Zinc Di-Organo dithiophosphate (ZDDP) Process description:
1. Acid manufacture, General Description: [Link]
Di-organo Dithiophoshoric acid is manufactured by reaction of phosphorus pentasulfide and
Alcohol. The reaction is operated by adding metered amount of powered PS and alcohol
simultaneously to agitated reactor. Excess of alcohol is fed to the reactor to keep the reaction
in safe control. Excess amount of PS is fed or when the reaction temperature is too high, the
product can be decompose to give off hydrogen sulfide, olefine and mercaptans and leave a tar
like residue in the reactor.
The PS is fed to reactor through PS conveying system and alcohol is fed to reactor through
pump via mass flow meter. The reaction is exothermic and exotherm is control by circulation
cooling water through coil. The reactor is agitated and circulated which keeps the particles of
PS in suspension in the liquid phase. The reactor is circulated also to permit clarification of the
product stream and sampling of the acid. The circulation stream is pumped through two
cyclone separators in series. The PS solids removed form the bottom of cyclone and return to
agitated part of the reactor and the clarified liquid flows from the top of cyclone to a quite
settling zone in the reactor and then to a receiver from which it is pumped through a heat
exchanger to product storage.
The H2S that is released in the reactor passes through a condenser to remove the alcohol which
saturates this gas stream. From the condenser the gasses then pass through a seal pot to
scrubber and via scrubber it goes to flare.
2. Nitrogen Blowing:
Acid is further sent (batch wise) for nitrogen blowing to remove H2S gas, After removing H2S
sample to be send to check acid number. In tank material is circulated and control amount of
nitrogen is pass through sparger to remove H2S, this H2S and nitrogen pass through a seal pot
to scrubber and via scrubber it goes to flare.
3. Zinc salt Manufacture: [Link]
Zinc salt i.e Zinc Di-organo Dithiophosphates is produced by adding acid to a slurry of zinc oxide.
Slurry is to be prepared by mixing of neutral oil and zinc powder. A slight excess of Zinc is used
to be sure that the acid is completely neutralized. Water is produced as a by product during
neutralization and acid is not stable with water.
The Acid is pumped through the dried heat exchanger and into the neutralizer tank which
contains some zinc oxide slurry in oil. The acid enters via a submerged pipe which has several
exit hole to help disperse the acid. As the acid is being charged, the balance of the zinc oxide is
added as rapidly as possible without getting the slurry so thick that zinc oxide settles in the
bottom of the tank. The acid feed is continued until the complete charge from the blowing tank.
The cooling water rate may be regulated to the coils to maintain neutralization temperature.
During the neutralization observe the color of neutralized material.
Then neutralized batch is flash dried to a filter hold tank. The 121 is pumped through the heat
exchanged and flash tank. The material pumped from the flash tank back to the neutralizer
until. Once the proper conditions are established, the dried 121 is pumped to the filter hold
tank. The alcohol and vapor from the vacuum flash tank are condensed and collected in the
condensate receiver and transferred to wet storage tank.
4. Filtration and transfer of [Link] to final storage.
Filter aid is added to the dried 121 in filter hold tank by keeping its agitator on. Then it is filter
by using Fundabac or plate and frame filter press. Circulate this material via Fundabac or plate
and frame filter press, once blot and clarity approved. Start transferring of material (filtrate) to
filter receiving tank. Add oil to adjust the final specification and transfer the batch to final
storage tank.
