MXPA99003202A - Process for making a low density detergent composition by non-tower process - Google Patents

Abstract

A non-tower process for continuously preparing granular detergent composition having a low density, preferably about 300 g/l to about 600 g/l is provided. The process comprises the steps of (a) (i) dispersing an aqueous or non-aqueous surfactant, and (ii) coating the surfactant with fine powders having a diameter from 0.1 to 500 microns, in the mixer which is operated under certain conditions to obtain irregular shape granules and excessive fine powders and, (b) spraying on finely atomized liquid to the irregular shape granules and excessive fine powders from step (a), in a mixer which is operated under certain conditions to bind the excessive fine powders onto the irregular-shaped granules.

Description

PROCEDURE TO MAKE A COMPOSITION OF LOW DENSITY DETERGENT BY A PROCEDURE THAT IS NOT A TOWER FIELD OF THE INVENTION The present invention generally relates to a non-tower process for producing a low density detergent composition. More particularly, the invention is directed to a continuous process during which detergent agglomerates are produced by feeding a surfactant and coating materials in a series of mixers. The process produces a free-flowing detergent composition, whose density can be adjusted for a wide range of consumer needs, and which can be sold commercially.

BACKGROUND OF THE INVENTION Recently, there has been considerable interest within the detergent industry for laundry detergents that are "compact" and, therefore, have low dosage volumes. To facilitate the production of these so-called low dosage detergents, many attempts have been made to produce high density global detergents, for example, with a density of 600 g / 1 or more. Low dosage detergents are currently in high demand because they conserve resources and can be marketed in small packages that are more convenient for consumers. However, the degree to which modern detergent products need to be "compact" in nature remains uncertain. In fact, many consumers, especially in developing countries, continue to prefer higher dosage levels in their respective laundry operations. A feature common to the existing process for producing modern detergent compositions by agglomeration, namely, a non-tower process, is that the bulk density of the granules by said process is typically not less than 600 g / 1. Accordingly, there is a need for the agglomeration technique (e.g., a non-tower method) to produce modern detergent compositions to achieve flexibility in the final density of the final composition, especially for low density (e.g., scale of the density is about 300 g / 1 to about 600 g / 1). In general, there are three primary types of procedures by which granules or detergent powders can be prepared. The first type of process involves spray drying an aqueous detergent suspension in a spray drying tower to produce highly porous detergent granules (eg, tower process for low density detergent compositions). The second type of process involves spray drying an aqueous detergent suspension in a spray drying tower as a first step, and then the resulting granules are agglomerated with a binder such as anionic or nonionic surfactant; finally, various detergent components are dry mixed to produce detergent granules (e.g., by the tower process plus an agglomeration process for high density detergent compositions). In the third type of process, the different detergent components are mixed dry after they are agglomerated with a binder such as an anionic or nonionic surfactant, to produce high density detergent compositions (eg, agglomeration process for detergent compositions) high density). In the three above processes, the important factors that determine the density of the resulting detergent granules are the shape, porosity and particle size distribution of said granules, the density of the different starting materials, the shape of the different starting materials. , and its respective chemical composition. There have been many attempts in the art to provide methods that increase the density of detergent granules or powders. Particular attention has been given to the densification of spray-dried granules by post-tower treatment. For example, an attempt involves an intermittent procedure in which granular or spray-dried detergent powders containing sodium tripolyphosphate and sodium sulfate are densified and spheronized in a Marumerizer®. This apparatus comprises a rotatable table, made rough and substantially horizontal, located inside and at the base of a substantially vertical smooth wall cylinder. However, this process is essentially an intermittent process and is therefore less convenient for the large-scale production of detergent powders. More recently, other attempts have been made to provide continuous processes to increase the density of spray-dried or post-tower detergent granules. Typically, said processes require a first apparatus that pulverizes or crushes the granules, and a second apparatus that increases the density of the pulverized granules by agglomeration. Although these methods achieve the desired increase in density by treating or densifying the spray-dried or "post-tower" granules, they are limited in their ability to go beyond the surfactant level without a subsequent coating step. In addition, the treatment or densification by "post tower" is not favorable in terms of economy (high capital cost) and complexity of operation. In addition, all of the aforementioned processes are directed primarily to densify or otherwise process spray-dried granules. Currently, the relative amounts and types of materials subjected to spray drying processes in the production of detergent granules have been limited. For example, it has been difficult to achieve high levels of surfactant in the resulting detergent composition, a feature that facilitates the production of detergents more efficiently. Thus, it would be convenient to have a method by which detergent compositions can be produced without having the limitations imposed by conventional spray drying techniques. To that end, the technique is also replete with descriptions of procedures involving agglomerating detergent compositions. For example, attempts have been made to agglomerate builders by mixing zeolite and / or layered silicates in a mixer to form free flowing agglomerates.

Although such attempts suggest that their process can be used to produce detergent agglomerates, they do not provide a mechanism by which starting detergent materials in the form of pastes, liquids and dry materials can effectively agglomerate into crisp and free-flowing detergent agglomerates that have low densities. Accordingly, there is a need in the art to have an agglomeration process (which is not tower) to continuously produce a detergent composition having low density and that is supplied directly from starting detergent ingredients, and preferably that the Density can be achieved by adjusting the condition of the procedure. Likewise, there is a need for such a process that is more efficient, flexible and economical to facilitate the large-scale production of detergents for flexibility in the final density of the final composition.

