Concentrated surfactant compositions

Abstract

Concentrated Surfactant Compositions A surfactant composition comprising a) 60-75 wt% of alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion; wherein the alpha-olefin sulfonates comprise from 2 to 10 wt% of one or more C4-C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. A method of forming said surfactant composition and a product comprising said surfactant composition are also described. Uses of one or more C4-C12 alpha-olefin sulfonates, a halide salt or a combination of both, to lower the viscosity of a surfactant composition comprising C14-C20 alpha-olefin sulfonates are also described.

Description

[0001] Concentrated Surfactant Compositions

[0002] Field

[0003] The present invention relates to surfactant compositions comprising alpha-olefin sulfonates and a halide salt, to a method of forming said surfactant compositions, to a product comprising the surfactant composition and to uses of said surfactant compositions. In particular, the present invention relates to surfactant compositions having a relatively high concentration of alpha-olefin sulfonates and a relatively low shear viscosity, for example at 55°C.

[0004] Background

[0005] Many surfactant-containing consumer goods such as personal care products contain ethoxylated surfactants as a main detergent component. The known processes for manufacturing ethoxylated surfactants may form 1 ,4-dioxane which will then be present in such surfactants and the consumer products formulated using these surfactants. However, regulations have been placed on the amount of 1 ,4-dioxane allowed in personal care products and it may be difficult to meet these limits when using such ethoxylated surfactants. Therefore in order to meet these restrictions on the levels of 1 ,4-dioxane in personal care products, in some instances ethoxylated surfactants may need to be replaced by alternative non-ethoxylated surfactants which do not contain 1 ,4-dioxane.

[0006] Alpha-Olefin Sulfonates (AOS) have been identified as potential replacement surfactants for currently used surfactants. AOS surfactants can be effective in many detergent-based products and can be produced without the formation of 1 ,4-dioxane.

[0007] Known surfactants for formulating into consumer products are generally provided in highly concentrated solutions. If AOS are to replace such surfactants in such applications, then it would be advantageous for AOS to be provided in similar highly concentrated solutions. However, AOS surfactants tend to thicken and form gels in aqueous media at relatively high concentrations, such as around 41 wt%. Such thickened or gelled solutions are more difficult to handle and formulate into consumer products, adding to the cost and complexity of the manufacture of AOS-containing products. Therefore AOS surfactants are usually provided and used at lower concentrations, for example about 38 wt% active material, to avoid excessive thickening or gelation. This may detract from the sustainability profile of the AOS surfactant, as the higher amount of water in the AOS surfactant concentrate compared to the highly concentrated surfactants means that transportation costs and associated energy consumption are higher for the AOS surfactants. Such lower concentrations of AOS surfactant in the concentrate may also make it difficult to achieve relatively high active concentrations of AOS surfactant in formulated products.Therefore, there is a need for an AOS-containing composition having a high concentration of active material and a viscosity which is sufficiently low at relevant temperatures to facilitate handling and processing of the AOS to form consumer products.

[0008] Previous efforts to solve this problem have involved adding various additional components to the AOS-containing solution to inhibit gelation. However, such components would inevitably become part of the final product, which may not be desirable.

[0009] Summary of the Invention

[0010] It may be one aim of the present invention to provide surfactant compositions comprising alpha-olefin sulfonates which comprise a relatively high concentration of alpha-olefin sulfonates and a relatively low viscosity, for example a concentration of at least 60 wt% active material (i.e. wt% alpha-olefin sulfonate surfactant content) and a shear viscosity of less than 8,000 cP at 55°C, whilst also providing the detergency required of such surfactant compositions.

[0011] The inventors have surprisingly found that the alpha-olefin sulfonate compositions of the present invention comprising one or more C4-C12 alpha-olefin sulfonates, for example C12 alpha-olefin sulfonates, and a halide salt, can be formed with a desirable high concentration of active material, i.e. 60-75 wt% of AOS, whilst having an advantageously low viscosity at temperatures relevant to processing, which allows efficient handling and formulation of the surfactant composition into consumer products. For example, the compositions of the present invention suitably have a shear viscosity of less than 8,000 cP at 55°C and are therefore pumpable in an industrial process carried out at around said temperature and can provide relatively high concentrations of active surfactant material to a product during formulation. The alpha-olefin sulfonate compositions of the present invention also suitably provide a desired level of detergency, for example a comparable detergency to known surfactant compositions, for example known alpha-olefin sulfonate compositions.

