and modifications can be made to adapt the various uses and characteristics without departing from the spirit and scope of the present invention as described above and set forth in the attached claims.