TECHNICAL BACKGROUND The following references are directed to densify spray-dried granules: Appel et al., U.S. No. 5,133,924 (Lever); Bortolotti et al., Patent of E.U.A. No. 5,160,657 (Lever); Johnson et al., British Patent No. 1,517,713 (Unilever); and Curtis, European patent application 451.894. The following references are directed to producing detergents by agglomeration: Charles et al., U.S. No. 4,992,079 (FMC Corporation), Beujean et al., Document open to the public No. WO93 / 23,523 (Henkel), Beerse et al., U.S. Pat. No. 5,108,646 (Procter &Gamble); Capeci et al., Patent of E.U.A. No. 5,366,652 (Procter &Gamble); Hollingsworth et al., European patent application 351 937 (Unilever); and Swatling et al., U.S. Patent. No. 5,205,958. For example, the document open to the public No. WO93 / 23,523 describes the process comprising pre-agglomeration by means of a low speed mixer and an additional agglomeration step by means of a high speed mixer to obtain a high density detergent composition, wherein less than 25% by weight of the granules have a diameter greater than 2 mm. This description also describes a method by which the density of the final agglomerate can be adjusted by adjusting the amount of liquid binder added in the second mixer. It is not clear from the description what contributes to the reduction of density. The process in the publicly available document No. WO93 / 23,523 differs from the invention described herein, which will be apparent to those skilled in the art. The patent of E.U.A. No. 4,992,079 discloses an agglomeration process for non-low density phosphate detergents having increased resistance to nonionic purging. The first step of the process agglomerates detergent ingredients with a non-aqueous liquid surfactant. The first step is followed by a second agglomeration step, where the particles charged with surfactant are dispersed in an inert gaseous medium, wetting the dispersed particles with a randomized stream of aqueous sodium silicate, or with atomized streams separated from water and concentrated sodium silicate to form the agglomerated detergent. It is not clear from the description what contributes to low density. In addition, the description does not include aqueous surfactants or detergents containing phosphate. The procedure in the patent of E.U.A. No. 4,992,079 differs from the invention described herein, which will be apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE INVENTION The present invention meets the aforementioned needs in the art by providing a process that allows to produce a low density granular detergent composition. The present invention also satisfies the aforementioned needs in the art, providing a process that allows to produce a granular detergent composition for flexibility in the final density of the final composition from an agglomeration process (e.g., which is not tower). The method of the proposed invention has the ability to adjust the density of the granules of the composition by controlling the shape thereof. Namely, the process of the present invention can be applied to obtain a granular detergent composition having a low density (for example, irregularly shaped granules having a density of about 300 to about 600 g / 1). The process does not make use of conventional spray drying towers, which is currently limited to produce high load compositions of surfactants. In addition, the process of the present invention is more efficient, economical and flexible with respect to the variety of detergent compositions that may be produced in the process. In addition, the process is more sensitive to environmental problems because it does not make use of spray-drying towers that typically emit particles and volatile organic compounds into the atmosphere. As used herein, the term "agglomerates" refers to particles formed by agglomerating raw materials with binder, such as surfactants and / or inorganic solutions / organic solvents and polymer solutions. As used herein, the term "irregularly shaped granules" refers to particles wherein the shape of the granules having irregular shape in the case of low density are formed by agglomerating starting detergent materials, fine powders and finely atomized liquid . All percentages used herein are expressed as "percent by weight," unless otherwise indicated. In accordance with one aspect of the invention, there is provided a process for preparing a granular detergent composition having a low density, preferably from about 300 g / 1 to 600 g / 1. The process comprises the steps of: (a) (i) dispersing an aqueous or non-aqueous surfactant, and (ii) coating the surfactant with fine powders having a diameter of 0.1 to 500 microns, in a mixer which is operated under the following conditions to obtain granules: [Average residence time: from about 5 to about 30 seconds, tip speed: from about 5 to about 10 m / s, energy condition: from about 0.15 to about 4.20 kj / kg], and then (b) sprinkling finely atomized liquid to the granules and the excess of fine powders from step (a), in a mixer which is operated under the following conditions to bind the excess of fine powders on the granules irregularly. [Average residence time: from about 0.2 to about 5 seconds, tip speed: from about 10 to about 23m / s, energy condition: from about 0.15 to about 2.9 kj / kg. Granular detergent compositions having a low density, preferably from about 300 g / l to about 600 g / l, produced by any of the methods described herein are also provided. Accordingly, an object of the present invention is to provide a method for continuously producing a detergent composition having flexibility with respect to the density of the final products by controlling the energy input, residence time condition, and tip speed condition. the mixers. It is also an object of the invention to provide a process that is more efficient, flexible and economical to facilitate the large-scale production of detergents with low and high dosage levels. These and other objects, characteristics and concomitant advantages of the present invention will become apparent to those skilled in the art upon reading the following detailed description of the preferred embodiment and the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a photograph showing irregular shaped agglomerates after the first step of the process of the present invention, having a low density (approximately 475-530 g / l). Figure 2 is a photograph showing Irregular agglomerates after the first and second steps of the present invention, having a low density (approximately 475-500g / l) =. Figure 3 is a photograph showing irregularly shaped agglomerates after the first and second steps of the present invention and the drying and cooling process, having a low density (approximately 450-475g / l). Figure 4 is a photograph showing round shaped agglomerates after the agglomeration process to obtain a high density (approximately 700-800g / l).

DETAILED DESCRIPTION OF THE PREFERRED MODALITY The present invention is directed to a process that allows producing free flowing granular detergent agglomerates having a low density of not less than about 300 g / l, preferably from about 300 to about 600 g / l. The process makes it possible to produce granular detergent agglomerates from an aqueous or non-aqueous surfactant which is then coated with fine granules having a diameter of 0.1 to 500 microns, to obtain low density granules.

Process First step In the first step of the process, one or more aqueous or non-aqueous surfactants are fed into the mixer which are in the form of powder, paste or liquid, and fine powders having a diameter of 0.1 to 500 microns, preferably about 1 to about 500 microns. (The definition of surfactants and fine powders is given in detail below). In another embodiment of the invention which is described in more detail below, the surfactants can be initially fed into a mixer and premixer (eg, a conventional worm extruder or other similar mixer) prior to agglomeration, after which The mixed detergent materials are fed into the mixer of the first step as described herein to achieve agglomeration. Generally speaking, to achieve low density (from about 300 g / 1 to about 600 g / 1), preferably, the average residence time in the mixer is about 5 to about 30 seconds, and the speed of the mixer is on the scale of about 5 m / s to about 10m / s, the energy per unit mass in the mixer is about 0.15 kj / kg to about 4.20 kj / kg, more preferably the average time of residence in the mixer is about 10 to about 15 seconds, and the tip speed for the mixer is on the scale of about 6m / s to about 8 m / s, the energy per unit mass for the mixer is around from 0.15 kj / kg to about 2.5 kj / kg, and most preferably, the average residence time in the mixer is from about 10 to about 15 seconds, and the tip speed for the mixer is on the scale of about 6.5 m / s approximately 7.5 m / s, and the energy per unit mass for the mixer is around 0.15 kj / kg to about 1.30 kj / kg. Examples of mixers for the first step can be any type of mixer known to those skilled in the art, as long as the mixer can maintain the condition mentioned above for the first step. An example can be the CB Lódige mixer, manufactured by the company Lódige (Germany). As a result of the first step, granules having fine powders can be obtained on the surface thereof (Figure 1).