[0012] According to aspects of the present invention, there is provided a surfactant composition, method and use as set forth in the appended claims. Other features of the invention will be apparent from the dependent claims, and from the description which follows.

[0013] According to a first aspect of the present invention, there is provided a surfactant composition comprising a) 60-75 wt% of alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion; wherein the alpha-olefin sulfonates comprise from 2 to 10 wt% of one or more C4-C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0014] Suitably, the first aspect of the present invention provides a surfactant composition comprising a) 60-75 wt% of alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion; wherein the alpha-olefin sulfonates comprise from 2to 10 wt% of C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0015] Alpha-olefin sulfonates

[0016] The term “alpha-olefin sulfonates” is used in the art and in the present disclosure to refer to the products of sulfonation of alpha-olefins followed by neutralisation. Such alpha-olefin sulfonates are typically a mixture comprising alkenyl sulfonates as the major components) and also comprising lesser amounts of hydroxyalkane sulfonate, alkenyl disulfonates and hydroxyalkane disulfonates. The alpha-olefin sulfonates may also comprise some unreacted alpha-olefins from the alpha-olefin composition used to form the alpha-olefin sulfonates. Said mixtures are referred to herein as “alphaolefin sulfonates”. For example, the “alpha-olefin sulfonates” used in the present invention may comprise 55 to 75 wt% of alkenyl sulfonates, 25 to 45% of hydroxyalkane sulfonates and 5 to 15% of a mixture of hydroxyalkane disulfonates and alkenyl disulfonates. The sulfonate salts referred to above are preferably sodium salts.

[0017] Furthermore, the term “total weight of the alpha-olefin sulfonates present in the surfactant composition” is used herein to refer to the total weight of the alkenyl sulfonates and also any hydroxyalkane sulfonate, alkenyl disulfonates and / or hydroxyalkane disulfonates which may be present in the composition, and which is typically present in such compositions, as described above.

[0018] The alpha-olefins used to form the alpha-olefin sulfonates of the composition of this first aspect is suitably a mixture of alpha-olefins having different carbon chain lengths, for example C12, C14, C16 and C18 alpha-olefins. The alpha-olefin mixture used also typically comprises branched alpha-olefins and internal olefins (i.e. wherein the olefinic bond is not located at the end of the carbon chain). This alpha-olefin mixture may be referred to herein as an alpha-olefin composition. Suitably the alphaolefin composition comprises alpha-olefins as the major component(s), for example at least 85 wt% of alpha-olefins. Suitably the alpha-olefin composition comprises linear alpha-olefins as the major components), for example at least 85 wt% of linear alpha-olefins. Suitably the alpha-olefin composition comprises no more than 15 wt% of branched alpha-olefins and internal olefins.

[0019] The alpha-olefins used to form the alpha-olefin sulfonates of the composition of this first aspect may be obtained from any suitable source, for example from fossil derived carbon sources, from biogenic carbon sources, from carbon derived from chemical recycling, or from carbon derived from the capture of carbon dioxide and its conversion to appropriate feedstocks (see below). The following are non-limiting examples of methods for making said alpha-olefins.

[0020] In some embodiments, the alpha-olefins may be obtained by the oligomerisation of ethylene. The ethylene may be derived from any of the following example sources:(i) cracking of one or more of the following: ethane, propane, naphtha, bio-naphtha including hydroprocessed esters and fatty acids (example feedstocks for which include plant oils, including vegetable oils and crude Tall Oil, fats, including animal fats and used cooking oil), gas oil, condensates (light naphtha), plastic waste pyrolysis oils, Fischer-Tropsch derived hydrocarbons where the feedstock for the syngas feedstock is fossil-derived, biomass-derived or CO2 + H2 derived, hydrocarbons derived microbial conversion of sugars;

[0021] (ii) dehydration of ethanol obtained from fermentation, including fermentation of sugars, fermentation of flue gases, methanol by catalytic conversion of CO2 + H2 or electrochemical reduction of CO2;

[0022] (iii) electrolysis of CO2, obtained as a by-product from ammonia manufacture or obtained by ‘carbon-capture’ techniques.

[0023] In some embodiments, the alpha-olefins may be obtained by the catalytic dehydration of fatty alcohols. The fatty alcohols can be derived either from chemical conversions of various vegetable oils or from a fermentation process. Suitable vegetable oils may be selected from one or more of palm oil, palm kernel oil, coconut oil, murumuru oil, babassu oil, and macauba oil.

[0024] In some embodiments, the alpha-olefins may be obtained by the enzymic conversion of fatty acid esters.

