Classifications

• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D11/00—Special methods for preparing compositions containing mixtures of detergents
  • C11D11/04—Special methods for preparing compositions containing mixtures of detergents by chemical means, e.g. by sulfonating in the presence of other compounding ingredients followed by neutralising
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D11/00—Special methods for preparing compositions containing mixtures of detergents
  • C11D11/02—Preparation in the form of powder by spray drying
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D17/00—Detergent materials or soaps characterised by their shape or physical properties
  • C11D17/06—Powder; Flakes; Free-flowing mixtures; Sheets
  • C11D17/065—High-density particulate detergent compositions
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
  • C11D3/02—Inorganic compounds ; Elemental compounds
  • C11D3/04—Water-soluble compounds
  • C11D3/10—Carbonates ; Bicarbonates
• • C—CHEMISTRY; METALLURGY
  • C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
  • C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
  • C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
  • C11D3/02—Inorganic compounds ; Elemental compounds
  • C11D3/12—Water-insoluble compounds
  • C11D3/124—Silicon containing, e.g. silica, silex, quartz or glass beads
  • C11D3/1246—Silicates, e.g. diatomaceous earth
  • C11D3/128—Aluminium silicates, e.g. zeolites

Definitions

• This invention relates generally to a process for the production of detergent powder by spray-drying.
• Liquid active blends allow for water and active together to act as a carrier for the solids.
• the active has changed its function in the slurry.
• the active instead of being a "solid additive" which must be suspended in the liquid water carrier has itself become part of the liquid carrier system. This change allows for a reduction in the amount of water needed in the slurry as a carrier, because the active substitutes for part of the water.
• U.S Patent 4,738,793 employs low moisture slurries for spray- drying but this is accomplished using nonionic surfactants in the substantial absence of anionic surfactant (less than 2% anionic is taught) .
• a method of slurry preparation and a slurry composition which exhibits exceptionally low viscosity even at low water content, thus enabling it to be spray-dried to a high surfactant concentration without unacceptable pluming has now been discovered.
• a spray-dried powder of exceptionally high density can be obtained.
• Gel formation may be avoided in producing a liquid active mixture by using a preferred order of addition: water plus caustic, then nonionic plus the acidic form of the anionic surfactant. Water plus caustic changes the characteristic viscosity curve so that when the nonionic is added an emulsion is formed in place of a gel.
• Emulsion viscosity is much less than gel viscosity.
• the acid precursor of the anionic may then be added and is preferably neutralized in situ. This makes the liquid active mixture more viscous, but still avoids the gel state.
• solids addition of the builder i.e. zeolite and/or carbonate as well as other builders such as NTA and the like may be carried out.
• a blend of surfactants may be used such as that disclosed in Hsu er al. Serial Number 07/808,314 filed 12/16/91 or
• nonionic surfactants are included.
• a low moisture content detergent slurry is manufactured utilizing liquid active surfactant blends containing anionic and nonionic surfactants. This low moisture slurry is then spray-dried using standard spray-drying techniques yielding, if desired, a concentrated or high density base powder.
• the invention provides a process for preparing by spray-drying, washing powders containing anionic active, nonionic active and builder, i.e., carbonate and zeolite, for example, crystalline and/or amorphous aluminosilicate including the zeolites disclosed in EP,384,070A and 448,297A.
• the builders are used in a proportion of at least about 5 to 50 percent of anionic to 1 to 50 percent of nonionic to 5 to 70 percent of__,a builder.
• the slurry is prepared by forming an aqueous mixture of a nonionic and anionic surfactant to which a builder and other detergent components may be added to produce the slurry for spray-drying.
• the aqueous anionic-nonionic mixture comprises water, a nonionic active and an anionic active wherein the anionic is incorporated as:
• the acid form of an anionic surfactant and the mixture further contains a neutralising agent whereby the acid is neutralised in situ to form the anionic surfactant; and/or;
• the anionic surfactant is incorportaed into the mixture as a surfactant
• the nonionic and anionic surfactant are mixed to form a surfactant blend which is then incorporated into the mixture.
• preparation of the slurry in which the surfactants are incorporated as a blend is comprised of:
• a viscosity adjuster in an amount of from 0 to 50% of said mixture, at any time during the slurry process to result in a viscosity of the final slurry mixture of about 1000 to 20,000 cps measured at a shear rate of 17 to 18 sec "1 and a temperature of 150° to 195°F.