Second step In the second step of the process, the product resulting from the first step (granules and excess of fine powders) is fed into a second mixer, and then finely atomized liquid is sprayed onto the granules in the mixer. To join the excess of fine powders on the granules of the first step, about 0 to 10%, more preferably about 2 to 5% of detergent powdered ingredients of the type used in the first step and / or other detergent ingredients may be added in the second step. Generally speaking, to achieve low density (from about 300g / l to about 600g / l), preferably the average residence time of the mixer for the second step is from about 0.2 to about 5 seconds, and the speed of tip of the mixer for the second step is on the scale of about 10 m / s to about 23 m / s, the energy per unit mass for the mixer (power condition) for the second step is around 0.15 kj / kg at about 2.9 kj / kg, more preferably, the average residence time of the mixer is about 0.5 to about 2 seconds, and the tip speed for the mixer is on the scale of about 13m / s at about 20m / s, the energy per unit mass for the mixer is about 0.15 kj / kg to about 1.9 kj / kg, most preferably, the average residence time in the mixer is about 0.5 to about 2 seconds, the speed of pu The mixer is on the scale of about 15 m / s to about 17.5 m / s, and the energy per unit mass for the mixer is about 0.15 kj / kg to about 1.0 kj / kg. Examples of mixers for the second step can be any type of mixer known to those skilled in the art, as long as the mixer can maintain the condition mentioned above for the first step. An example can be the Flexomic model manufactured by the company Schugi (Holland). As a result of the second step, the granular detergent composition can be obtained (Figure 2). The process of the present invention surprisingly produces the amount of excess recirculated fine particles of the second step, compared to the amount of excess fine particles recirculated due to common agglomeration procedures known to those skilled in the art. The existence of an excess of fine particles leads to excessive recirculation currents that interrupt the process and, therefore, are not economically favorable. In accordance with the present invention, the recirculated fine particles of the second step will typically comprise from about 10% to about 40% of the total amount of fine particle powders used in the first step.

Detergent materials starting The total amount of the surfactants for the present invention, which include the following finally atomized liquid detergent materials and adjunct detergent ingredients, is generally from about 5% to about 60%, more preferably from about 12% to about 40% , most preferably from about 15% to about 35%, in the total amount of the final product obtained by the process of the present invention. The surfactants that must be included in the above process can be from any point in the process of the present invention, for example, one of the first step or the second step, or both of the steps of the present invention.

Detergent surfactant (aqueous / non-aqueous) The amount of the aqueous or non-aqueous surfactant of the present process may be from about 5% to about 60%, more preferably from about 12% to about 40%, most preferably from about 15% to about 35%, in the total amount of the final product obtained by the process of the present invention. The aqueous or non-aqueous surfactant of the present process, which is used as the starting detergent materials mentioned above in the first step, is in the form of paste or powder raw materials. The surfactant itself is preferably selected from ammonium, nonionic, zwitterionic, amphoteric and cationic classes, and compatible mixtures thereof. Detergent surfactants useful herein are described in the U.S.A. 3,664,961, Norris, issued May 23, 1972, and the US patent. 3,929,678, Laughiin et al., Issued December 30, 1975, which are incorporated herein by reference. Useful cationic surfactants also include those described in the U.S.A. 4,222,905, Cockrell, issued September 16, 1980, and in the patent of E.U.A. 4,239,659, Murphy, issued December 16, 1980, which are also incorporated herein by reference. Of the surfactants, anionics and nonionics are preferred, with anionics being more preferred.

Non-limiting examples of surfactants useful herein include the conventional Cn-C-is alkylbenzene sulphonates ("LAS"), the C-10-C20 ("AS") alkyl sulphates ("AS") primary, branched chain and random, the alkyl sulfates ( 2,3) secondary of C10-C18 of the formula CH3 (CH2) x (CHOS? 3-M +) CH3 and CH3 (CH2) and (CHOS? 3-M +) CH2CH3j where. xy (y + 1) are integers of at least about 7, preferably at least about 9, and M is a cation of solubilization in water, especially sodium, unsaturated sulfates such as oleyl sulfate and the alkylalkoxy sulfates of C- | o- - | 8 ("AEXS", especially ethoxysulfates EO 1-7).

Useful anionic surfactants also include water-soluble salts of 2-acyloxy-alkane-1-sulfonic acids containing from about 2 to 9 carbon atoms in the acyl group, and from about 9 to about 23 carbon atoms in the alkane portion; water-soluble salts of olefin sulphonates containing about 12 to 24 carbon atoms; and beta-alkyloxy-alcansulfonates containing from about 1 to about 3 carbon atoms in the alkyl group, and about 8 to 20 carbon atoms in the alkane portion.

Optionally, other examples of surfactants useful in the paste of the invention include C 1 J alkyl alkoxycarboxylates O-C-I S (especially the EO 1-5 ethoxycarboxylates), the glycerol ethers of C < | o- 8 > C-10-C18 alkyl polyglycosides and their corresponding sulfated polyglycosides, and alphasulfonated fatty acid esters of C-j2_Ci8- If desired, conventional amphoteric and nonionic surfactants such as 1,2-alkylethoxylates ("AE") including the so-called narrow-chain alkyl ethoxylates and the C-C-12 alkylphenol-alkoxylates (especially ethoxylates and ethoxy / mixed propoxy), amine oxides of C- | o_Ci8 >; and the like, can also be included in the overall compositions. The N-C 1 or 8 alkyl N-alkyl polyhydroxy fatty acid amides may also be used. Typical examples include the C 12 -C 18 N-methylglucamides. See WO 9,206,154. Other surfactants derived from sugar include the N-alkoxy polyhydroxy fatty acid amides, such as N- (3-methoxypropyl) glucamide of C? O_Ci8- The glucamides of N-propyl to N-hexyl of C-12-18 can be Use for low foam formation. Conventional C- | Q-C20 soaps can also be used- If high foaming is desired, C10-16 d® branched chain soaps can be used. Mixtures of anionic and nonionic surfactants are especially useful. Other conventional useful surfactants are mentioned in normal texts.

Cationic surfactants may also be used as the detergent surfactant herein, and suitable quaternary ammonium surfactants are selected from N-alkyl or alkylammonium surfactants of Cß-Ciß, wherein the remaining N positions are substituted by methyl groups, hydroxyalkyl or hydroxypropyl.

