Sulfurized Calcium Alkyl Phenolate Extraction for Low Free Phenol
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Solution Overview
Problem
Current metal detergents, such as sulfurized calcium alkyl phenolate, contain high levels of free alkyl phenol, which can have adverse environmental and health effects due to their persistence and toxicity, and existing methods do not effectively reduce these levels.
Innovation Solution
A method involving mixing alkyl phenol with a calcium source and base oil, followed by sulfurization and carbonation reactions, using a solvent containing solvent oil, water, and an oxygenous derivative of hydrocarbon to extract and refine sulfurized calcium alkyl phenolate, resulting in a product with a free alkyl phenol content below 1.5 wt%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional sulfurization method is used to produce sulfurized calcium alkyl phenolate, then the production process is simple, but the free alkyl phenol content in the product is high (5-10 wt%), causing environmental toxicity and reduced oxidation resistance
Solution Approach 1:
The patent applies extraction principle by introducing a three-component solvent system (solvent oil, water, and oxygenous derivative of hydrocarbon) to selectively extract and remove free alkyl phenol from the reaction mixture. The oxygenous derivative (ketone or alcohol) specifically targets and extracts the harmful free alkyl phenol, separating it from the desired sulfurized calcium alkyl phenolate product, thereby reducing the free alkyl phenol content to below 1.5 wt%.
Solution Approach 2:
The patent employs a composite solvent system combining three different components (solvent oil, water, and oxygenous derivative of hydrocarbon) rather than using a single solvent. This composite approach leverages the synergistic effects of different solvent properties to achieve superior extraction efficiency and product purity while maintaining environmental compatibility.
2Object-affected harmful factors
If free alkyl phenol content is reduced to below 1.5 wt%, then environmental safety and oxidation resistance are improved, but the extraction process complexity increases
Solution Approach 1:
The oxygenous derivative of hydrocarbon (ketone or alcohol) serves as an intermediary substance in the extraction system. It specifically interacts with free alkyl phenol through hydrogen bonding and polarity matching, facilitating its selective extraction from the reaction mixture. This intermediary component bridges the gap between the non-polar solvent oil and the polar free alkyl phenol, enabling efficient removal of the harmful substance.
Solution Approach 2:
The patent optimizes the mass ratios of the three solvent components to achieve optimal extraction efficiency. By adjusting the parameters of the solvent system composition and the extraction conditions, the process achieves high removal efficiency of free alkyl phenol while controlling the complexity of the extraction system.
3Reliability
If conventional production method is used, then production cost is low, but the product has poor oxidation resistance and detergency due to high free alkyl phenol content
Solution Approach 1:
The patent performs extraction and purification of free alkyl phenol during the production process itself, rather than as a separate post-treatment step. By integrating the extraction operation into the manufacturing流程, the process removes harmful free alkyl phenol before the product is finalized, ensuring high oxidation resistance and detergency while avoiding additional complex post-processing steps.
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 significantly reduces the free alkyl phenol content in sulfurized calcium alkyl phenolate, enhancing its environmental safety and performance as a metal detergent, while maintaining its detergency and oxidation resistance properties.
Implementation Method 1
extracting the free alkyl phenol in the product from carbonation reaction with a solvent comprising solvent oil and oxygenous derivative of hydrocarbon
Data Source
AI summary
The present invention relates to the field of metal detergent, especially to a metal detergent and a preparation method thereof and a lubricant oil containing the metal detergent. The metal detergent provided by the present application is sulfurized calcium alkyl phenolate, the method for preparing the metal detergent includes the following steps: a) mixing alkyl phenol, a calcium source and base oil to obtain a mixed solution; b) mixing the mixed solution, ethylene glycol and a sulfur source to carry out sulfurization reaction to obtain a sulfurization reaction solution; c) implementing carbonation reaction between the sulfurization reaction solution and CO2 to obtain a carbonation reaction solution; and d) extracting the carbonation reaction solution with a solvent, upon refining, to obtain sulfurized calcium alkyl phenolate; wherein the solvent includes solvent oil, water and oxygenous derivative of hydrocarbon. Experimental results show that the content of free alkyl phenol is below 1.5 wt% in the sulfurized calcium alkyl phenolate prepared using the preparation method provided by the present application.