The Lubrizol Corporation

Allen J Rolfes

Scot Eric Jaynes

A. process for producing an overbased oil soluble calcium sulfonate, comprising the steps of: (a) mixing a substrate comprising a sulfonic acid or a calcium salt of a sulfonic acid, with at least one alcohol, a diluent oil, a carboxylic acid, an acidic material, water and calcium oxide to form a mixture; (b) heating the mixture to its reflux point to form a neutral calcium salt of the acid moieties; (c) removing a substantial portion of distillable solvents to form an intermediate residue; (d) adding to the intermediate residue at least one alcohol, a surfactant, calcium oxide and water such that for every 100 parts of substrate, there are not more than 25 parts water to form an intimate mixture having a direct base number of 90-250; (e) heating said intimate mixture (d) to below its reflux point to form a heated intimate mixture; (f) passing gaseous carbon dioxide into the heated intimate mixture (e) to form an overbased calcium sulfonate and a mixture of calcium hydroxide, calcium carbonate and regenerated water until the direct base number is from 90-150; (g) adding additional calcium oxide until the direct base number is from 90-250 followed by the passing of additional gaseous carbon dioxide until the direct base number is from 90-150; (h) continuing the passsing of gaseous carbon dioxide to a direct base number of 0-75 after the last portion of calcium oxide is added; (i) removing any distillable solvents to form a final residue; and (j) filtering the final residue to obtain a substantially solvent-free and solids-free oil soluble overbased calcium sulfonate; with the proviso that calcium oxide is the only substantial source of overbasing calcium.

Process for making overbased calcium sulfonate detergents using calcium oxide and a less than stoichiometric amount of water

A process for producing an overbased oil soluble calcium sulfonate, comprising the steps of: (a) mixing a substrate comprising a sulfonic acid or a calcium salt of a sulfonic acid, with at least one alcohol, a diluent oil, a carboxylic acid, an acidic material, water and calcium oxide to form a mixture; (b) heating the mixture to its reflux point to form a neutral calcium salt of the acid moieties; (c) removing a substantial portion of distillable solvents to form an intermediate residue; (d) adding to the intermediate residue at least one alcohol, a surfactant, calcium oxide and water such that for every 100 parts of substrate, there are not more than 25 parts water to form an intimate mixture having a direct base number of 90-250; (e) heating said intimate mixture (d) to below its reflux point to form a heated intimate mixture; (f) passing gaseous carbon dioxide into the heated intimate mixture (e) to form an overbased calcium sulfonate and a mixture of calcium hydroxide, calcium carbonate and regenerated water until the direct base number is from 90-150; (g) adding additional calcium oxide until the direct base number is from 90-250 followed by the passing of additional gaseous carbon dioxide until the direct base number is from 90-150; (h) continuing the passing of gaseous carbon dioxide to a direct base number of 0-75 after the last portion of calcium oxide is added; (i) removing any distillable solvents to form a final residue; and (j) filtering the final residue to obtain a substantially solvent-free and solids-free oil soluble overbased calcium sulfonate; with the proviso that calcium oxide is the only substantial source of overbasing calcium.

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Mentor, OH, United States of America

Allen J Rolfes