• preparation of the slurry in which the anionic surfactant is incorporated in the acid form is comprised of:
• a viscosity adjuster in an amount of from 0 to 50% of said mixture, at any time during the slurry process to result in a viscosity of the final slurry mixture of about 1000 to 20,000 cps measured at a shear rate of 17 to 18 sec "1 and a temperature of 150° to 195°F.
• the water content will be from 10% to 40% by weight of the slurry, in which case it will be possible to spray-dry the powder to a bulk density above 500 g/liter, desirably from 500 to 900 g/liter.
• Viscosity is extremely important since for ease of operation any composition, e.g. a slurry, must be capable of being sprayed at pressures commonly used such as 10 psi to 1000 psi through nozzle sizes of about 0.1 mm to 11 mm or more at temperatures of about room temperature of about 65°F up to about 200°F. Such low temperatures avoid excess evaporation.
• the viscosity of such composition is about 1000 centipoise to 20,000 centipoise at a temperature of 150° to 185°F or even somewhat higher at a shear rate of 17 to 18 sec "1 .
• compositions having a ratio of anionic surfactant to nonionic surfactant of 1:3 to 3:1 may be employed but 1:2 to 2:1 are of especial interest.
• the composition of slurry should be formulated so that the viscosity of the final slurry is about 7,000 to 20,000 cps, preferably less than 20,000 centipoise, more preferably less than 10,000 centipoise, measured at a shear rate of 17 to 18 sees "1 at a temperature of 150° to 185°F.
• the slurry must be sufficiently fluid to allow thorough mixing of all of the components in the mixer. After mixing is finished, the slurry must remain sufficiently fluid to pump it out of a mixing vessel to a spray tower. As better and more efficient mixers become available processing of more viscous systems becomes easier. Conversely, as pumps are improved, higher viscosity slurried can be pumped.
• the viscosity must be such that the desired physical mixing and pumping can be done economically and chemical reactions if any, such as neutralization take place readily.
• the final point prior to spray-drying is the actual atomization of the slurry in the tower spray nozzles. There are many different designs of spray nozzles well known to those skilled in the art with which to achieve appropriate atomization.
• Liquid mixing can be defined as a Reynolds number (N Re ) where N Re is defined as follows:
• N Re Reynolds Number
• N impeller speed
• D impeller diameter
• p specific gravity
• ⁇ viscosity at a shear rate of N ⁇ sec "1 .
• the final slurry in the mixer should have a flow with a Reynolds Number of about 1 to 10,000 which is conveniently produced by an appropriate impeller design.
• the viscosity of the slurry thus depends upon many functional parameters.
• the viscosity to be achieved must be appropriate for the slurry to be mixed, pumped and atomized in a spray tower.
• the viscosity thus may vary within fairly wide ranges.
• the viscosity of the slurry can be adjusted by the addition of an organic or inorganic additive in a sufficient amount to result in a viscosity in the final slurry of about 1000 to 20,000 cps at a shear rate of 17 to 18 sec "1 and a temperature of 150° to 185°F.
• viscosity adjusters examples include nonionic surfactants, hydrotropes (e.g., sodium xyiene sulfonate) , polyethylene glycol, polypropylene glycol and inorganic salts (e.g., Na 2 S0 4 ) .
• This viscosity adjuster may be introduced into the water at the beginning or optionally during the process or may even be added after the anionic precursor but it is preferably added prior to most of the zeolite or other builder solids to insure proper fluidity.
• the viscosity adjuster may also be put into any of the additives as a mixture and added in this way.
• the amount of viscosity adjuster employed is sufficient to insure slurry fluidity and varied from about 0.5% of the slurry weight to about 30% of the slurry weight. It also must be realised that when an anionic sulfated or sulfonated precursor is prepared, a certain amount of free or acidic sulfate will be formed. Due to these impurities in the precursor, some sulfate salt will be present. In normal commercial products, this is usually insufficient to fully fluidize the slurry.
• the slurry should contain a nonionic surfactant.
• the nonionic surfactant will be an ethoxylated or ethoxylated propoxylated primary or secondary linear or branched chain alcohol having a carbon chain length in the hydrophobic portion of from 5 to 25, and containing from about 5 to about 35 moles of ethylene/oxide and/or propylene oxide per mole of alcohol.
• examples of such materials are ethoxylates the Dobanol and Neodol (Registered Trade Mark) alcohols, sold by Shell Chemicals and the Tergitol (Registered Trade Mark) ethoxylated alcohols sold by Union Carbide Corporation.