[0025] The formation of the alpha-olefin sulfonates from such an alpha-olefin composition provides the sulfonation products discussed above, i.e. alkenyl sulfonates, hydroxyalkane sulfonates, alkenyl disulfonates and / or hydroxyalkane disulfonates, of any branched olefins and internal olefins present in the alpha olefin mixture, in addition to the sulfonation products from the linear alpha-olefins. As the alpha-olefin composition comprises alpha-olefins as the major component (for example at least 85 wt% of all olefins present), then the alpha-olefin sulfonates comprise the sulfonation products of the alpha-olefins as the major components.

[0026] The alpha-olefin sulfonates of the composition of this first aspect suitably comprise a mixture of alpha-olefin sulfonates (i.e. alkenyl sulfonates, hydroxyalkane sulfonates, alkenyl disulfonates and / or hydroxyalkane disulfonates) having different carbon chain lengths, for example C12, C14, C16 and C18 alpha-olefin sulfonates. The distribution of the carbon chain lengths of the alpha-olefin sulfonates is dependent upon the distribution of the carbon chain lengths in the olefins of the alphaolefin composition used to form the alpha-olefin sulfonates.

[0027] Suitably the alpha-olefin sulfonates comprise C12, C14 and C16 alpha-olefin sulfonates. Suitably the alpha-olefin sulfonates are formed from an alpha-olefin composition comprising C12, C14 and C16 alpha-olefins.The alpha-olefin sulfonates of the surfactant composition of this first aspect comprise from 2 to 10 wt% of one or more C4-C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. The one or more C4-C12 alpha-olefin sulfonates may comprise one or more of C4, C6, C8, C10 or C12 alpha-olefin sulfonates. Suitably the alphaolefin sulfonates comprise from 2 to 10 wt% of C6-C12 alpha-olefin sulfonates, suitably 2 to 10 wt% of C8-C12 alpha-olefin sulfonates, suitably 2 to 10 wt% of C10-C12 alpha-olefin sulfonates. In some embodiments, the alpha-olefin sulfonates comprise 2 to 10 wt% of one or more C8, C10 or C12 alpha-olefin sulfonates, or a mixture thereof.

[0028] In some embodiments, the one or more C4-C12 alpha-olefin sulfonates are provided by one or more C4-C10 alpha-olefin sulfonates. Therefore the alpha-olefin sulfonates may comprise from 2 to 10 wt% of one or more C4-C10 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. The one or more C4-C10 alpha-olefin sulfonates may comprise one or more of C4, C6, C8 or C10 alpha-olefin sulfonates, suitably one or more of C6, C8 or C10 alpha-olefin sulfonates, suitably one or more of C8 or C10 alpha-olefin sulfonates.

[0029] The alpha-olefin sulfonates of the surfactant composition of this first aspect suitably comprise from 2 to 10 wt% of C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. The alpha-olefin sulfonates of the surfactant composition of this first aspect are suitably formed from an alpha-olefin composition comprising from 2 to 10 wt% of C12 olefins, predominantly C12 alpha-olefins. Suitably the alpha-olefin sulfonates of the surfactant composition of this first aspect are formed from an alpha-olefin composition comprising from 2 to 10 wt% of C12 alpha-olefins, based on the total weight of alpha-olefins present in the alpha-olefin composition.

[0030] The alpha-olefin sulfonates of the surfactant composition of this first aspect may comprise at least 2 wt% of one or more C4-C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably at least 3 wt% or at least 4 wt%.

[0031] The alpha-olefin sulfonates may comprise up to 10 wt% of one or more C4-C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 9 wt%, up to 8 wt%, up to 7 wt% or up to 6 wt%.

[0032] The alpha-olefin sulfonates may comprise from 2 to 8 wt% of one or more C4-C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 3 to 7 wt%, from 4 to 6 wt% or from 4.5 to 5.5 wt%. The alpha-olefin sulfonates may comprise approximately 5 wt% of one or more C4-C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. The one or more C4-C12 alpha-olefin sulfonates may be as described above.The alpha-olefin sulfonates of the surfactant composition of this first aspect may comprise at least 2 wt% of C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably at least 3 wt% or at least 4 wt%.

[0033] The alpha-olefin sulfonates may comprise up to 10 wt% of C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 9 wt%, up to 8 wt%, up to 7 wt% or up to 6 wt%.

