Sulfurized Calcium Phenate Detergent Phenol Removal
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Solution Overview
Problem
Existing sulfurized calcium alkyl phenate detergents contain unreacted alkylphenol, which can cause corrosion and are classified as reproductive toxins, and previous methods to remove phenol, such as protonation and distillation, result in the formation of detrimental acid salts in lubricants.
Innovation Solution
A process involving the addition of an organic solvent with a boiling point above 100°C but below that of the unsulfurized alkyl-substituted phenol to the sulfurized calcium phenate detergent, followed by distillation, to reduce the phenol content without generating harmful species.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional distillation methods are used to remove phenol from detergent, then phenol content is reduced, but acid salts are formed that are detrimental to the engine
Solution Approach 1:
A basic compound (such as an amine or metal oxide) is introduced as an intermediary substance during the distillation process. This intermediary accepts protons from the phenol, preventing the formation of acid salts while facilitating the removal of phenol through distillation. The intermediary acts as a buffer that neutralizes the acidic byproducts in real-time.
Solution Approach 2:
The invention converts the harmful acidic environment that normally leads to acid salt formation into a beneficial basic environment. By adding basic compounds, the process transforms the detrimental protonation reaction into a useful neutralization reaction, where the same distillation process that removes phenol also prevents acid salt formation through the basic medium.
2Productivity
If steam stripping is used to remove phenol, then filtration efficiency is improved, but the process complexity increases
Solution Approach 1:
The invention merges the phenol removal function with the existing distillation process by introducing basic compounds into the same system. Instead of adding a separate steam stripping unit and filtration system, the basic compound is added to the detergent mixture before or during distillation, combining multiple functions (phenol removal, neutralization, and filtration preparation) into a single integrated process step.
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
Effectively reduces the unsulfurized alkyl-substituted phenol content in the detergent while maintaining engine compatibility, as demonstrated by examples showing lower viscosity and phenol content compared to conventional methods.
Implementation Method 1
distilling the organic solvent from the detergent thereby to reduce the content of the unsulfurized alkyl-substituted phenol
Implementation Method 2
distilling the organic solvent from the detergent
Data Source
AI summary
Sulfurized calcium phenate detergents having a reduced unsulfurized alkyl-substituted phenol content are made by:(A) providing, made from an unsulfurized alkyl-substituted phenol, a sulfurized calcium phenate detergent that, optionally, may have been further reacted with carbon dioxide;(B) adding to the detergent from 1 to 100 mass %, based on the mass of the detergent, of an organic solvent that has a boiling point of above 100° C. and below the boiling point of the unsulfurized alkyl-substituted phenol; and(C) removing the organic solvent from the detergent thereby to reduce the unsulfurized alkyl-substituted phenol content.