Organo-Al-Chloride Catalyzed Poly-N-Butenes Process

1. Field of the Invention

This invention relates to the polymerization of butenes and, more particularly, this invention relates to the production of poly-n-butenes from a mixed C.sub.4 feedstream utilizing an organo aluminum chloride-hydrogen chloride co-catalyst system.

2. Description of Prior Art

The production of isobutylene polymers from mixed C.sub.4 hydrocarbon feedstreams is generally known in the art. It is also known to utilize AlCl.sub.3 as the polymerization catalyst in such processes and the prior art discloses a number of co-catalyst or catalyst promoters, including hydrogen chloride for use under various conditions in isobutylene polymerization.

Representative disclosures include U.S. Pat. No. 2,957,930 which shows the use of 10 to 20% AlCl.sub.3 catalyst in the production of polyisobutylene from a C.sub.1 to C.sub.5 petroleum gas feedstock with 0.08 to 0.12 percent HCl, relative to AlCl.sub.3, used as a catalyst promoter. This reference notes that correspondingly small quantities of water vapor or chloroform, which can react with AlCl.sub.3 to release HCl, may also be used. British Pat. No. 1,195,760 (1970) discloses the production of olefin polymers by polymerization in the presence of the catalyst comprising a liquid complex of AlCl.sub.3, HCl and an alkyl benzene. Polymerization products include materials other than polyisobutylene and products with a narrow molecular weight distribution are disclosed in this reference.

U.S. Pat. Nos. 3,200,169 and 3,200,170 deal with the reaction mixture separation methods after polymerization of propylene or butylene feeds utilizing an ammonia treatment process. HCl is disclosed in the references as a suitable catalyst promoter added to the reaction zone which contains an AlCl.sub.3 catalyst.

U.S. Pat. No. 3,997,129 discloses polybutylenes from a C.sub.1 to C.sub.5 liquefied refinery stream wherein the catalyst is solid particles of AlCl.sub.3 promoted with HCl gas or its equivalent. This process employs a static mixer for mixing catalysts and feed prior to conducting polymerization.

U.S. Pat. No. 3,985,822 relates to the production of poly-n-butenes by use of AlCl.sub.3 promoted with HCl but the objective is to reduce the isobutylene content of the polymer product.

U.S. Pat. No. 3,119,884 discloses a series of vertical column reactors useful for polymerizing isobutylene and further discloses a catalyst comprising AlCl.sub.3 and HCl or a substance which generates HCl. The catalyst system is described as an acid promoted AlCl.sub.3 catalyst. In such a system, a reaction between HCl and AlCl.sub.3 occurs to form H.sup.+ AlCl.sub.4 .sup.- which is the species that initiates polymerization. According to this process, one method of introducing catalysts and reactants is to have the three materials, i.e., AlCl.sub.3, HCl and liquid feed, enter the reactor through the same duct. This necessarily results in polymerization beginning in the duct line in an exothermic reaction and the reaction is not controlled by the refrigeration system of the reactor. Any product formed under these conditions will have an undesirable low molecular weight and broad molecular weight distribution.

U.S. Pat. No. 3,501,551 is directed to a process for producing normal butene polymers at molecular weights of from about 200-750 wherein a C.sub.3-5 hydrocarbon mixture containing isobutylene and normal butylenes as substantially the only olefins present are reacted in liquid phase with an aluminum chloride catalyst to form a reaction mixture containing only isobutylene polymers. The isobutylene polymers are separated and thereafter the resulting reaction mixture is treated with a Friedel-Crafts catalyst to form a second reaction mixture containing normal butylene polymers. The aluminum chloride in the first polymerization section is indicated to be added alone or in combination with promoters, such as alkyl chloride, e.g., isopropyl chloride.

U.S. Pat. No. 3,639,661 relates to processes for polymerization of isobutylene employing as polymerization catalysts either a reaction product of titanium tetrafluoride with a chlorine bearing Friedel-Crafts catalyst which is soluble in isobutylene or a reaction product of titanium tetrachloride or boron trichloride with a fluorine bearing compound whose fluorine atoms are capable of partly replacing chlorine atoms in the titanium tetrachloride or boron tetrachloride. It is indicated that the catalyst can be made in situ by adding the catalyst components separately to the reaction medium.

U.S. Pat. No. 3,991,129 relates to the production of polybutene employing recycled reaction liquid, liquefied butenes and Friedel-Crafts catalyst, which is stated to be preferably aluminum chloride promoted with hydrochloric acid gas or its water equivalent. The catalyst is admixed with the recycle and fresh feed lines upstream of a static mixer prior to charging to the polymerization reaction column.

U.S. Pat. No. 4,465,887 relates to a process for producing butylene polymers having molecular weights of from about 400-5,000 wherein the feedstream containing mixed butenes is fractionated to remove recited amounts of cis-2-butene. The overhead fraction from the fractionating step contains isobutylene and is reacted in the presence of an aluminum chloride catalyst to polymerize the isobutylene and to form a reaction mixture consisting of isobutylene polymers and unreaction hydrocarbons including normal butenes. This reaction mixture is flashed distilled or recover the isobutylene polymers and the unreacted hydrocarbon mixture is then reacted in a presence of a catalyst system consisting of aluminum chloride and a promoter to polymerize butylenes in the fraction and form in a second reaction product mixture containing butylene polymers having lower molecule weights, e.g., of from 400-900 molecular weight. The patent indicates that a promoter is essential of a second polymerization reaction, and indicates that typical promoters are isopropyl chloride, t-butyl chloride, water and hydrogen chloride. The patent's promoters are added to the reactor separately from the aluminum chloride and the first hydrocarbon reaction mixture containing the unreacted normal butene.