[0034] The alpha-olefin sulfonates may comprise from 2 to 8 wt% of C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 3 to 7 wt%, from 4 to 6 wt% or from 4.5 to 5.5 wt%. The alpha-olefin sulfonates may comprise approximately 5 wt% of C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0035] The alpha-olefin sulfonates of the surfactant composition of this first aspect may comprise at least 50 wt% of C14 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably at least 55 wt% or at least 60 wt%.

[0036] The alpha-olefin sulfonates may comprise up to 75 wt% of C14 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 70 wt% or up to 68 wt%.

[0037] The alpha-olefin sulfonates may comprise from 50 to 75 wt% of C14 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 55 to 70 wt%, from 60 to 68 wt% or from 64 to 66 wt%. The alpha-olefin sulfonates may comprise approximately 65 wt% of C14 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0038] The alpha-olefin sulfonates of the surfactant composition of this first aspect may comprise at least 20 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably at least 25 wt% or at least 28 wt%.

[0039] The alpha-olefin sulfonates may comprise up to 40 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 35 wt% or up to 33 wt%.

[0040] The alpha-olefin sulfonates may comprise from 20 to 40 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 25 to 35 wt%, from 28 to 34 wt% or from 28 to 33 wt%. The alpha-olefin sulfonates may comprise approximately 30 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.Suitably, the alpha-olefin sulfonates comprise from 3 to 8 wt% of one or more C4-C12 alpha-olefin sulfonates, from 55 to 70 wt% of C14 alpha-olefin sulfonates and from 25 to 35 wt% of C16 alphaolefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0041] Suitably, the alpha-olefin sulfonates comprise from 4 to 6 wt% of one or more C4-C12 alpha-olefin sulfonates, from 60 to 68 wt% of C14 alpha-olefin sulfonates and from 28 to 34 wt% of C16 alphaolefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0042] Suitably, the alpha-olefin sulfonates comprise at least 85 wt% C4-C16 alpha-olefin sulfonates, suitably at least 90 wt%, at least 95 wt% or at least 99 wt% C4-C16 alpha-olefin sulfonates, based on the total weight of alpha-olefin sulfonates present in the surfactant composition.

[0043] In some embodiments, the alpha-olefin sulfonates consist essentially of C4-C16 alpha-olefin sulfonates, for example one or more C4, C6, C8, C10 or C12 alpha-olefin sulfonates, C14 alphaolefin sulfonates and C16 alpha-olefin sulfonates, suitably in the amounts discussed above.

[0044] In some embodiments, the alpha-olefin sulfonates consist essentially of one or more C4-C10 alphaolefin sulfonates, C14 alpha-olefin sulfonates and C16 alpha-olefin sulfonates.

[0045] In some embodiments, the alpha-olefin sulfonates consist essentially of one or more C6-C10 alphaolefin sulfonates, C14 alpha-olefin sulfonates and C16 alpha-olefin sulfonates.

[0046] In some embodiments, the alpha-olefin sulfonates consist essentially of one or more C8-C10 alphaolefin sulfonates, C14 alpha-olefin sulfonates and C16 alpha-olefin sulfonates.

[0047] Suitably, the alpha-olefin sulfonates comprise from 3 to 8 wt% of C12 alpha-olefin sulfonates, from 55 to 70 wt% of C14 alpha-olefin sulfonates and from 25 to 35 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. Suitably, the alpha-olefin sulfonates comprise from 4 to 6 wt% of C12 alpha-olefin sulfonates, from 60 to 68 wt% of C14 alpha-olefin sulfonates and from 28 to 34 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. Suitably, the alpha-olefin sulfonates comprise at least 85 wt% C12-C16 alpha-olefin sulfonates, suitably at least 90 wt%, at least 95 wt% or at least 99 wt% C12-C16 alpha-olefin sulfonates, based on the total weight of alpha-olefin sulfonates present in the surfactant composition.

[0048] In some embodiments, the alpha-olefin sulfonates consist essentially of C12-C16 alpha-olefin sulfonates, for example C12, C14 and C16 alpha-olefin sulfonates, suitably in the amounts discussed above.The alpha-olefin composition used to form the alpha-olefin sulfonates suitably comprises C4, C6, C8, C10, C12, C14 and / or C16 alpha-olefins in the amounts discussed above for the C4, C6, C8, C10, C12, C14 and / or C16 alpha-olefin sulfonates, based on the total weight of alpha-olefins present in the alpha-olefin composition.