• nonionic surfactants can also be used, alkyl phenol ethoxylates for example, including in particular the reaction products of alkylene osices, usually ethylene oxide, with alkyl (C 6 -C 22 ) phenols, generally 5-25 EO, i.e. 5-25 units of ethylene oxide per molecule; and products made by condensation of ethylene oxide with the reaction products of propylene oxide and ethylene diamine.
• alkyl phenol ethoxylates for example, including in particular the reaction products of alkylene osices, usually ethylene oxide, with alkyl (C 6 -C 22 ) phenols, generally 5-25 EO, i.e. 5-25 units of ethylene oxide per molecule; and products made by condensation of ethylene oxide with the reaction products of propylene oxide and ethylene diamine.
• nonionic surfact-actives that may be used include alkyl polyglycosides, long chain tertiary amine oxides, long chain tertiary
• the amount of nonionic in the final powder will be about 5 to 50%, preferably 10 to 30%.
• Anionic surfactants which may be formed from precursors (e.g., sulfonic acids) are also essential.
• Typical anionic surfactants include sodium alkylbenzene sulphonates, sodium alkyl sulphates, sodium alkane sulphonates and sodium alkyl ether sulphates. More particularly, C 8 -C 24 primary and secondary alkyl or alcohol sulfates C 8 -C 24 secondary alkane sulfonates, C 8 -C 24 olefin sulfonates, C 10 -C 22 soaps and the like may be employed, preferably, sodium or potassium alkylbenzene sulfonates or alkyl sulfates are employed.
• alkylbenzene -sulfonates are sodium C ⁇ -C ⁇ 5 alkylbenzene sulfonates.
• Suitable alkyl sulfates are C ⁇ -C 15 alkyl sulfates, although other alkyl sulfates and sulfonates outside this carbon chain length range, may also be used.
• the acid form of the precursor is neutralized in the mixture with sodium, potassium or ammonium hydroxide.
• the amount of anionic in the final powder will be about 5 to 50%, preferably about 10 to 40%.
• the method of preparation of the blend is important . Simple admixture of normally 50% aqueous neutralized alkylbenzene sulphonate paste and liquid nonionic surfactant in the desired proportions will give not a mobile isotropic liquid but a highly viscous gel which is difficult to handle. Liquid nonionic surfactant may be gradually added to an alkylbenzene sulphonate paste (neutral salt) which will typically have an active matter content of about 50% by weight. The resulting viscous material, containing more than 10% water, is then heated to a sufficiently high temperature for a sufficient period of time for the water content to fall below 10% by evaporation. A clear mobile liquid is obtained and this remains clear and mobile when allowed to cool to ambient temperature.
• alkylbenzene sulphonic acid may be mixed with nonionic surfactant, and the mixture treated with concentrated aqueous sodium hydroxide or potassium hydroxide to effect partial or complete neutralization.
• Mixtures fluid at 20° to 80°C and containing about 6 to 7% by weight of water may be produced by this method.
• the alkylbenzene sulphonic acid starting material may be in partially neutralized form.
• compositions containing anionic surfactant, nonionic surfactant and water in relatively high amounts up to about 35% may be prepared containing sodium or potassium hydroxide in excess of that necessary to neutralize the anionic sulfonic acid if a precursor is used.
• These compositions are sufficiently mobile at temperatures no higher than about 90°C.
• the blends employed are liquid surfactant compositions mobile at a temperature within the range of about 15° to 90°C or if the anionic to nonionic ratio is appropriate and the type of nonionic is appropriate even down to about 5°C.
• This composition contains preferably; (a) a sodium or potassium salt of an alkylbenzene sulfonate or alkyl sulfate in an amount not exceeding 80% by weight and preferably 5 to 80% or even 20% to 60% by weight,
• Viscosity of the blend is extremely important since for ease of operation any composition must be capable of being processed. Typically, the viscosity of such compositions is about 50 centipoise to 5000 centipoise at a temperature of 60°C or even somewhat higher.
• compositions having a ration of anionic surfactant to nonionic surfactant of 0.125:1 to 4:1 may be employed but 1:1 to 3:1 are of especial interest.
• an improvement with regard to the processability properties may be obtained in the blend if 0.5-80% by weight of a C 8 -C 22 fatty acid is incorporated in the liquid surfactant composition.