Amphoteric surfactants may also be used as the detergent surfactant herein, which include aliphatic derivatives of heterocyclic secondary and tertiary amines; switterionic surfactants including derivatives of aliphatic quaternary ammonium, phosphonium and sulfonium compounds; water-soluble salts of esters of fatty acids alphasulfonated; alkyl ether sulfates; water-soluble salts of olefin sulphonates; beta-alkyloxy-alcansulfonates; betaines having the formula R (R1) 2N + R2COO ~ > wherein R is a hydrocarbyl group of CQ-C- \ Q, preferably an alkyl group of Cl? "Ci 6 ° 9ruP ° C-10-C16 alkylacylamide, each Rl is typically C-1-C3 alkyl, preferably methyl , and R 2 is a C 1 -C 5 hydrocarbyl group, preferably C 1 -C 3 alkylene group, more preferably an C 1 -C 2 alkylene group Examples of suitable betaines include coconut acrylamidopropyldimethylbetaine, hexadecyldimethylbetaine, acrylamidopropylbetaine C -12-C14; C8-C14 acylamidohexyldiethylbetaine; 4 [C4-C4-acylmethylamidodietyl-J6-J6J-1-carboxybutane; CI QC- acrylamidodimethylbetaine; C-12-16 acylamidopentanodiethylbetaine; and acylmethylamidodimethylbetaine; C-J2-16- Preferred betaines are dimethylammonium hexanoate of C-J2-18 and acetylamidopropane (or ethane) dimethyl (or diethyl) betaines of C-10-C18; and 'sultaines having the formula R ( R1) 2N + R2SO3"wherein R is a C6-C? 8 hydrocarbyl group, preferably an alkyl group of C10-C-16, m s preferably a C-12-C13 alkyl group, each R1 is typically C1-C3 alkyl, preferably methyl, and R2 is a hydrocarbyl group of C -? - C6, preferably a C1-C3 alkylene or, preferably, a C1-C3 hydroxyalkylene group. Examples of suitable sultaines include C 2 -C 4 dimethylammonium-2-hydroxypropyl sulfonate, amidopropylammonium-2-hydroxypropyl sultaine of C 12 -C 14, dihydroxyethylammonium propanesulfonate of C 1 -C 4 and dimethylammonium hexansulfonate of Ci 6 -C 8. , with amidopropylammonium-2-hydroxypropyl sultaine of C-12-C being preferred.

