Sulfurized Alkyl Phenate Composition With High Sulfurization Stability
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Solution Overview
Problem
Existing methods struggle to achieve high sulfurization ratios of sulfurized alkyl phenates while minimizing unsulfurized alkyl phenates, particularly in overbased additives, leading to regeneration of unsulfurized variants during processing.
Innovation Solution
A method involving sulfurizing alkyl phenol with sulfur monochloride or dichloride, neutralizing and optionally overbasing in the presence of a solvent at controlled temperatures, followed by post-processing steps to maintain a sulfurization ratio of 500:1 or greater, without removing residual unsulfurized alkyl phenate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional methods are used to prepare overbased sulfurized alkyl phenates, then the additive provides detergent and dispersant functions, but the sulfurization ratio is low due to regeneration of unsulfurized variants during processing
Solution Approach 1:
The patent applies parameter changes by precisely controlling the mol ratio of sulfur source to alkyl phenol (0.66 to 3.5) and conducting neutralization/overbasing at temperatures not exceeding 140°C. These parameter optimizations prevent the regeneration of unsulfurized variants while maintaining high sulfurization ratios of 500:1 or greater in the final product
Solution Approach 2:
The patent employs preliminary action by conducting the sulfurization step before neutralization and overbasing operations. This sequence ensures that the sulfurized form is established prior to subsequent processing steps that could otherwise cause regeneration of unsulfurized variants, thereby preserving the high sulfurization ratio throughout the manufacturing process
2Productivity
If temperature is increased to improve reaction rate during neutralization and overbasing, then processing efficiency increases, but sulfurization ratio decreases due to regeneration of unsulfurized alkyl phenates
Solution Approach 1:
The patent optimizes the temperature parameter by conducting neutralization and overbasing at temperatures not exceeding 140°C. This temperature control prevents the regeneration of unsulfurized variants while still allowing the reactions to proceed at acceptable rates, thus maintaining both productivity and high sulfurization ratios
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
The method achieves sulfurization ratios of 500:1 to 5000:1 with less than 0.2% unsulfurized alkyl phenate, maintaining high sulfurization levels throughout processing and avoiding the need to remove unsulfurized variants.
Implementation Method 1
sulfurizing an alkyl phenol with a source of sulfur to provide a sulfurized alkyl phenol, wherein the alkyl phenol is derived from an alkylation of a phenol and wherein a mol ratio of the sulfur source to the alkyl phenol is about 0.66 to about 3.5
Implementation Method 2
The process includes sulfurizing an alkyl phenol with a source of sulfur to provide a sulfurized alkyl phenol
Implementation Method 3
neutralizing and optionally overbasing the sulfurized alkyl phenol in the presence of a solvent to provide a sulfurized alkyl phenate composition
Data Source
Figure 1
AI summary
The present disclosure provides a method for preparing a sulfurized alkyl phenate product to achieve a high sulfurization ratio of sulfurized alkyl phenate to unsulfurized alkyl phenate/phenol in the context of a neutralized and optionally overbased additive.