U.S. Pat. No. 4,558,170 relates to the preparation of polyisobutylene from a mixed C.sub.4 hydrocarbon feedstream containing at least about 6 wt% isobutylene using an AlCl.sub.3 - HCl catalyst system wherein the HCl is introduced separately into the feedstream to form organochlorides therein prior to introduction into the polymerization reactor.

U.K. Pat. No. 1,449,840 describes a process for alkylating benzene, wherein benzene is contacted with a polybutene in the presence of aluminum chloride. The polybutene itself is prepared by polymerizing a mixed C.sub.4 feedstock containing from 2-20 wt. % of isobutene. The polybutenes are stated to be prepared bY conventional polymerization process using a Friedel-Crafts catalyst such as aluminum chloride.

Belgium Pat. No. 731,006 relates to the alkylation of aromatic hydrocarbons using n-butene polymers, wherein the polymers are produced from a refiner stream containing n-butene basically free from isobutylene which are polymerized in the presence of aluminum chloride.

European Pat. No. 115,635 relates to a continuous process for producing polyisobutylene from isobutylene feeds, wherein solvents and monomer vaporized during the polymerization are recycled after liquefaction to the polymerization zone.

The present invention provides a further improvement in the process disclosed in U.S. Pat. No. 4,558,170, by virtue of permitting advantageous production of poly-n-butenes from the spent C.sub.4 olefin containing stream produced as by-product in the process of forming polyisobutylene.

The present invention is considered distinguished from the remaining foregoing references in that it produces poly-n-butenes which are especially suitable as the oil soluble hydrocarbon component of a lubricating oil detergent. Poly-n-butenes produced in this invention are characterized by a narrow molecular weight distribution in the detergent molecular weight range, that is, a number average molecular weight (M.sub.n) of about 300 to 900. Molecular weight distribution is used here in its normal sense as a measure of the breadth of molecular weight distribution and is defined as the ratio of M.sub.w (weight average molecular weight) to M.sub.n. This narrow molecular weight distribution results in a product having a relatively lower viscosity than polyisobutylenes produced in heretofore conventional processes in the same molecular weight range. The process is especially characterized in the technique of addition of HCl co-catalyst to the feedstream prior to the feedstream entering the reactor. Other methods of providing HCl which the prior art considers suitable, i.e., such as adding HCl to the reactor itself, adding water or other HCl-generating reagents or adding HCl to catalyst prior to initiation of polymerization are not suitable in this invention and do not provide the degree of process control and product quality achieved herein.

FIG. 1 is a diagrammatic illustration of one embodiment of the process of the present invention which is integrated with a process for producing polyisobutylene whereby the spent C.sub.4 stream from the polyisobutylene process units is advantageously converted into the improved poly-n-butene polymers of the present invention.

In accordance with the present invention there has been discovered a process for preparing low molecular weight poly-n-butene having an M.sub.n in the range of about 300 to about 900, and preferably from about 400 to 800, and a molecular weight distribution less than about 1.4 (and preferably from about 1.2 to 1.4) from a feedstream mixture of C.sub.4 hydrocarbons containing less than about 5% by weight isobutylene and containing at least about 12 wt.% normal-butenes in a stirred reaction zone maintained at a temperature of less than about 90.degree. C., which comprises: (a) injecting HCl in an amount of from about 0.01 to 0.6 parts by weight per 100 parts by weight of the feedstream mixture into the feedstream mixture, in the substantial absence of the organo-aluminum catalyst and under conditions sufficient to substantially completely react the injected HCl with normal-butenes, thereby producing a treated feedstream mixture which contains not greater than about 1.0 ppm free HCl; (b) simultaneously introducing the treated feedstream mixture and the organo-aluminum chloride catalyst as separate streams into the reaction zone; (c) contacting the introduced treated feedstream mixture and the introduced catalyst in the reaction zone for a time and under conditions sufficient to form a polymerization reaction mixture containing the poly-n-butene; (d) withdrawing the polymerization reaction mixture from the reaction zone; and (e) recovering the poly-n-butene product from said withdrawn polymerization reaction mixture. The poly-n-butenes can be recovered from the reaction mixture by quenching the withdrawn reaction mixture with aqueous alkali and separating therefrom poly-n-butenes product, which can then be stripped of unreacted C.sub.4 hydrocarbons and poly-n-butenes below M.sub.n of about 200.