[0049] The alpha-olefin composition used to form the alpha-olefin sulfonates suitably comprises C4, C6, C8, C10, C12, C14 and / or C16 alpha-olefins in the amounts discussed below, based on the total weight of alpha-olefins present in the alpha-olefin composition, which may provide the amounts of the C4, C6, C8, C10, C12, C14 and / or C16 alpha-olefin sulfonates discussed above.

[0050] The alpha-olefin composition may comprise at least 2 wt% of one or more C4-C12 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably at least 3 wt% or at least 4 wt%.

[0051] The alpha-olefin composition may comprise up to 10 wt% of one or more C4-C12 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably up to 9 wt%, up to 8 wt%, up to 7 wt% or up to 6 wt%.

[0052] The alpha-olefin composition may comprise from 3 to 8 wt% of one or more C4-C12 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably from 4 to 6 wt% or from 4.5 to 5.5 wt%. The alpha-olefin composition may comprise approximately 5 wt% of one or more C4-C12 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition.

[0053] The alpha-olefin composition used to form the alpha-olefin sulfonates suitably comprises C12, C14 and / or C16 alpha-olefins in the amounts discussed above for the C12, C14 and / or C16 alpha-olefin sulfonates, based on the total weight of alpha-olefins present in the alpha-olefin composition.

[0054] The alpha-olefin composition used to form the alpha-olefin sulfonates suitably comprises C12, C14 and / or C16 alpha-olefins in the amounts discussed below, based on the total weight of alpha-olefins present in the alpha-olefin composition, which may provide the amounts of the C12, C14 and / or C16 alpha-olefin sulfonates discussed above.

[0055] The alpha-olefin composition may comprise at least 2 wt% of C12 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably at least 3 wt% or at least 4 wt%.

[0056] The alpha-olefin composition may comprise up to 10 wt% of C12 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably up to 9 wt%, up to 8 wt%, up to 7 wt% or up to 6 wt%.The alpha-olefin composition may comprise from 3 to 8 wt% of C12 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably from 4 to 6 wt% or from 4.5 to 5.5 wt%. The alpha-olefin composition may comprise approximately 5 wt% of C12 alphaolefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition.

[0057] The alpha-olefin composition may comprise at least 50 wt% of C14 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably at least 55 wt% or at least 60 wt%.

[0058] The alpha-olefin composition may comprise up to 75 wt% of C14 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably up to 70 wt% or up to 65 wt%.

[0059] The alpha-olefin composition may comprise from 50 to 75 wt% of C14 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably from 50 to 70 wt%, from 55 to 70 wt%, from 55 to 65 wt% or from 60 to 65 wt%. The alpha-olefin composition may comprise approximately 62 wt% of C14 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition.

[0060] The alpha-olefin composition may comprise at least 20 wt% or at least 25 wt% of C16 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably at least 28 wt% or at least 30 wt%.

[0061] The alpha-olefin composition may comprise up to 70 wt% of C16 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably up to 60 wt%, up to 50 wt%, up to 40 wt%, suitably up to 38 wt% or up to 36 wt%.

[0062] The alpha-olefin composition may comprise from 20 to 70 wt% of C16 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition, suitably from 25 to 40 wt%, from 28 to 38 wt%, from 30 to 36 wt% or from 32 to 34 wt%. The alpha-olefin composition may comprise approximately 33 wt% of C16 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition.

[0063] Suitably the alpha-olefin composition used to form the alpha-olefin sulfonates suitably comprises 3 to 8 wt% of one or more C4-C12 alpha-olefins, from 55 to 65 wt% of C14 alpha-olefins and from 28 to 38 wt% of C16 alpha-olefins, based on the total weight of the alpha-olefins present in the alphaolefin composition.

[0064] Suitably the alpha-olefin composition used to form the alpha-olefin sulfonates suitably comprises 4 to 6 wt% of one or more C4-C12 alpha-olefins, from 60 to 65 wt% of C14 alpha-olefins and from 30to 36 wt% of C16 alpha-olefins, based on the total weight of the alpha-olefins present in the alphaolefin composition.

[0065] Suitably, the alpha-olefin composition used to form the alpha-olefin sulfonates comprise at least 85 wt% C4-C16 alpha-olefins, suitably at least 90 wt%, at least 95 wt% or at least 99 wt% C4-C16 alpha-olefins, based on the total weight of the alpha-olefins present in the mixture.

[0066] In some embodiments, the alpha-olefin composition consists essentially of C4-C16 alpha-olefins, for example one or more of C4, C6, C8, C10 or C12 alpha-olefins, C14 alpha-olefins and C16 alphaolefins, suitably in the amounts discussed above.