• the blend provides a liquid surfactant composition which is mobile at a temperature within the range of 20 to 80°C and which comprises a sodium or potassium salt of an alkylbenzene sulfphonate or alkyl sulphate in an amount preferably not exceeding 70% by weight; an ethoxylated nonionic surfactant in an amount preferably not exceeding 80% by weight; and water in an amount preferably not exceeding 20% by weight, more preferably not exceeding 10% by weight; characterized in that it further comprises 0.5 to 80% by weight of a fatty acid having 8 to 22 carbon atoms.
• a process for the manufacture of the above liquid surfactant composition by mixing said nonionic surfactant with a concentrated aqueous alkali metal hydroxide solution having about 80% to 98% of the stoichiometric amount of said alkali metal hydroxide necessary to neutralize an acid precursor of said sulphate or sulphonate, to form a nonionic alkali dispersion; mixing said acid precursor with said dispersion form a blend; adjusting the pH to about 7; and then mixing the blend with the fatty acid to form the mobile composition.
• the compositions include in addition 0.5-70%, preferably 2- 15%, more preferably 2-7% by weight of a fatty acid having 8 to 22 carbon atoms. It is preferred if the fatty acid possesses 12 to 20 carbon atoms, and more in particular 16 to 18 carbon atoms.
• a suitable fatty acid is coconut fatty acid.
• Selected builder materials are added to the slurry.
• the builders are preferably zeolite and/or sodium carbonate.
• Other substantially solution materials which have a detergency builder action may be used by including them in the slurry.
• these builders may be added by post dosing to the composition produced by the spray-drying step.
• substantially soluble detergency builders are sodium tiproly-, pyro- and orothophosphates, sodium citrate and various organic detergency builders such as sodium nitrilotriacetate, ODS; TMS/TDS homopolymers of acrylic acid and copolymers of acrylic and maleic acids.
• Substantially insoluble builders are, for example, sodium aluminosilicates including zeolites, crystalline, amorphous, as well as calcite, and the like.
• Generally detergency builders will be present in amounts of from 5 to 70% by weight of the final product, amounts of from 25 to 40% by weight being more general.
• the slurries can also contain a number of optional components such as lather controllers, anti-redeposition agents such as sodium carboxymethlycellulose, fabric softening agents such as quaternary ammonium salts either alone or in combination with clays, anti-ashing aids, starches, slurry stabiliziers such as homopolymers of acrylic acid and copolymers of acrylic acid and maleic acid; ethylene and maleic anhydride, and of vinyl methyl ether and maleic anhydride, usually in salt form; antioxidants and fluorescers.
• lather controllers anti-redeposition agents such as sodium carboxymethlycellulose
• fabric softening agents such as quaternary ammonium salts either alone or in combination with clays
• anti-ashing aids starches
• slurry stabiliziers such as homopolymers of acrylic acid and copolymers of acrylic acid and maleic acid; ethylene and maleic anhydride, and of vinyl methyl ether and maleic anhydride, usually in salt form;
• the spray-dried powder produced can be dosed with ingredients that are incompatible with the spray-drying process conditions in the amounts required to produce a finished powder.
• Components may be incompatible for many reasons, including heat sensitivity, pH sensitivity, degradation in aqueous systems and the like.
• the usual heat-sensitive zwitterionic surfactants such as derivatives of alphiphatic quanternary ammonium phosphonium acid, sulphonium compounds in which one of the aliphatic constituents contains an anionic water solubilizing group may be added.
• Additional components which may be added in this manner are sodium perborate mono- and tetrahydrates, sodium percarbonates and acid bleach precursors such as tetracetylethylene diamine, tetracetylglycouril and sodium nonyl oxybenzene sulphonate, perfumes, enzymes and composite adjuncts.
• acid bleach precursors such as tetracetylethylene diamine, tetracetylglycouril and sodium nonyl oxybenzene sulphonate
• perfumes enzymes and composite adjuncts.
• the process is especially suitable for use where it is intended to add composite adjuncts to the spray-dried powder in a dry-dosing step, since such adjuncts normally have very high bulk density and tend to separate from lighter powders.
• composite adjuncts are antifoam granules, for instance, granules based on a starch core having a coating of a mixture of liquid and waxy hydrocarbons; composite colored speckles prepared in any way, e.g., containing spray-dried base powder granulated with a colored binder solution; and adjuncts containing calcium carbonate seed crystals such as high surface area calcite (80-90 m 2 g _1 ) .
• the mixer includes a Lightnin (R) A-320 impeller to promote mixing. 252 lbs. of water is charged into the mixer and heated to 100-120°F. The agitator is set at 40 RPM. 121 lbs. of 50% caustic solution (enough for the neutralisation reactions of precursor alkylbenzene sulfonic acid and citric acid) is added next while maintaining the agitator at about 40 RPM. A temperature rise to 130-140°F is observed.