The feedstock for the process of this invention comprises a mixture of pressure liquefied C.sub.4 hydrocarbons which comprise less than about 5% (preferably less than about 4.9 wt%, e.g. from about 0.1 to 4.9 wt%) isobutylene, and at least about 12 wt. % (preferably at least about 15 wt%, e.g. from about 15 to 85 wt%) total normal-butenes (i.e., butene-1, cis- and trans-butene-2), together with n-butane, isobutane and less than about 1% (preferably less than about 0.8 wt%, e.g. from about 0 to 0.8 wt%) butadiene. The C.sub.4 feedstream preferably is substantially free of H.sub.2 and sulfur contaminants (e.g., mercaptans), e.g.<20 wppm H.sub.2 and <5 wppm S. Such low levels of free H.sub.2 minimize the degree of saturation in the poly-n-butene products of this invention, and the low S levels are desired to avoid undesired side-reactions with the monomer, polymer and catalyst components, and to avoid the need to resort to added expense and technical difficulties in removing the sulfur contaminants from the polymers thereby formed. Further, the C.sub.4 feedstream is preferably substantially anhydrous, that it, contains less than about 0.05 wt% water, more preferably less than about 300 wppm water, based on the C.sub.4 monomers in the feedstream. It has been found that water, which can be typically present in spent C.sub.4 streams produced in the manufacture of polyisobutylene (as will be more completely described below) is not an effective co-catalyst: in the manufacture of the poly-n-butene polymers of the present invention employing the organo-aluminum catalyst/HCl pre-reacted cocatalyst systems in the present invention. Rather, such excess water are undesired due to side-reactions of the water with the organo-aluminum catalyst which decrease the effective catalyst concentration in the reactor, and which do not offer any offsetting enhancement in the rate of polymerization or in any observed polymer performance property.

The preferred C.sub.4 feedstream comprises spent C.sub.4 streams produced as by-product in the manufacture of polyisobutylene and contains (by weight) less than about 5% isobutylene, about 10-70% saturated butanes and about 15-85% 1- and 2-butenes. The C.sub.4 products other than butenes (e.g., saturated C.sub.4 hydrocarbons), function as diluent or solvent in the reaction mixture and are a non-critical aspect of this invention. The isobutylene content of the feedstock should not be greater than about 5 wt. % of the feedstream. The C.sub.4 feedstream is maintained at a sufficient pressure to be in liquid form both in the reactor inlet and in the reaction mixture itself at the reaction temperature, which is generally from about 5.degree. C. to 90.degree. C., conventional cooling means (e.g., providing cooling coils within the reactor; cooling the external surfaces of the reactor; withdrawing a portion of the reaction mixture from the reaction zone to an external cooler and recycling it to the reaction zone; etc.) being used to maintain the reaction at these temperatures in view of the exothermic nature of the reaction. Preferred reaction temperatures are about 10.degree. C. to 70.degree. C., and most preferred 10.degree. C. to 60.degree. C. Generally, relatively higher temperatures tend to produce relatively low molecular weight polymer. Reaction pressures are generally from about 250 to 1,000 kPa, and more typically from about 300 to 700 kPa.

The process of the present invention employs either a tubular reactor or a stirred reactor (preferably a continuous type stirred reactor) having two separate inlet means for introduction of C.sub.4 feedstream and the organo-aluminum chloride catalyst, the latter being added alone or in admixture with a diluent or solvent which is substantially inert under the premixing and polymerization conditions. Useful diluents include liquid organo saturated hydrocarbons, such as n-butane, isobutane or mixtures of saturated butanes.

The feedstream inlet means (e.g., a conduit) is fitted with a device for injection (preferably for continuous injection) of HCl (preferably gaseous HCl) co-catalyst into the C.sub.4 feedstream at a point prior to reactor entry. The HCl injection point should be introduced into the C.sub.4 feedstream sufficiently in advance of the reactor entry to permit substantially complete reaction of the HCl in the feedstream with 1- and 2-butenes prior to the polymerization reaction zone. The HCl is believed to rcact with the 1- and 2-butenes to form a 2-chlorobutane in the resulting treated feedstream mixture. Other organo chlorides can also be formed, principally t-butyl chloride from reaction with the isobutylene content of the monomer feedstream. The concentration of free HCl in the treated feedstream mixture at the point of reactor entry should therefore be not greater than about 1.0 ppm (parts per million) or less in order to achieve the advantage of the invention. The concentration of the HCl can be determined by conventional means, for example by analyzing the feedstream for organic chlorides and free HCl using a gas chromatograph equipped with a Hall detector. The rate of mixing (and, hence, reaction) of the monomers and the HCl can be conveniently enhanced by use of an in-line static (kinetic) mixer in the feedstream conduit downstream of the HCl injection point. To further enhance the rate of mixing of the HCl and monomers, the mixture of the HCl and the C.sub.4 feedstream is preferably maintained at a temperature of from at least about 5.degree. C., e.g., from about 5.degree. to 70.degree. C.

Preferably, the organo-aluminum chloride catalyst is not admixed with the C.sub.4 feedstream prior to, or during, the injection of the HCl (and preferably is not admixed with the C.sub.4 monomer containing stream prior to the charging of the treated feedstream mixture into the reactor); otherwise uncontrolled, exothermic polymerization will be initiated unless extreme measures are taken (such as maintaining the admixture at a temperature below that which polymerization proceeds. Of course, the extent of such undesired pre-polymerization will vary, depending on the residence time of the admixture outside of the reactor's reaction zone.