Fine powders The amount of fine powders of the present process, which are used in the first step, may be from about 94% to 30%, preferably from 86% to 54%, in a total amount of the starting material for the first step. The starting fine powders of the present process are preferably selected from the group consisting of sodium carbonate base, sodium tripolyphosphate powder (STPP), hydrated tripolyphosphate, sodium sulfate base, aluminosilicates, layered crystalline silicates, nitrilotriacetates (NTA), phosphates , precipitated silicates, polymers, carbonates, citrates, powdered surfactants (such as powdered alkanesulfonic acids) and recirculated fine particles that occur from the process of the present invention, wherein the average diameter of the powder is 0.1 to 500 microns, preferably from 1 to 300 microns, more preferably from 5 to 100 microns. In case of using STPP hydrated as fine powders of the present invention, STPP which is hydrated to a level of not less than 50% is preferred: The aluminosilicate ion exchange materials used herein as builder have a high capacity of calcium ion exchange and a high exchange rate. While not wishing to be limited by theory, it is thought that such high capacity and rate of calcium ion exchange are a function of several interrelated factors that are derived from the method by which the aluminosilicate ion exchange material is produced. In this regard, the aluminosilicate ion exchange materials used herein are preferably produced in accordance with Corkill et al., U.S. Pat. No. 4,605,509 (Procter &; Gamble), whose description is incorporated herein by reference. Preferably, the aluminosilicate ion exchange material is in the "sodium" form, since the potassium and hydrogen forms of the present aluminosilicate do not exhibit a capacity and an ion exchange rate as high as provided by the sodium form. Additionally, preferably the aluminosilicate ion exchange material is in dehydrated form to facilitate the production of crisp detergent agglomerates as described herein. The aluminosilicate ion exchange materials used herein preferably have particle size diameters that optimize their effectiveness as builders. The term "particle size diameter", as used herein, represents the average diameter of particle size of a given aluminosilicate ion exchange material determined by conventional analytical techniques, such as microscopic determination and with scanning electron microscopy. (SEM). The preferred particle size diameter of the aluminosilicate is from about 0.1 microns to about 10 microns, more preferably from about 0.5 microns to about 9 microns. Most preferably, the diameter of particle size is from about 1 miera to about 8 micras. Preferably, the aluminosilicate ion exchange material has the formula Naz [(AIO2) z (Si? 2) y] xH2 ?, where z and y are integers of at least 6, the molar ratio of z: y is about 1 to about 5, and x is from about 10 to about 264. More preferably, the aluminosilicate has the formula Nai2 [(Al ?2) i2 (S¡O2) 12] xH2 ?, wherein x is about 20 to about 30, preferably about 27. These preferred aluminosilicates * are commercially available, for example, under the designations Zeolite A, Zeolite B and Zeolite X. Alternatively, aluminosilicate ion exchange materials that occur naturally or that are synthetically derived and suitable for used in the present, can be obtained as described in Krummel et al., US patent No. 3,985,669, the disclosure of which is incorporated herein by reference. The aluminosilicates used herein are further characterized by their ion exchange capacity which is at least about 200 mg hardness equivalents of CaCOs g, calculated on an anhydrous basis, and which is preferably on a scale of about 300 to 352 mg hardness equivalents of CaCO3 / g. Additionally, the aluminosilicate ion exchange materials of the present are further characterized by their calcium ion exchange rate, which is at least about 2 grains of Ca ++ / 3.785 liters / minute / gram / 3.785 liters, and more preferably on a scale of about 2 grains of Ca ++ / 3.785 liters / minute / gram / 3.785 liters to about 6 grains of Ca ++ / 3.785 liters / minute / gram / 3.785 liters. Finely atomized liquid The amount of finely atomized liquid of the present process, which is used in the second case, may be from about 1% to about 10% (on an active basis), preferably from about 2% to about 6% (on an active base) in a total amount of the final product obtained by the process of the present invention. The finely atomized liquid of the present process can be selected from the group consisting of liquid ionic or cationic silicate surfactants, which are in liquid form, aqueous or non-aqueous polymer solutions, water, and mixtures thereof. Other optional examples for the finely atomized liquid of the present invention may be sodium carboxymethylcellulose solution, polyethylene glycol (PED) and dimethylenetriaminepentamethylphosphonic acid (DETMP) solutions. Preferable examples of the anionic surfactant solutions that can be used as the finely atomized liquid in the present invention are HLAS about 88 to 97% active, NaLAS about 30 to 50% active, solution of AE3S about 28% active, liquid silicate about 40 to 50% active, etc. Cationic surfactants may also be used as the finely atomized liquid herein, and suitable quaternary ammonium surfactants are selected from N-alkyl or alkenyl ammonium surfactants of C6-C? , wherein the remaining N positions are substituted by methyl, hydroxyethyl or hydroxypropyl groups. Preferable examples of the aqueous or non-aqueous polymer solutions which can be used as the finely atomized liquid in the present invention are modified polyamines comprising a polyamine base structure corresponding to the formula: H [H2N-R] n + 1- [N-R3m- [N-R] n-NH2 which has a modified polyamine formula V (n + -nWmYnZ or a pollamine base structure corresponding to the formula: H R I I [H2N-R] n.k + 1- [N-R] m- [N-R] n- [N-R] k-NH2 having a modified polyamine formula V ^ .k + ^ WmYnY'k Z, wherein k is less than or equal to n, said polyamine base structure, prior to modification, has a molecular weight greater than about 200 daltons, in where: i) units V are terminal units that have the formula: E X- O E-N-R- E-N + -R E-N-R- ii) units W are base structure units that have the formula: E X- -N-R- or -N + -R- -N-R- I E iii) the Y units are branching units having the formula: E X- O -N-R- -N + -R- -N-R- iv) Z units are terminal units that have the formula: X- -N-E N + I I E E wherein the basic structure linker units R are selected from the group consisting of C2-C-12 alkylene. C4-C12 alkenylene. hydroxy alkylene of C3-C- | 2 > C4-C12 dihydroxyalkylene. dialkylarylene of C8-C-12. - (R1O) xR1-, - (R10) xR5 (OR1) X, - (CH2CH (OR2) CH2O) Z (R1O) and R1 - (OCH2CH (OR2) CH2) W ". -C (Q) (R4) rC (O) -, -CH2CH (0R) CH2-, and mixtures thereof, wherein R1 is C2-C6 alkylene, and mixtures thereof, R2 is hydrogen, - (R1O) xB, and mixtures thereof R 3 is C 1 -C 8 alkyl, C 7 -C 12 arylalkyl, aryl substituted with C 7 -C 2 alkyl, C 6 -C 12 aryl, and mixtures thereof; R 4 is C 1 -C 12 alkylene, C 4 -C 20 alkenylene, C 8 -C 12 arylalkylene, C 6 -C 10 arylene and mixtures thereof, R 5 is C 1 -C 12 alkylene, C 3 -C 12 hydroxyalkylene. C4-C12 dihydroxyalkylene, C8-C12 dialkylarylene, -C (O) -, -C (O) NHR6NHC (O) -, -R1 (OR1) -, -C (O) (R4) rC (O) -, CH2CH (OH) CH2-, CH 2 CH (OH) CH 2? - (R 1?) And R 1? CH 2 CH (OH) CH 2 - and mixtures thereof; R6 is C2-C12 alkylene or C ar-C- arylene, and units E are selected from the group consisting of hydrogen, C 1 -C 22 alkyl, C 3 -C 22 alkenyl. C7-C22 arylalkyl, C2-C22 hydroxyalkyl > - (CH2) pC? 2M, - (CH2) qS? 3M, -CH (CH2C? 2M) CO2M, - (CH2) pP? 3M, - (Rl?) XB, -C (O) R3, and mixtures of the same; oxide; B is hydrogen, CJ alkyl, - (CH2) qS03M, - (CH2) pC02M, - (CH2) q (CHSO3M) CH2S? 3M, - (CH2) q- (CHS02M) CH2S03M, - (CH2) pPO3M , -PO3M and mixtures thereof; M is hydrogen or a cation soluble in water in an amount sufficient to satisfy the balance of the charge; X is a water soluble anion; m has the value of 4 to about 400; n has the value from 0 to about 200; p has the value of 1 to 6, q has the value of 0 to 6; r has the value of 0 or 1; w has the value of 0 or 1; x has the value of 1 to 100; "y" has the value of 0 to 100; z has the value of 0 or 1. An example of the most preferred polyethylene imines would be a polyethylenimine having a molecular weight of 1800, which is further modified by ethoxylation to a degree of about 7 ethyleneoxy residues per nitrogen (PEI 1800, E7 ). It is preferred that the above polymer solution is premixed with an anionic surfactant such as NaLAS. Other preferred examples of the aqueous or non-aqueous polymer solutions which can be used as the finely atomized liquid in the present invention are polymeric polycarboxylate dispersants which can be prepared by polymerizing or copolymerizing suitable unsaturated monomers, preferably in their acid form. Unsaturated monomeric acids which can be polymerized to form suitable polymeric polycarboxylates include acrylic acid, maleic acid (or maleic anhydride), fumaric acid, taconic acid, aconitic acid, mesaconic acid, citraconic acid and methylenemalonic acid. The presence, in the polymeric polycarboxylates of the present, of monomeric segments which do not contain carboxylate radicals such as vinyl methyl ether, styrene, ethylene, etc., is suitable, provided that said segments do not constitute more than about 40% by weight. Preferred are homopolymeric polycarboxylates having molecular weights greater than 4000, such as those described below. Particularly suitable homopolymeric polycarboxylates can be derived from acrylic acid. Said polymers based on acrylic acid, which are useful herein, are the water-soluble salts of polymerized acrylic acid: The average molecular weight of said polymers in acid form preferably ranges from more than 4,000 to 10,000, preferably from more than 4,000 to 7,000, and most preferably more than 4,000 to 5,000. The water-soluble salts of said acrylic acid polymers may include, for example, the alkali metal, ammonium and substituted ammonium salts. Copolymeric polycarboxylates such as a copolymer based on acrylic acid / maleic acid can also be used. Such materials include the water-soluble salts of the copolymer of acrylic acid and maleic acid. The average molecular weight of said copolymers in acid form preferably ranges from about 2,000 to 100,000, more preferably from about 5,000 to 75,000, and most preferably from about 7,000 to 65,000. The ratio of acrylate: maleate segments in said copolymers will generally vary from about 30: 1 to about 1: 1, more preferably from about 10: 1 to 2: 1. The water-soluble salts of said copolymers of acrylic acid: maleic acid may include, for example, the alkali metal, ammonium and substituted ammonium salts. It is preferred that the above polymer solution be premixed with an anionic surfactant such as LAS.