[0067] In some embodiments, the alpha-olefin composition consists essentially of one or more C4-C10 alpha-olefins, C14 alpha-olefin sulfonates and C16 alpha-olefins.

[0068] In some embodiments, the alpha-olefin composition consists essentially of one or more C6-C10 alpha-olefins, C14 alpha-olefins and C16 alpha-olefins.

[0069] In some embodiments, the alpha-olefin composition consists essentially of one or more C8-C10 alpha-olefins, C14 alpha-olefins and C16 alpha-olefins.

[0070] Suitably the alpha-olefin composition used to form the alpha-olefin sulfonates suitably comprises 3 to 8 wt% of C12 alpha-olefins, from 55 to 65 wt% of C14 alpha-olefins and from 28 to 38 wt% of C16 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition. Suitably the alpha-olefin composition used to form the alpha-olefin sulfonates suitably comprises 4 to 6 wt% of C12 alpha-olefins, from 60 to 65 wt% of C14 alpha-olefins and from 30 to 36 wt% of C16 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition. Suitably, the alpha-olefin composition used to form the alpha-olefin sulfonates comprise at least 85 wt% C12-C16 alpha-olefins, suitably at least 90 wt%, at least 95 wt% or at least 99 wt% C12-C16 alpha-olefins, based on the total weight of the alpha-olefins present in the mixture.

[0071] In some embodiments, the alpha-olefin composition consists essentially of C12-C16 alpha-olefins, for example C12, C14 and C16 alpha-olefins, suitably in the amounts discussed above.

[0072] In some embodiments, the alpha-olefin sulfonates comprise C18 alpha-olefin sulfonates.

[0073] In such embodiments, the alpha-olefin sulfonates suitably comprise one or more of C4, C6, C8, C10 orC12 alpha-olefin sulfonates, C16 alpha-olefin sulfonates and C18 alpha-olefin sulfonates. Suitably the alpha-olefin sulfonates are formed from an alpha-olefin composition comprising one or more of C4, C6, C8, C10 or C12 alpha-olefins, C16 alpha-olefins and C18 alpha-olefins, suitably in amounts corresponding to the amounts of the C4, C6, C8, C10, C12, C16 and C18 alpha-olefin sulfonatesdescribed herein. In such embodiments, the alpha-olefin sulfonates may comprise some C14 alphaolefin sulfonates.

[0074] In some embodiments, the alpha-olefin composition suitably comprises one or more of C4, C6, C8 or C10 alpha-olefins, C16 alpha-olefins and C18 alpha-olefins.

[0075] In such embodiments, the alpha-olefin sulfonates suitably comprise C12, C16 and C18 alpha-olefin sulfonates. Suitably the alpha-olefin sulfonates are formed from an alpha-olefin composition comprising C12, C16 and C18 alpha-olefins, suitably in amounts corresponding to the amounts of the C12, C16 and C18 alpha-olefin sulfonates described herein. In such embodiments, the alphaolefin sulfonates may comprise some C14 alpha-olefin sulfonates.

[0076] In such embodiments, the alpha-olefin sulfonates of the surfactant composition of this first aspect may comprise at least 15 wt% of C18 alpha-olefin sulfonates, based on the total weight of the alphaolefin sulfonates present in the surfactant composition, suitably at least 20 wt% or at least 30 wt%.

[0077] The alpha-olefin sulfonates may comprise up to 50 wt% of C18 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 45 wt% or up to 40 wt%.

[0078] The alpha-olefin sulfonates may comprise from 15 to 50 wt% of C18 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 15 to 40 wt%, from 30 to 50 wt% or from 30 to 45 wt%.

[0079] In such embodiments, the alpha-olefin sulfonates may comprise at least 25 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably at least 35 wt% or at least 45 wt%. The alpha-olefin sulfonates may comprise up to 80 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 75 wt%, up to 70 wt% or up to 65 wt%. The alpha-olefin sulfonates may comprise from 45 to 75 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 50 to 65 wt% or from 50 to 70 wt%.

[0080] In such embodiments, the alpha-olefin sulfonates may comprise from 3 to 8 wt% of one or more C4-C12 alpha-olefin sulfonates, from 50 to 65 wt% of C16 alpha-olefin sulfonates and from 30 to 45 wt% of C18 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0081] In such embodiments, the alpha-olefin sulfonates may consist essentially of one or more of C4, C6, C8, C10 or C12 alpha-olefin sulfonates, C16 alpha-olefin sulfonates and C18 alpha-olefin sulfonates, suitably in the amounts discussed above.In such embodiments, the alpha-olefin sulfonates may comprise from 3 to 8 wt% of C12 alpha-olefin sulfonates, from 50 to 65 wt% of C16 alpha-olefin sulfonates and from 30 to 50 wt% of C18 alphaolefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0082] In such embodiments, the alpha-olefin sulfonates may consist essentially of C12, C16 and C18 alpha-olefin sulfonates, suitably in the amounts discussed above.