Therefore, the treated feedstream mixture, containing the C.sub.4 monomers and the pre-reacted HCl, is preferably added (preferably continuously) to the reactor with organo-aluminum chloride catalyst being introduced into the reaction mixture through a separate inlet.

The process of this invention can be practiced in a batchwise, semi-continuous or (as is preferred) in a continuous manner. Preferably, the treated feedstream mixture, containing the C.sub.4 monomers and the pre-reacted HCl, and the organo-aluminum chloride catalyst streams are added to the reaction zone substantially simultaneously, at a rate sufficient to maintain the selected ratio of the monomers and organo-aluminum catalyst in the liquid reaction mixture. However, it is also possible to add these streams in a stagewise manner to a liquid reaction mixture.

Polymerization occurs in an exothermic reaction in the reaction zone by contacting the two incoming streams in a cooled reactor with reactor temperature, preferably maintained at about 5.degree. C. to 80.degree. C. For a continuous-type stirred reactor, average reactant residence time will generally be about 10 to 45 minutes. There will generally be employed from about 0.05 to 1.5 wt. % of organo-aluminum chloride catalyst per part by weight of treated feedstream mixture and from about 0.005 to 0.6 wt. % of HCl co-catalyst per parts by weight of this treated feedstream mixture, with the preferred range being from about 0.02 to 0.2 wt. % HCl. Generally, the organo-aluminum chloride catalyst and HCl-cocatalyst will be employed in a wt:wt ratio of from about 0.3 to 18 parts, preferably from about 0.4 to 5 parts, and more preferably from about 0.5 to 4 parts, of the organo-aluminum chloride catalyst per part of the HCl-cocatalyst (calculated as HCl).

The organo-aluminum chloride useful in the process of this invention comprises at least one compound of the formula:

wherein R is C.sub.1 to C.sub.20 hydrocarbyl and x is an integer of from 1 to 2. R can comprise branched or straight chained alkyl, cycloalkyl, aryl, alkaryl, aralkyl, alkenyl, and alkynyl, a nd hydrocarbyl (e.g., C.sub.1 to C.sub.10) substituted derivatives thereof. When R is alkyl, the alkyl group can contain from 1 to 20, preferably from 1 to 10, and most preferably from 1 to 4, carbon atoms. Illustrative of such alkyl groups are methyl, ethyl, isopropyl, propyl, n-butyl, isobutyl, tertbutyl, pentyl, hexyl, heptyl, octyl, nonyl, decyl, dodecyl, tridecyl, tetradecyl, octadecyl and the like. When R is alkeyl, the alkeyl group can contain from 2 to 20, preferably from 2 to 10, and most preferably from 2 to 4, carbon atoms. Illustrative of such alkeyl groups ethenyl, isopropenyl, propenyl, n-butenyl, isobutenyl, tertbutenyl, pentenyl, hexenyl, heptenyl, octenyl, nonenyl, decenyl, dodecenyl, tridecenyl, tetradecenyl, octadecenyl and the like. When R is alkynyl, the alkynyl group can contain from 2 to 20, preferably from 2 to 10, and most preferably from 2 to 4, carbon atoms. Illustrative of such alkynyl groups are ethynyl, isopropynyl, propynyl, n-butynyl, isobutynyl, tertbutynyl, pentynyl, hexynyl, heptynyl, octynyl, nonynyl, decynyl, dodecynyl, tridecynyl, tetradecynyl, octadecynyl and the like. When R is aryl, the aryl group can contain from 6 to 10 carbon atoms. Illustrative of such aryl groups are phenyl, naphthyl and the like. When R is alkaryl, the alkaryl group can contain from 7 to 20, preferably from 7 to 15, and most preferably from 7 to 10, carbon atoms. Illustrative of such alkaryl groups are tolyl, xylyl, di(ethyl)phenyl, di(hexyl)phenyl, and the like. When R is aralkyl, the aralkyl group can contain from 7 to 20, preferably from 7 to 15, and most preferably from 7 to 10, carbon atoms. Illustrative of such aralkyl groups are benzyl, ethylbenzyl, phenylhexyl, naphthylhexyl, and the like. When R is cycloalkyl, the cycloalkyl group can contain from 3 to 20, preferably from 3 to 10, and most preferably from 3 to 4, carbon atoms. Illustrative of such cycloalkyl groups are cylcopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, cyclooctyl, cyclononyl, cyclodecyl, cyclododecyl, cyclotridecyl, cyclotetradecyl, cyclooctadecyl and the like. Illustrative of hydrocarbyl-substituted derivatives of the foregoing groups are 2-ethylcyclohexyl, cyclopropylphenyl, phenylcylohexyl, and the like.