Detergent ingredients attached The starting detergent material in the present process may include additional detergent ingredients, and / or any number of additional ingredients may be incorporated into the detergent composition during the subsequent steps of the present process. These adjunct ingredients include other detergency builders, bleaches, bleach activators, foaming enhancers, or foam suppressors, anti-rust and anti-corrosion agents, soil suspending agents, soil release agents, germicides, pH adjusting agents, fountains. alkalinity without builder, chelating agents, smectite clays, enzymes, enzyme stabilizing agents, and perfumes. See the patent of E.U.A. 3,936,537, issued February 3, 1976 to Baskerville, Jr., et al., Incorporated herein by reference. Other detergency builders can generally be selected from the various water-soluble alkali metal, ammonium or ammonium phosphates, polyphosphates, polyphosphonates, carbonates, borates, polyhydroxysulfonates, polyacetates, carboxylates and polycarboxylates substituted. Alkali metal, especially sodium, salts of the above are preferred. Preferred for use herein are the phosphates, carbonates, C-io-iß fatty acids. polycarboxylates, and mixtures thereof. More preferred are sodium tripolyphosphate, tetrasodium pyrophosphate, citrate, tartrate, mono- and di-succinates, and mixtures thereof (see below). Compared to the amorphous sodium silicates, the crystallized sodium silicate laminates exhibit a clearly increased calcium and magnesium ion exchange capacity. In addition, stratified sodium silicates prefer magnesium ions over calcium ions, a feature necessary to ensure that substantially all of the "hardness" is removed from the wash water. However, these layered crystalline sodium silicates are generally more expensive than amorphous silicates, as well as other detergency builders. Consequently, in order to provide an economically feasible laundry detergent, the proportion of the crystalline layered sodium silicates used must be judiciously determined. The layered crystalline sodium silicates suitable for use herein preferably have the formula: NaMSix? 2x +? And H2? wherein M is sodium or hydrogen, x is from about 1.9 to about 4, and y is from about 0 to about 20. More preferably, the layered crystalline sodium silicate has the formula: NaMSi2 5.yH2O wherein M is sodium or hydrogen, and y is from about 0 to about 20. These and other stratified crystalline sodium silicates are described in Corkill et al., US Patent No. 4,605,509, previously incorporated herein by reference. Specific examples of inorganic phosphate builders are sodium and potassium tripolyphosphate, pyrophosphate, polymeric metaphosphate having a degree of polymerization of about 6 to 21, and orthophosphates. Examples of polyphosphonate builders are the sodium and potassium salts of ethylene diphosphonic acid, the sodium and potassium salts of ethane 1-hydroxy-1,1-diphosphonic acid, and the sodium and potassium salts of acid 1, 1, 2-triphosphonic acid. Other phosphorus builder compounds are described in US Patents. 3,159,581; 3,213,030; 3,422,021; 3,422,137; 3,400,176 and 3,400,148, all of which are incorporated herein by reference. Examples of non-phosphorus inorganic builders are tetraborate decahydrate and silicates having a weight ratio of SiO 2: alkali metal oxide of about 0.5 to about 4.0, preferably about 1.0 to about 2.4. The non-phosphorus water-soluble organic builders found useful herein include the various alkali metal, ammonium and substituted ammonium polyacetates, carboxylates, polycarboxylates and polyhydroxysulfonates. Examples of polyacetate builders and polycarboxylate builders are the sodium, potassium, lithium, ammonium and substituted ammonium salts of ethylenediaminetetraacetic acid, nitrilotriacetic acid, oxydisuccinic acid, melific acid, benzene polycarboxylic acids, and citric acid. Polycarboxylate polymeric detergency builders are described in the U.S. Patent. 3,308,067, Diehl, issued March 7, 1967, the disclosure of which is incorporated herein by reference. Such materials include the water-soluble salts of homo- and co-polymers of aliphatic carboxylic acids such as maleic acid, itaconic acid, mesaconic acid, fumaric acid, aconitic acid, citraconic acid and methylenemalonic acid. Some of these materials are useful as the water-soluble anionic polymer as described below, but only if they are in intimate admixture with the non-soap anionic surfactant. Other polycarboxylates suitable for use herein are the polyacetal carboxylates described in the U.S. Patent. 4,144,226, issued March 13, 1979 to Crutchfield et al., And the U.S. Patent. 4,246,495, issued March 27, 1979 to Crutchfield et al., Which are incorporated herein by reference. These polyacetal carboxylates can be prepared by bringing together a glyoxylic acid ester and a polymerization initiator under polymerization conditions. The resulting polyacetal carboxylate ester is then attached to chemically stable end groups to stabilize the polyacetal carboxylate against rapid depolymerization in alkaline solution, converted to the corresponding salt, and added to a detergent composition. Particularly preferred polycarboxylate builders are ether carboxylate builder compositions comprising a combination of tartrate monosuccinate and tartrate disuccinate described in the U.S.A. 4,663,071, Bush et al., Issued May 5, 1987, the disclosure of which is incorporated herein by reference. Bleach agents and activators are described in the US patent. 4,412,934, Chung et al., Issued November 1, 1983, and in the U.S. patent. 4,483,781, Hartman, issued November 20, 1984, which are incorporated herein by reference. Chelating agents are also described in the U.S.A. 4,663,071, Bush et al., In column 17, line 54 to column 18, line 68, incorporated herein by reference. Foam modifiers are also optional ingredients, and are described in the U.S. Patents. 3,933,672, issued January 20, 1976 to Bartolotta et al., And 4,136,045, issued January 23, 1979 to Gault et al., Which are incorporated herein by reference. Smectite clays suitable for use herein are described in the U.S.A. 4,762,645, Tucker et al., Issued August 9, 1988, column 6, line 3 to column 7, line 24, incorporated herein by reference. Other builders suitable for use herein are listed in the Baskerville patent, column 13, line 54 to column 16, line 16, and in U.S. Patent 4,663,071, Bush et al., Issued May 5, 1987, which are incorporated herein by reference. As a comparison with the present invention, a photograph of high density agglomerates (the average density is approximately 700-800g / l) obtained by a series of the mixers operated under different conditions of the present invention, is shown in figure 4. In said figure, they were used to achieve agglomeration a CB Lódige mixer (CB-30, operated at 550 RPM), then a Schugi flexomixer (operated at 2800 RPM), and finally a KM Lódige mixer (KM-600, operated at 100 RPM with normal plows) . The material used to obtain the agglomerates of Figure 4 is the same as that used in Example 2, and are described in detail in the examples.