[0083] In some embodiments wherein the alpha-olefin sulfonates comprise C18 alpha-olefin sulfonates, the alpha-olefin sulfonates may comprise C14 alpha-olefin sulfonates. Therefore the alpha-olefin sulfonates may comprise or consist essentially of one or more of C4, C6, C8, C10 or C12 alphaolefin sulfonates, C14 alpha-olefin sulfonates, C16 alpha-olefin sulfonates and C18 alpha-olefin sulfonates.

[0084] In some embodiments, the alpha-olefin sulfonates may comprise or consist essentially of one or more of C4, C6, C8 or C10 alpha-olefin sulfonates, C14 alpha-olefin sulfonates, C16 alpha-olefin sulfonates and C18 alpha-olefin sulfonates.

[0085] In some embodiments wherein the alpha-olefin sulfonates comprise C18 alpha-olefin sulfonates, the alpha-olefin sulfonates may comprise C14 alpha-olefin sulfonates. Therefore the alpha-olefin sulfonates may comprise or consist essentially of C12, C14, C16 and C18 alpha-olefin sulfonates.

[0086] In such embodiments, the alpha-olefin sulfonates may comprise at least 5 wt% of C14 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably at least 10 wt% or at least 15 wt%. The alpha-olefin sulfonates may comprise up to 35 wt% of C14 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 30 wt% or up to 25 wt%. The alpha-olefin sulfonates may comprise from 5 to 30 wt% of C14 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 10 to 25 wt%.

[0087] In such embodiments, the alpha-olefin sulfonates may comprise at least 15 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably at least 20 wt% or at least 25 wt%. The alpha-olefin sulfonates may comprise up to 60 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 55 wt% or up to 50 wt%. The alpha-olefin sulfonates may comprise from 20 to 55 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 25 to 50 wt%.

[0088] In such embodiments, the alpha-olefin sulfonates of the surfactant composition of this first aspect may comprise at least 10 wt% of C18 alpha-olefin sulfonates, based on the total weight of the alphaolefin sulfonates present in the surfactant composition, suitably at least 15 wt% or at least 20wt%.The alpha-olefin sulfonates may comprise up to 50 wt% of C18 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably up to 45 wt% or up to 40 wt%.The alpha-olefin sulfonates may comprise from 10 to 45 wt% of C18 alphaolefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition, suitably from 15 to 40 wt%.

[0089] In such embodiments, the alpha-olefin sulfonates may comprise from 3 to 8 wt% of one or more C4-C12 alpha-olefin sulfonates, from 10 to 25 wt% of C14 alpha-olefins, from 25 to 50 wt% of C16 alphaolefin sulfonates and from 15 to 40 wt% of C18 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0090] In such embodiments, the alpha-olefin sulfonates may consist essentially of one or more of C4, C6, C8, C10 orC12 alpha-olefin sulfonates, C14 alpha-olefin sulfonates, C16 alpha-olefin sulfonates and C18 alpha-olefin sulfonates, suitably in the amounts discussed above.

[0091] In such embodiments, the alpha-olefin sulfonates may consist essentially of one or more of C4, C6, C8 or C10 alpha-olefin sulfonates, C14 alpha-olefin sulfonates, C16 alpha-olefin sulfonates and C18 alpha-olefin sulfonates, suitably in the amounts discussed above.

[0092] In such embodiments, the alpha-olefin sulfonates may comprise from 3 to 8 wt% of C12 alpha-olefin sulfonates, from 10 to 25 wt% of C14 alpha-olefins, from 25 to 50 wt% of C16 alpha-olefin sulfonates and from 15 to 40 wt% of C18 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0093] In such embodiments, the alpha-olefin sulfonates may consist essentially of C12, C14, C16 and C18 alpha-olefin sulfonates, suitably in the amounts discussed above.

[0094] Suitably, the alpha-olefin sulfonates, and therefore the surfactant composition, comprise less than 5 wt% of C20 alpha-olefin sulfonates, suitably less than 2 wt% or less than 1 wt% C20 alpha-olefin sulfonates. Suitably the surfactant composition is substantially free of C20 alpha-olefin sulfonates.