Illustrative of useful organo-aluminum chlorides are (CH.sub.3)AlCl.sub.2,(CH.sub.3).sub.2 AlCl, C.sub.2 H.sub.5 AlCl.sub.2, (C.sub.2 H.sub.5).sub.2 AlCl,(CH.sub.3).sub.2 CHAlCl.sub.2, [(CH.sub.3).sub.2 CH].sub.2 AlCl, (C.sub.3 H.sub.7)AlCl.sub.2, (C.sub.3 H.sub.7).sub.2 AlCl, CH.sub.3 CH(CH.sub.3)AlCl.sub.2, [CH.sub.3 CH(CH.sub.3)].sub.2 AlCl, (CH.sub.3).sub.3 CAlCl, [(CH.sub.3).sub.3 C].sub.2 AlCl, C.sub.6 H.sub.13 AlC1.sub.2, C.sub.5 H.sub.11 AlCl.sub.2, C.sub.10 H.sub.21 AlCl.sub.2, and mixtures thereof. Especially preferred are C.sub.2 H.sub.5 AlCl.sub.2, (C.sub.2 H.sub.5).sub.2 AlCl and mixtures thereof. Preferred are organo-aluminum chloride catalysts which are liquids under the reaction conditions.

The poly-n-butenes prepared in accordance with this invention generally contain an average of about 1 double bond per polymer chain and up to about 10 percent of the polymer chains may be saturated.

The poly-n-butenes prepared in accordance with this invention offers a number cf advantages over poly-n-butenes prepared by prior art techniques with respect to those properties which are important for its use in making lubricating oil additives, typically in a form of detergents.

The significant aspect is that the process of this invention permits a more precise control of poly-n-butenes production than heretofore possible.

In the process of the present invention, a high degree of reactor controllability is achieved and the target specification of molecular weight and molecular weight distribution which is desired can be met through monitoring and adjustment of incoming catalyst addition rate, such as the HCl addition rate relative to normal butene content, reactor temperature, residence time, feedstream introduction rate and the like. These parameters and the quality of the finished product can be monitored at close time intervals in the practice of the present invention. Thus, for a given poly-n-butene molecular weight desired, process conditions can be defined which will direct the process toward the target product.

The process of this invention also provides a number of product quality improvements in the poly-n-butenes product which are carried over to the quality of the detergent additive ultimately produced.

Another advantage of the invention is a significant reduction in the quantity of so called "light ends" in the polymer product. These are poly-n-butenes in the undesirable M.sub.n range of about 110 to 200. The process of this invention minimizes the quantity of these materials and the yield of desired product in the high molecular weight range increases accordingly. Products of this invention will generally contain less than about 10% by weight of such low molecular weight polybutenes in the reaction mixture prior to product finishing. After stripping of volatiles and light ends of M.sub.n 200 and below, the finished product polymer will preferably contain less than about 5% by weight of polybutenes having an M.sub.n below 250. The exact amount of acceptable low molecular weight polybutenes will vary depending on product viscosity and the intended end-use of the polymer products. For use in the preparation of lubricating oil metal detergents (to be described more completely below), the poly-n-butene polymer produced by the present invention will be characterized by a number average molecular weight of from about 340 to 800 and by a molecular weight distribution of from about 1.1 to 1.3.

The technique of addition of HCl to the feedstream in the absence of organo-aluminum chloride to form a pre-reacted feedstream offers the further advantage of substantially reducing the presence of chlorinated polybutenes in the finished product. Any polymerization process which permits free HCl to exist in the reactor has the problem of corrosion and the present invention

successfully avoids it through use of the pre-reacted feedstream.

In the present invention, HCl injected into the feedstream reacts quickly with normal-butenes to produce 2-chlorobutane which, upon entering the reactor, functions as a co-catalyst with the organo-aluminum chloride (e.g., EADC) to initiate the polymerization, the EADC reacting with the 2-chlorobutane to form C.sub.2 H.sub.5 AlCl.sub.3.sup.- and a butyl cation and thereby initiating polymerization. In contrast to this, when HCl is used to promote EADC, the species H.sup.+ C.sub.2 H.sub.5 AlCl.sub.3.sup.- , which is formed by reaction between HCl and EADC, initiates the polymerization. Polymerization in accordance with the catalyst species of the present invention is more efficient and provides a degree of process control and product quality not obtainable with prior art procedures based upon the use of EADC.

Referring to FIG. 1, wherein one embodiment of the process of the present invention is illustrated, a liquid monomer feed 4 comprising 1-butene, 2-butene, isobutylene, and saturates (butanes), and generally containing at least about 6 wt% (e.g., from about 10 to 50 wt %) isobutylene, and a polymerization catalyst 6 are introduced into first polymerization reaction zone 10 wherein the isobutylene monomer is selectively polymerizaed to form a polyisobutylene (PIB) polymer mixture 18 containing PIB and unreacted monomers. Mixture 18 is passed to catalyst removal zone 20 wherein the polymerization catalyst 22 is separated from the remaining components of the polymerization mixture. The resulting liquid PIB/monomer mixture 24 is passed to a polymer recovery zone 30 for separation of monomer stream 32 from liquid PIB stream 34. Typically, monomer stream 24 is removed from zone 30 as a gas. Stream 32 comprises a crude spent C.sub.4 stream and comprises 1-butene, 2-butene, unreacted isobutylene, and butanes, and also contains water, typically in amounts of from about 50 to 600 wppm, more typically from about 100 to 500 wppm, e.g. due to the use in zone 20 of an aqueous caustic catalyst quench/water wash step, or from the use in polymerization zone 10 of water as a co-catalyst in the formation of the PIB polymer.