Optional steps of the procedure An optional step of the process is drying, if it is desired to reduce the moisture level in the agglomerates of the second step. This can be achieved by several apparatuses, well known to those skilled in the art. The fluid bed apparatus is preferred, which will be referred to in the following description. In another optional step of the present process, the detergent agglomerates emerging from the fluid bed dryer are further conditioned by additional cooling in a cooling apparatus. The preferred apparatus is a fluid bed apparatus. Another optional step of the process involves adding a coating agent to improve the flowability and / or to minimize the over-agglomeration of the detergent composition in one or more of the following points of the present process: (1) the coating agent can be added directly after using the fluid bed cooler or dryer; (2) the coating agent can be added between the fluid bed dryer and the fluid bed cooler; (3) the coating agent may be added between the fluid dryer and a moderate speed mixer to achieve agglomeration, which is commonly known to those skilled in the art; and / or (4) the coating agent can be added directly to a moderate speed mixer to achieve agglomeration, which is commonly known to those skilled in the art, and subsequently in a fluid bed dryer. The coating agent is preferably selected from the group consisting of aluminosilicates, silicates, carbonates, and mixtures thereof. The coating agent not only improves the free fluidity of the resulting detergent composition, which is desirable by consumers, since it allows easy evaluation of the detergent during use, but also serves to control the agglomeration, preventing or minimizing over-agglomeration , especially when added directly to the moderate speed mixer. As those skilled in the art will know, over-agglomeration can lead to very inconvenient flow and aesthetic properties of the final detergent product. Optionally, the method may comprise the step of sprinkling an additional binder in the first and second mixers or in one of them for the present invention, or fluid bed dryers and / or fluid bed coolers. A binder is added for the purpose of improving agglomeration by providing a "binder" or "adherent" agent for the detergent components. The binder is preferably selected from the group consisting of water, anionic surfactants, nonionic surfactants, liquid silicates, polyethylene glycol, polyvinylpyrrolidone, polyacrylates, citric acid, and mixtures thereof. Other suitable binding materials including those included herein are described in Beerse et al., U.S. Pat. No. 5,108,646 (Procter &Gamble Co.), the disclosure of which is incorporated herein by reference. Other optional steps contemplated by the present method include atomizing the oversized detergent agglomerates in an atomizing apparatus which can take various forms including, but not limited to, conventional screens selected for the desired particle size of the finished detergent product. Other optional steps include conditioning the detergent agglomerates by subjecting them to further drying, by the apparatus described above. Another optional step of the present process is to finish the resulting detergent agglomerates by various methods including spraying and / or mixing other conventional detergent ingredients. For example, the finishing step encompasses the spraying of perfumes, brighteners and enzymes onto the finished agglomerates to provide a more complete detergent composition. Said techniques and ingredients are well known in the art. Representative examples of the series of mixers that make it possible to obtain the granular detergent compositions according to the process of the present invention, more optional procedures, are the following: A. (1) agglomeration in CB Lódige model, (2) and then in the Schugi flexic model, (3) sizing in a Mogensen sizer to remove particles larger than 4.5 mm, (4) drying in a fluid bed dryer, (5) cooling in a fluid bed cooler, (6) sizing in a Mogensen sizer to remove particles larger than 1.2 mm, (7) grinding to reduce the oversized agglomerates of the sizers, and (8) feedback of the basic agglomerates to the fluid bed dryer or fluid bed cooler or CB Lódige mixer; B. (1) agglomeration in the CB Lódige model, (2) then in the KM Lodige model, (3) in addition in the Schugi flexomic model, (4) sizing in a Mogensen sizer to remove particles larger than 4.5 mm, (5) drying in a fluid bed dryer, (6) cooling in a fluid bed cooler, (7) sizing in a Mogensen sizer to remove particles larger than 1.2 mm, (8) crushing to reduce oversized agglomerates of the sizers, and (9) feedback of the basic agglomerates to the fluid bed dryer or fluid bed cooler or CB Lódige mixer. The other essential step of the process involves a highly active paste structuring process, for example, curing an aqueous slurry of anionic surfactant, incorporating a paste hardening material by the use of an extruder, prior to the process of the present invention. . The details of the highly active paste structuring process are described in co-application No. JA162F (filed October 4, 1996), which was filed on the same day that the present invention was filed. To make the present invention more easily understood, reference is made to the following examples, which are intended to be illustrative only and not to be limiting of the present invention.

EXAMPLES EXAMPLE 1 Irregularly shaped agglomerates after the first step of the present invention The following is an example for obtaining agglomerates using only the CB Lódige mixer (CB-30), followed by the fluid bed dryer (FBD), the fluid bed cooler (FBC), and then sizing and grinding. The 259 kg / h of coconut fatty alcohol sulphate aqueous surfactant paste (71.5% active) is dispersed by the pin tools of a CB-30 mixer together with the 217 kg / h of STPP powder (average size of particle from 40 to 75 microns), the 169 kg / h of micronized sodium carbonate (average particle size of 5 to 30 microns), the 103 kg / h of micronised sulphate (average particle size of 5 to 30 microns) and 288 kg / h of fine particles recirculated. The surfactant paste is fed at about 40 to 55 ° C, and the powders are fed at room temperature. The conditions of the CB-30 mixer are the following: Average residence time: 14 to 20 seconds Top speed: 6.5 to 7.0 m / s Energy condition: 0.15 to 1.0 kj / kg After agglomeration, the temperature of the bed of the FBD is maintained between 40 and 60 ° C, and the bed temperature of the BCF is maintained between 15 and 30 ° C. The resulting granules have a density of 475-530 g / l (Figure 1). The level of fineness after using the CB-30 mixer is 30 to 50% against 25% of the target.

EXAMPLE 2 Irregularly shaped agglomerates obtained after the first and second steps of the present invention The following is an example to obtain agglomerates using the CB Lódige mixer (CB-30), then the Schugi flexomixer, followed by the fluid bed dryer (FBD), the fluid bed cooler (FBC), and then sizing and grinding (the procedure and the content of materials are the same as those of Example 1, except for the incorporation of an agglomeration step by means of a Schugi flexomixer after the agglomeration step by means of the CB Lódige mixer). The agglomerates of the mixer CB-30 are fed to the Schugi flexomixer. The 30 kg / h of HLAS are atomized and sprayed in the Schugi flexomixer. The conditions of the Schugi mixer are as follows: Average residence time: 0.5 to 2 seconds Peak speed: 15 to 18 m / s Energy condition: 0.15 to 1.0 kj / kg. The resulting granules after using the Schugi mixer have a density of 475-500 g / l (figure 2), and the resulting granules after sizing and grinding have a density of 450-475 g / l (figure 3). The level of fineness of the Schugi flexomixer is from 22 to 30%.

