Mist-control of polyalphaolefin (PAO) lubricants using long pairwise end-associative polymers

Accidental release of pressurized hydrocarbon fuels and lubricants are a major fire hazard due to the formation of small droplet mists that can readily evaporate and ignite. Mist control through increasing droplet size and suppressing droplets has been previously demonstrated with high molecular weight polymer additives, but traditional long polymer additives do not survive the pumping that would usually precede accidental release. This constraint inspired associative polymer additives that can transiently form the high molecular weights needed for mist control, while reversibly breaking during pumping. A prior study demonstrated the efficacy of such a system in fuel: long telechelic polycyclooctadiene (PCOD) with pairwise associating acid and base end-groups. Here, we address an obstacle to applying this same polymeric system in a polyalphaolefin (PAO) solvent—its poorer solvent quality for PCOD than fuel. We measured the effects of the end-associative PCOD compared to a non-associative control on the rheological properties of solutions in both PAO (a common lubricant and heat transfer fluid) and decahydronapthalene (decalin, a solvent with PCOD solubility similar to fuel) in shear and extension, and connect those rheological modifications to observed changes in PAO spray under simulated accidental release conditions. The PCOD additives demonstrated substantial mist control in PAO, both in terms of reduced spray angle and droplet suppression. Despite the worse solubility in PAO and thus smaller effective coil size, these associative PCOD additives are effective at the low concentrations (¡0.1 wt %) necessary for practical use as a safety measure.