The crude spent monomer stream 32 is then passed to drying zone 40 wherein water is removed, to provide a C.sub.4 monomer feedstream 42 containing less than about 200 wppm, preferably less than about 100 wppm, water (e.g., 5 to 100 wppm, more preferably from about 5 to 50 wppm water). The C.sub.4 monomer feedstream 42 is then contacted with HCl 44 in a portion 46 of conduit 42 to form the treated feedstream mixture containing not greater than about 1 wppm free HCl which is then charged to polymerization reaction zone 50, along with a separately charged organo-aluminum catalyst stream 52, for polymerization as described above to form the poly-n-butene polymers of this invention. The resulting poly-n-butene polymerization reaction mixture 54 can be withdrawn from zone 50 and treated as described above for recovery of the polymer product, including the steps of catalyst removal and stripping to remove low molecular weight polymer fractions, as desired.

The catalysts and polymerization conditions, and the methods of catalyst separation and polymer recovery, employed in zones 10, 20 and 30, respectively, are conventional. Exemplary catalysts for PIB polymerization are AlCl.sub.3, HF, BF.sub.3, AlBr.sub.3, and organo-aluminum chlorides, such as those indicated above in Formula I, which can be employed together with co-catalysts or promoters such as alkanols (e.g., methanol, ethanol, propanol, isopropanol, butanol, tert-butanol and the like), phenol, and C.sub.1 to C.sub.4 alkyl esters of such hydroxy compounds, and preformed complexes of any of these catalysts and co-catalysts (e.g., AlCl.sub.3 -ethanol complexes, HF-ethanol complexes, and the like). Especially preferred catalysts are AlCl.sub.3, BF.sub.3 and organo-aluminum chlorides of Formula I wherein R is C.sub.1 to C.sub.4 alkyl and x is 1 or 2. The temperature in the first polymerization reaction 10 will generally from about -10.degree. to +10.degree. C.

The drying of the crude spent C.sub.4 monomer stream in zone 40 can be accomplished by contacting the stream with a dessicant which is substantially nonreactive with any organic component of the stream, such as CaCl.sub.2, molecular sieves (e.g., mol sieves 3A and 13X from Linde Division, Union Carbide), and the like. Drying zone 40 can comprise one or more vessels containing a solid dessicant through which stream 32 is passed, and usefully can comprise a series of separate vessels arranged in parallel to fascilitate the charging to any vessel of fresh dessicant in the continuous practice of the process of this invention.

Poly-n-butenes prepared in accordance with this invention are particularly useful as a feedstock for the production of improved lubricating oil detergents. Such detergents include the metal salts of alkyaryl sulphonic acids, alkyl phenols, sulphurized alkyl phenols, alkyl salicylates, alkyl naphthenates, and other oil soluble mono- and di-carboxylic acids, wherein the detergent contains at least one alkyl group comprising a polymer corresponding to the poly-n-butene polymer produced in the process of this invention. Usually these metal containing detergents are used in lubricating oil in amounts of about 0.01 to 10, e.g. 0.1 to 5 wt. %, based on the weight of the total lubricating composition. Marine diesel lubricating oils typically employ such metal-containing detergents (which are also sometimes termed "metal rust inhibitors") in amounts of up to about 20 wt.%.

Preferred detergent materials comprise oil-soluble metal salts of hydrocarbon sulfonic acids wherein the sulfonic acids are prepared from aromatic hydrocarbons, which has been alkylated with the polymers of this invention. The aromatic hydrocarbons from which the alkyl substituted aromatic hydrocarbons can be derived include benzene, toluene, xylene, naphthalene, diphenyl and the halogen derivatives such as chlorobenzene, chlorotoluene and chloronaphthalene. The alkylated aromatic compounds can then be sulfonated and converted to the metal salt in the usual manner. If desired, these alkyl-substituted aromatic hydrocarbons, containing alkyl-groups derived from the polybutenes of this invention, can be admixed with other alkyl-substituted aromatic hydrocarbons such that the sulfonation step is performed upon a mixture of such alkyl-substituted aromatic hydrocarbons. Such other conventional alkyl-substituted aromatic hydrocarbons include those obtained from the fractionation of petroleum by distillation and/or extraction.

The precise manner in which the alkylation reaction is carried out is not critical, and any conventional alkylation process can be employed. The following discussion will illustrate the alkylation employing benzene as the aromatic hydrocarbon, although it will be understood that any convenient aromatic hydrocarbon can also be employed.

Alkylation is generally carried out in the presence of a Friedel-Crafts type catalyst at temperatures in the range of from about -10.degree. to 75.degree. C., e.g., at 5.degree. C., for times of from 5 to 60 minutes, e.g., 10 to 20 minutes. Suitable catalysts include, for example, AlCl.sub.3, HF, BF.sub.3 and AlBr.sub.3, polyphosphoric acid, H.sub.2 SO.sub.4, and aluminum chloride hydrocarbon complexes. Aluminum chloride is the preferred catalyst, which may be either fresh AlCl.sub.3 or spent AlCl.sub.3 sludge from a previous alkylation step, fortified by the addition of from 5 to 20 wt% fresh AlCl.sub.3.