EXAMPLE 3 Irregularly shaped agglomerates obtained from the process of the present invention The following is an example for obtaining agglomerates using the CB Lódige mixer (CB-30), then the Schugi flexomixer, followed by the fluid bed cooler (FBC), and then sizing and grinding. The 220 kg / h of non-aqueous linear alkylbenzenesulfonic acid (94-96% active) are dispersed by the pin tools of a CB-30 mixer together with the 300 kg / h of STPP powder (average particle size of 40 to 75 microns), the 230 kg / h of micronized sodium carbonate (average particle size of 5 to 30 microns), the 100 kg / h of micronized sulphate (average particle size of 5 to 30 microns), the 90 kg / h of zeolite and 100 kg / h of recirculated fine particles. The surfactant is fed at about 40 to 55 ° C, and the powders are fed at room temperature. The conditions of the CB-30 mixer are as follows: Average residence time: 10 to 18 seconds Top speed: 6 to 13 m / s Energy condition: 0.15 to 3.5 kj / kg The agglomerates of the CB-30 mixer are fed to the Schugi flexomic mixer. The 30 kg / h of HLAS are atomized and sprayed in the Schugi flexomixer and 20 kg / h of carbonate are added to said mixer. The conditions of the Schugi mixer are as follows: Average residence time: 0.5 to 2 seconds Peak speed: 15 to 18 m / s Energy condition: 0.15 to 1.0 kj / kg. The resulting granules after using the Schugi mixer and after sizing and grinding have a density of 500-550 g / l.

EXAMPLE 4 Irregularly shaped agglomerates obtained from the process of the present invention The following is an example to obtain agglomerates using the CB Lódige mixer (CB-30), then the KM Lódige mixer (KM-600) and then the Schugi flexomixer, followed by the fluid bed cooler (FBC), and then sizing and grinding. The 220 kg / h of non-aqueous linear alkylbenzenesulfonic acid (94-96% active) are dispersed by the pin tools of a CB-30 mixer together with the 300 kg / h of STPP powder (average particle size of 40 to 75 microns), the 230 kg / h of micronisodium carbonate (average particle size of 5 to 30 microns), the 100 kg / h of micronisulphate (5 to 30 microns), the 90 kg / h of zeolite and the 100 kg / h of fine recirculated particles. The surfactant is fed at about 40 to 55 ° C, and the powders are fed at room temperature. The conditions of the CB-30 mixer are the following: Average residence time: 10 to 18 seconds Top speed: 6 to 13 m / s Energy condition: 0.15 to 3.5 kj / kg The agglomerates of the CB mixer are charged to a mixer KM, where the retention is approximately 40 to 60 kg. The RPM of the plow is 100, and the RPM of the blade is 1300 (3 blades are in the mixer). The agglomerates of the KM mixer have a density of 750-800 g / l. The agglomerates of the mixer KM are fed to the Schugi flexomixer (FX-160). The 30 kg / h of HLAS are atomiand sprayed in the Schugi flexomixer and 20 kg / h of carbonate are added to said mixer. The conditions of the Schugi mixer are as follows: Average residence time: 0.5 to 2 seconds Peak speed: 15 to 18 m / s Energy condition: 0.15 to 1.0 kj / kg. The resulting granules after using the Schugi mixer and after sizing and grinding have a density of about 600 g / l. Having thus described the invention in detail, it will be apparent to those skilled in the art that various changes can be made without departing from the scope of the invention, and that the latter should not be considered to be limited to what is described in the specification.

Claims (12)

NOVELTY OF THE INVENTION CLAIMS

1. - A non-tower method for preparing a granular detergent composition having a low density, from about 300 g / l to about 600 g / l, characterized in that it comprises the steps of: (a) (i) dispersing a surfactant aqueous or non-aqueous, and (i) coating the surfactant with fine powders having a diameter of 0.1 to 500 microns, in a mixer which is operated under the following conditions to obtain granules: [Average residence time: around from 5 to about 30 seconds, tip speed: from about 5 to about 10 m / s, energy condition: from about 0.15 to about 4.20 kj / kg], and then (b) sprinkling finely atomized liquid to the granules and the excess of fine powders of step (a), in a mixer which is operated under the following conditions to bind the excess of fine powders on the irregularly shaped granules, under the following conditions: [Mean time residence: from about 0.2 to about 5 seconds, tip speed: from about 10 to about 23m / s, power condition: from about 0.15 to about 2.9 kj / kg.

2. The method according to claim 1, further characterized in that said surfactant is selected from the group consisting of anionic surfactant, nonionic surfactant, cationic surfactant, switterionic surfactant, amphoteric surfactant, and mixtures thereof. .

3. The process according to claim 1, further characterized in that said surfactant is selected from the group consisting of alkylbenzene sulfonates, alkylalkoxy sulfates, alkylethoxylates, alkylsulfates, coconut fatty alcohol sulphates, and mixtures thereof.

4. The process according to claim 1, further characterized in that an aqueous or non-aqueous polymer solution is dispersed with said surfactant in step (a) (i). The process according to claim 1, further characterized in that the fine powders are selected from the group consisting of sodium carbonate, sodium tripolyphosphate powder, hydrated tripolyphosphate, sodium sulfates, aluminosilicates, layered crystalline silicates, phosphates, silicates precipitates, polymers, carbonates, citrates, nitrilotriacetates (NTA), powder surfactants, recirculated fine particles of step (b), and mixtures thereof. 6. The process according to claim 1, further characterized in that the finely atomized liquid is selected from the group consisting of liquid silicates, anionic surfactants, cationic surfactants, aqueous polymeric solutions, non-aqueous polymer solutions, water, and mixtures of the same. The method according to claim 1, further characterized in that the average residence time of the detergent agglomerates in the mixer of step (a) is on the scale of about 10 seconds to about 15 seconds, the tip speed of the detergent agglomerates in the mixer of step (a) is on the scale of about 6 m / s to about 8 m / s, and the scale of the power condition of the mixer of step (a) is set to about 0.15 kj / kg to approximately 2.5 kj / kg. The method according to claim 5, further characterized in that the average residence time of the detergent agglomerates in the mixer of step (b) is on the scale of about 0.5 seconds to about 2 seconds, the tip speed of the detergent agglomerates in the mixer of step (b) is in the range of about 13 m / s to about 20 m / s, and the scale of the power condition of the mixer of step (b) is set to about 0.15 kj / kg to approximately 1.9 kj / kg. 9. The method according to claim 1, further characterized in that the total amount of recirculated fine particles from the result of step (b) in a total amount of the fine particle powders of step (a), is from about 10% to about 40%. 10. The process according to claim 1, further characterized in that the fine powders is STPP, which is hydrated at a level not less than 50%. The method according to claim 1, further characterized in that the total amount of surfactants for the process according to claim 1, is from about 5% to about 60%, in a total amount of a composition obtained by the process according to claim 1. 12. The granular detergent composition obtained according to the method of claim 1.