Process for producing metal salts of oil-soluble organosulfonic acids

Claim 2

A process for producing a metal salt of an organosulfonic acid and a metal selected from alkali metals, and alkaline earth metals, said process comprising the steps of: (i) providing a mixture comprising the organosulfonic acid and at least 2 moles of water per equivalent of said sulfonic acid; (ii) adding to the mixture a compound of at least one of said metals in the form of a carbonate, in an amount sufficient to provide a molar excess of said compound of at least about 1%; (iii) reacting and heating the mixture until the carbonate/acid equilibrium point is reached; and (iv) adding a small amount of up to about 1%, based on the weight of the carbonate, of a compound selected from a metal oxide or metal hydroxide which has a base strength greater than that of bicarbonate ion, sufficient to effect complete neutralization of the remainder of said organosulfonic acid.

Claim 3

A process as defined in claim 1 wherein the equilibrium point is taken as the point in time where the hydrogen ion concentration measured on a substantially carbonate- and bicarbonate-free sample of the reaction mixture becomes stabilized at a fixed value.

Claim 4

A process as defined in claim 2 wherein the end point is taken as the point in time where the pH of the substantially carbonate- and bicarbonate-free sample stabilizes in a range of from about 6.0 to about 6.38.

Claim 5

A process as defined in claim 1 wherein the organosulfonic acid is an oil-soluble organosulfonic acid, and said mixture also includes an inert solvent.

Claim 6

A process as defined in claim 1 wherein the compound added in step (iv) is a metal oxide or a metal hydroxide.

Claim 7

A process as defined in claim 5 wherein the compound added in step (iv) is the same as the metal of the carbonate added in step (ii).

Claim 8

A process as defined in claim 4 wherein the oil-soluble organosulfonic acid is selected from mono- , di- and trisulfonic acids of aliphatic or aromatic hydrocarbons, and has a molecular weight of greater than about 350.

Claim 9

A process as defined in claim 7 wherein the oil-soluble organosulfonic acid dinonylnaphthalene sulfonic acid.

Claim 10

A process as defined in claim 1 wherein the organosulfonic acid is dinonylnaphthalene disulfonic acid.

Claim 11

A process as defined in claim 1 wherein the metal in the carbonate used in step (ii) is selected from sodium, potassium, lithium, barium, calcium, and magnesium.

Claim 12

A process as defined in claim 10 wherein the metal in the carbonate used in step (ii) is barium.

Claim 13

A process as defined in claim 10 wherein the metal in the carbonate used in step (ii) is calcium.

Claim 14

A process as defined in claim 10 wherein the metal in the carbonate used in step (ii) is lithium.

Claim 15

A method as defined in claim 5 wherein the metal compound added in step (iv) is barium hydroxide.

Claim 16

A method as defined in claim 5 wherein the metal compound added in step (iv) is calcium hydroxide.

Claim 17

A method as defined in claim 5 wherein the metal compound added in step (iv) is lithium hydroxide.

Claim 18

A process for producing a metal salt of dinonylnaphthalene sulfonic acid and a metal selected from sodium, potassium, lithium, calcium, magnesium, and barium, said process comprising the steps of: (i) forming a solution of dinonylnaphthalene sulfonic acid in an inert volatile organic solvent and at least two moles of water per equivalent of said sulfonic acid; (ii) adding to the solution a compound of at least one of said metals in the form of a carbonate, in an amount sufficient to provide a molar excess of said compound in the range of from 1 to 10%; (iii) reacting and heating the mixture at a temperature of at least about 60° C. until the carbonate/acid equilibrium point is reached and the pH measured on a substantially carbonate- and bicarbonate-free sample would fall in the range of from about 6.0 to about 6.38; and (iv) adding a small amount of up to 1%, based on the weight of the carbonate, of a metal compound which has a base strength greater than that of the bicarbonate ion, sufficient to effect complete neutralization of the remainder of said dinonylnaphthalene sulfonic acid.

Claim 19

A process for producing a metal salt of dinonylnaphthalene sulfonic acid and a metal selected from sodium, potassium, lithium, calcium, magnesium, and barium, said process comprising the steps of: (i) forming a solution of dinonylnaphthalene sulfonic acid in an inert volatile organic solvent and at least two moles of water per equivalent of said sulfonic acid; (ii) adding to the solution a compound of at least one of said metals in the form of a carbonate, in an amount sufficient to provide a molar excess of said compound in the range of from 1 to 10%; (iii) reacting and heating the mixture at a temperature of at least about 60° C. until the carbonate/acid equilibrium point is reached and the pH measured on a substantially carbonate- and bicarbonate-free sample would fall in the range of from about 6.0 to about 6.38; and (iv) adding a small amount of up to 1%, based on the weight of the carbonate, of a metal compound which has a base strength greater than that of the bicarbonate ion, sufficient to effect complete neutralization of the remainder of said dinonylnaphthalene sulfonic acid.

Claim 20

A process as defined in claim 17 including the steps of adding a relatively non-volatile hydrocarbon oil to the reaction mixture at any stage, and as a final step, selectively removing the inert volatile organic solvent and water, to produce a solution of the metal salt of said sulfonic acid in said hydrocarbon oil.

Claim 21

A process as defined in claim 18 wherein the volatile solvent and water are removed by distillation and the amount of hydrocarbon oil used produces a solution comprising 40 to 60% by weight of the metal sulfonate.

Claim 22

A process as defined in claim 17 wherein the metal in the carbonate compound used in step (ii) and in the metal compound of step (iv) is barium.

Claim 23

A process as defined in claim 17 wherein the metal in the carbonate compound used in step (ii) and in the metal compound of step (iv) is calcium.

Claim 24

A process as defined in claim 17 wherein the metal in the carbonate compound used in step (ii) and in the metal compound of step (iv) is lithium.

Claim 25

A process as defined in claim 17 including the steps of adding a relatively non-volatile ester lubricant to the neutral mixture, selectively removing the inert volatile organic solvent and water and thereby producing a solution of the metal salt of said sulfonic acid in said ester lubricant.

Claim 26

A process as defined in claim 1 wherein said heating in step (iii) is carried out in the range of from about 60° C. to about 90° C.

Claim 27

A process as defined in claim 1 wherein said heating in step (iii) is carried out at a temperature of from about 75° C. to about 80° C.