It is generally desirable to maintain in the reaction mixture a volume ratio of benzene to polymer of at least 3:1, e.g. 5:1, although ratios of up to 20:1 may be used.

Although temperatures during the alkylation with AlCl.sub.3 can range as high as 60.degree. C, it is preferred to use temperatures of between about -5.degree. to 30.degree. C. Weight ratios of polymer to catalyst will be in the range of about 30:1 to 7:I. Additionally, in the case of AlCl.sub.3, an activator such as HCl can be added in an amount of from 15 to 40 wt%, based on the AlCl.sub.3.

If a liquid HF catalyst is used for alkylation, it is preferred to use an HF-to-hydrocarbon reactants volume ratio of 0.1:1 to 1.0:1, and temperatures in the range of from 0.degree. to 20 .degree. C. The concentration of this catalyst can range from 85 to 100 wt% HF, its water content being maintained very low, e.g. no higher than 1 or 2 wt%, the remainder being dissolved hydrocarbon material.

The alkylated fraction is recovered from the alkylation reaction mass and is sulfonated in a known manner, e.g. by contact with an excess of concentrated sulfuric acid, oleum, ClSO.sub.3 H, sulfur trioxide, etc. The sulfonation can be carried out at temperatures up to about 60.degree. C. Acid up to about 100 wt% concentration can be employed, and preferably oleum containing up to e.g., 20 wt% or more SO.sub.3. With higher acid concentration, lower reaction times are required, e.g. about 3 to 4 hours with 98 wt% acid, about 2 hours with 100 wt% acid, and preferably from about 0.5 to 1.0 hour with oleum. Volume ratios of sulfuric acid to hydrocarbon can range from 0.8:1 to 1.25:1, with a 1:1 ratio being suitable.

The sulfonated product can be recovered as described in U.S. Pat. 3,367,865, the disclosure of which is hereby incorporated in its entirety.

The alkali and alkaline earth metal salts (e.g., the Ca, Mg, Ba, Na, K, Li, etc. salts) of the sulfonated aromatic materials thereby producted can be prepared in a known manner using conventional techniques, such as are described in U.S. Pat. 3,367,865. Highly basic alkaline earth metal sulfonates are usually produced by heating a mixture comprising an oil-soluble alkaryl sulfonic acid, with an excess of alkaline earth metal compound above that required for complete neutralization of any sulfonic acid present and thereafter forming a dispersed carbonate complex by reacting the excess metal with carbon dioxide to provide the desired overbasing. The alkaline earth metal compounds which may be used in neutralizing these alkaryl sulfonic acids to provide the sulfonates includes the oxides and hydroxides, alkoxides, carbonates, carboxylate, sulfide, hydrosulfide, nitrate, borates and ethers of magnesium, calcium, and barium. Examples are calcium oxide, calcium hydroxide, magnesium acetate and magnesium borate. As noted, the alkaline earth metal compound is used in excess of that required to complete neutralization of the alkaryl sulfonic acids. Generally, the amount ranges from about 100 to 220%, although it is preferred to use at least 125%, of the stoichiometric amount of metal required for complete neutralization.

Various other preparations of basic alkaline earth metal alkaryl sulfonates are known, such as U.S. Pat. Nos. 3,150,088 and 3,150,089 wherein overbasing is accomplished by hydrolysis of an alkoxide-carbonate complex with the alkaryl sulfonate in a hydrocarbon solvent-diluent oil.

Preferred alkaline earth sulfonate additives are calcium and magnesium alkyl aromatic sulfonate having a total base number ranging from about 200 to about 400 with the magnesium sulfonate content ranging from about 25 to about 32 wt. %, and the calcium sulfonate content ranging from about 20 to 40 wt%, based upon the total weight of the additive system dispersed in mineral lubricating oil.

Neutral metal sulfonates are frequently used as rust inhibitors. Polyvalent metal alkyl salicylate and naphthenate materials are known additives for lubricating oil compositions to improve their high temperature performance and to counteract deposition of carbonaceous matter on pistons (U.S. Pat. No. 2,744,069). An increase in reserve basicity of the polyvalent metal alkyl salicylates and naphthenates can be realized by utilizing alkaline earth metal, e.g. calcium, salts of mixtures of C.sub.8 -C.sub.26 alkyl salicylates and phenates (see U.S. Pat. No. 2,744,069) or polyvalent metal salts of alkyl salicyclic acids, said acids obtained from the alkylation of phenols (e.g., as described above) followed by phenation, carboxylation and hydrolysis (U.S. Pat. No. 3,704,315) which could then be converted into highly basic salts by techniques generally known and used for such conversion. The reserve basicity of these metal-containing rust inhibitors is usefully at TBN levels of between about 60 and 150. Included with the useful polyvalent metal salicylate and naphthenate materials are the methylene and sulfur bridged materials which are readily derived from alkyl substituted salicylic or naphthenic acids or mixtures of either or both with alkyl substituted phenols. Basic sulfurized salicylates and a method for their preparation is shown in U.S. Pat. No. 3,595,791. Such materials include alkaline earth metal, particularly magnesium, calcium, strontium and barium salts of aromatic acids having the general formula:

where Ar is an aryl radical of 1 to 6 rings, R.sup.1 is a poly-n-butene alkyl group, X is a sulfur (--S--) or methylene (--CH.sub.2 --) bridge, y is a number from 0 to 4 and n is a number from 0 to 4.

