Branched Polysulfide Synthesis via Mercaptan Mixture
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Solution Overview
Problem
The existing processes for producing polysulfides are costly due to the need for numerous purification steps, and there is a demand for mercaptan compositions suitable for diverse applications that can utilize mercaptan mixtures rather than single pure compounds.
Innovation Solution
A composition comprising at least 50 wt.% branched C20 to C60 polysulfides and/or monosulfides, produced through reacting branched C10 to C30 mercaptans and sulfur in the presence of a catalyst, or by reacting hydrogen sulfide with branched C10 to C30 olefins to form branched C10+ mercaptans, which are then reacted with sulfur to produce C20+ polysulfides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If individual pure mercaptans are produced through existing processes, then high purity is achieved, but production cost increases due to numerous purification steps
Solution Approach 1:
The patent changes the compositional parameters by producing mixed mercaptan compositions with controlled distributions of different chain lengths (C10-C30) and structures (branched/linear) rather than single pure compounds. This parameter change allows the process to accept broader feedstock specifications and reduce purification requirements while still meeting application requirements
Solution Approach 2:
The patent creates a homogeneous mixture of mercaptans with similar chemical properties (all are thiol compounds with comparable reactivity) that can be used together in applications. The mixed composition maintains functional homogeneity even though it contains multiple components, eliminating the need for separation into individual pure compounds
2Ease of manufacture
If mixed mercaptan compositions are produced, then production cost decreases and versatility increases, but manufacturing precision (purity) is reduced
Solution Approach 1:
The patent creates a mixed mercaptan composition that serves multiple functions and applications simultaneously. The composition can be used as chain transfer agents in polymerization, lubricant additives, and other applications that benefit from a mixture of mercaptan chain lengths and structures, increasing versatility while reducing production cost
3Reliability
If polysulfides are produced from mercaptans, then desired product functionality is achieved, but process complexity increases
Solution Approach 1:
The patent performs preliminary oxidation of mercaptans to disulfides before the final polysulfide formation step. This preliminary action creates intermediate products that control the subsequent reaction with sulfur, preventing runaway polymerization and enabling better control over the final polysulfide composition and chain length distribution
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method reduces production costs by minimizing purification steps and provides mercaptan compositions suitable for various applications, including lubricants and sulfiding agents, by producing a mixture of polysulfides and monosulfides with specific weight percentages.
Implementation Method 1
reacting a feedstock comprising one or more branched C10 to C30 mercaptans and sulfur in the presence of a catalyst
Implementation Method 2
reacting hydrogen sulfide (H2S) and a feedstock comprising one or more branched C10 to C30 olefins in the presence of an initiating agent to produce a branched C10+ mercaptans crude composition
Data Source
AI summary
A composition comprising polysulfides, wherein at least about 50 wt. % of the polysulfides are branched C20 to C60 polysulfides represented by general formula R15S1—[S]n—S2R16 wherein R15 and R16 are each independently a branched C10 to C30 alkyl group and wherein n is an integer from 1 to 10. A process of producing a polysulfides crude product comprising one or more branched C20 to C60 polysulfides comprising: (A) reacting a feedstock comprising one or more branched C10 to C30 mercaptans and sulfur in the presence of a catalyst and (B) collecting the polysulfides crude product.