• R Lightnin
• nonionic surfactant in this case, Neodol 25-7, a 7EO nonionic
• the temperature is observed to decrease approximately 10°F to 120-130°F.
• the agitator may be increased to about 50 RPM, 196 lbs. of alkylbenzene sulfonic acid is then added.
• the acid neutralizes the temperature increases and the mixture turns from a transparent emulsion to a brown liquid to a white paste. As the mixture reaches the white paste stage, the slurry mixture becomes significantly thicker.
• the temperature increase from the neutralisation reaction is about 30-40°F resulting in a slurry temperature of 160-165°F.
• citric acid for example, Citrosol ⁇ R 503, a 50% solution
• a 50% solution is charged into the mixer.
• a second neutralisation reaction takes place and the temperature rises 10-20°F to 175-185°F.
• Increasing the agitation to about 70 RPM and a two minute hold time is beneficial after the citric acid addition in order to facilitate mixing and completion of the reaction.
• 58 lbs. of sodium sulfate, a viscosity adjuster is added at this point. A few minutes may be necessary for complete mixing of the sodium sulfate. No effective temperature change is observed.
• 0.16 lbs. of Silicone defoamer is added in order to help remove entrapped air bubbles from the slurry. Removal of entrapped air results in a denser slurry which in turn will result in a denser spray-dried powder.
• the agitator should be increased to about 80 RPM.
• a powder is prepared from the slurry of this invention containing the following ingredients:
• This slurry formulation will yield an approximate Slurry Moisture Content (SMC) of 30%. Water losses due to evaporation may result in a lower SMC measuremen . Extra water can be added to compensate.
• SMC Slurry Moisture Content
• compositions of Example I, II, III and IV A through F all use separate mixing of the anionic and nonionic actives.
• Example IVG is a prepared neutralized blend.
• the surfactant mixtures were prepared as taught herein. Premanufactured or prepared blends either neutralized or not could be employed in place of the individual addition.
• the blends may be prepared as follows:
• Nonionic surfactant (C 12 -C 15 alcohol ethoxylates),
• N13EO Nonionic surfactant (C 12 -C 14 alcohol ethoxylates) , Shell trademark Neodol 25-3
• the neutralized mobile liquid surfactant mixture listed in Example V is prepared by mixing the nonionic surfactant with the indicated amount of concentrated aqueous sodium hydroxide solution (50 w/w%) and subsequently mixing with alkylbenzene sulfonic acid, Stepan Bio-Soft S-100.
• Examples V-VII indicate that a higher NaOH content maintains the liquid state for a higher level of water present in the composition. The percentages reported in the following Table are based on the final total content of materials.
• liquid surfactant mixtures are prepared by mixing the nonionic surfactant with concentrated aqueous sodium hydroxide solution (50 w/w%) in an amount stoichiometric to the alkylbenzene sulfonic acid plus the excess quantity of NaOH solution. This mixture is then mixed with the alkylbenzene sulfonic acid. The viscosity is measured by a Contraves Rheomat model 108E at room temperature. Examples VIII-X demonstrate the effect of the excess of sodium hydroxide in reducing the viscosity of the surfactant compositions.
• the following mobile liquid surfactant mixtures are prepared by mixing the nonionic surfactant with concentrated aqueous sodium hydroxide solution (50% w/v) in an amount which is slightly less than stoichiometric to the alkylbenzene sulphonic acid, adding the C 10 -C 13 alkyl benzene sulphonic acid and then a small amount of a 50% (w/v) sodium hydroxide solution to bring the pH to a value of about 8. Due to the exothermic neutralization reaction, the temperature is raised to about 80°C.
• the pH of the mixtures of Examples XII-XV was between 5.5 and 7 at a temperature of about 80°C.

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• 1993
  • 1993-08-28 BR BR9307023A patent/BR9307023A/pt not_active IP Right Cessation
  • 1993-08-28 WO PCT/EP1993/002340 patent/WO1994005767A1/en not_active Application Discontinuation
  • 1993-08-28 CA CA002143869A patent/CA2143869C/en not_active Expired - Fee Related
  • 1993-08-28 JP JP6506859A patent/JPH08501118A/ja active Pending
  • 1993-08-28 EP EP93919218A patent/EP0659208A1/de not_active Withdrawn
  • 1993-08-28 AU AU49553/93A patent/AU688277B2/en not_active Ceased

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