Preparation of the overbased methylene bridged salicylate-phenate salt is readily carried out by conventional techniques such as by alkylation of a phenol followed by phenation, carboxylation, hydrolysis, methylene bridging a coupling agent such as an alkylene dihalide followed by salt formation concurrent with carbonation. An overbased calcium salt of a methylene bridged phenol-salicylic acid of the general formula: ##STR1## wherein R.sup.1 is as defined above, with a TBN of 60 to 150 is highly useful in this invention.

The sulfurized metal phenates can be considered the "metal salt of a phenol sulfide" which thus refers to a metal salt whether neutral or basic, of a compound typified by the general formula: ##STR2## where x =1 or 2, n =0, 1 or 2; or a polymeric form of such a compound, where R.sup.1 is as defined above, and n and x are each integers from 1 to 4. The metal salt is prepared by reacting an poly-n-butene substituted phenol sulfide with a sufficient quantity of metal containing material to impart the desired alkalinity to the sulfurized metal phenate.

Regardless of the manner in which they are prepared, the sulfurized alkyl phenols which are useful generally contain from about 2 to about 14% by weight, preferably about 4 to about 12 wt. % sulfur based on the weight of sulfurized alkyl phenol.

The sulfurized alkyl phenol may be converted by reaction with a metal containing material including oxides, hydroxides and complexes in an amount sufficient to neutralize said phenol and, if desired, to overbase the product to a desired alkalinity by procedures well known in the art. Preferred is a process of neutralization utilizing a solution of metal in a glycol ether.

The neutral or normal sulfurized metal phenates are those in which the ratio of metal to phenol nucleus is about 1:2. The "overbased" or "basic" sulfurized metal phenates are sulfurized metal phenates wherein the ratio of metal to phenol is greater than that of stoichiometric, e.g. basic sulfurized metal poly-n-buteny substituted phenate, wherein the polybutyl group is derived from a poly-n-butene polymer of this invention having a number average molecular weight of from about 300 to 400, has a metal content up to and greater than 100% in excess of the metal present in the corresponding normal sulfurized metal phenates wherein the excess metal is produced in oil-soluble or dispersible form (as by reaction with CO.sub.2).

Lubricating oil compositions will typically contain other additives in customary amounts to provide their normal attendant functions such as dispersants (e.g., ashless dispersants such as long chain hydrocarbyl substituted succinimides [e.g., polyisobutenyl succinimides]; long-chain hydrocarbyl Mannich Base dispersants [e.g., Mannich Base dispersants prepared by condensation of polyisobutylene-substituted phenol, formaldehyde and alkylene polyamines]; and long-chain hydrocarbyl-substituted amines [e.g., polyisobutylene-substituted alkylene polyamines]; and borated derivatives thereof), anti-wear additives (e.g., zinc dihydrocarbyl dithiophosphates), anti-oxidants (e.g., copper antioxidants and supplemental antioxidants as disclosed in European Pat. No. 24,146), viscosity modifiers (e.g., ethylene-propylene copolymers, hydrogenated polyisoprene-styrene copolymers, hydrogenated polybutadiene-styrene copolymers, hydrogenated poly(isoprene-butadiene-styrene) terpolymers, etc.) and the like.

Lubricating oil compositions will usually contain detergents in amounts of from about 0.01 to 20 wt%, and more typically from about 0.01 to 3 wt%. Detergents are conveniently packaged and dispensed in the form of solution concentrates containing about 5 to 70 wt. % (e.g., from about 20 to 60 wt. %) detergents in mineral oils.

The invention is further illustrated by the following examples which are not to be considered as limitative of its scope.

In a series of runs, liquefied anhydrous feedstream composed of 1.8 wt. % to 4.9 wt% isobutene and the selected quantity of 1-butene, 2-butene, n-butane and isobutane were mixed for pre-reaction with the selected amount of gaseous anhydrous HCl. In Examples 1-6 and 8-21, analysis showed less than 1 ppm HCl remained unreacted. The pre-reacted feed was introduced in liquefied form at the rate of 56 ml per minute into a continuous type stirred reactor maintained at the selected temperature by means of a cooling bath. Liquid ethylaluminum dichloride (EADC) was introduced into the reactor continuously and adjusted to maintain the desired monomer conversion and molecular weight of polymer. Reaction product was withdrawn continuously at a rate corresponding to the rate of introduction of the feed and the molecular weight of the product was continuously evaluated. Average residence time was between 25 to 35 minutes. The polymer product was recovered, stripped with dry N2 (at 150.degree. C. to remove the light molecular weight fraction <200) and analyzed. The data thereby obtained are summarized in Tables I, II and III below.

The principles, preferred embodiments, and modes of operation of the present invention have been described in the foregoing specification. The invention which is intended to be protected herein, however, is not to be construed as limited to the particular forms disclosed, since these are to be regarded as illustrative rather than restrictive. Variations and changes may be made by those skilled in the art without departing from the spirit of the invention.