[0095] The surfactant composition of this first aspect comprises 60-75 wt% of the alpha-olefin sulfonates as defined above, based on the total weight of the surfactant composition. Suitably the surfactant composition comprises from 62 to 73 wt% of said alpha-olefin sulfonates, based on the total weight of the surfactant composition, suitably 63 to 72 wt% of alpha-olefin sulfonates, suitably 64 to 70 wt% or 65 to 70 wt%. In some embodiments, the surfactant composition comprises from 65 to 75 wt% of said alpha-olefin sulfonates, based on the total weight of the surfactant composition.

[0096] Suitably, the surfactant composition comprises at least 85 wt% of linear alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. Suitably the surfactant composition comprises less than 15 wt% of branched alpha-olefin sulfonates andolefin sulfonates formed from internal olefins, combined, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0097] In the surfactant composition of this first aspect, the alpha-olefin sulfonates suitably provide at least 75 wt% of the total weight of all surfactants present in the surfactant composition, suitably at least 80 wt%, at least 85 wt%, at least 90 wt% or at least 95 wt%. Suitably the alpha-olefin sulfonates are substantially the only surfactant component(s) present in the surfactant composition.

[0098] Halide salt

[0099] The surfactant composition of this first aspect comprises a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion.

[0100] Suitably the surfactant composition comprises at least 0.5 wt% of the halide salt, suitably at least 1 wt%, based on the total weight of the surfactant composition.

[0101] Suitably the surfactant composition comprises up to 6 wt% of the halide salt, suitably up to 5 wt%, up to 4 wt% or up to 3 wt%, based on the total weight of the surfactant composition.

[0102] Suitably the surfactant composition comprises from 0.5 to 6 wt% of the halide salt, suitably from 0.5 to 5 wt%, from 1 to 5 wt%, from 1 to 4 wt% or from 1 to 3 wt%, based on the total weight of the surfactant composition.

[0103] The halide salt may be a salt of any suitable halide, for example a chloride, bromide or iodide salt. Suitably the halide salt is a chloride salt.

[0104] In some embodiments, the halide salt is a halide salt of an ammonium ion (i.e. NH4+) or a substituted ammonium ion. Suitable substituted ammonium ions may be selected from primary, secondary, tertiary or quaternary ammonium ions. Such substituted ammonium ions may comprise 1 to 4 C1-C10 optionally substituted hydrocarbyl groups, suitably 1 to 4 C1-C10 alkyl, aryl, alkaryl, or hydroxy alkyl groups. For example, a suitable substituted ammonium ion may be derived from an alkanolamine. Suitably, the substituted ammonium ion is a quaternary ammonium salt. Suitable substituted ammonium ions include tetramethyl ammonium and benzyltrimethyl ammonium ions. In such embodiments, the halide salt may be selected from tetramethyl ammonium chloride and benzyltrimethylammonium chloride. Suitably the halide salt is an ammonium salt, suitably ammonium chloride.

[0105] In some embodiments, the halide salt is a halide salt of an alkali metal or an alkaline earth metal. Suitably the halide salt is a halide salt of sodium, lithium, potassium, magnesium or calcium, suitably sodium. Suitably the halide salt is a chloride salt of sodium, lithium, potassium, magnesium or calcium.Suitably the halide salt is a halide salt of an alkali metal, suitably sodium, lithium or potassium. Suitably the halide salt is a chloride salt of sodium, lithium, potassium,

[0106] Preferably the halide salt is sodium chloride.

[0107] In some embodiments, the surfactant composition of this first aspect comprises from 0.5 to 6 wt% of sodium chloride, suitably from 0.5 to 5 wt%, from 1 to 5 wt%, from 1 to 4 wt% or from 1 to 3 wt% of sodium chloride, based on the total weight of the surfactant composition.

[0108] The inventors have found that the inclusion of sodium chloride in the surfactant composition in these amounts is particularly effective in providing a relatively high concentration of alpha-olefin sulfonates whilst maintaining a relatively low viscosity at an appropriate temperature to facilitate handling and processing, for example a temperature of at least 50°C or at least 55°C.

[0109] Water content

[0110] The surfactant composition of this first aspect suitably comprises water. The surfactant composition may be a solid at room temperature. The surfactant composition may be a solid at 20°C. For example, the surfactant composition may be a non-flowable paste at 20°C.

[0111] The surfactant composition may comprise at least 10 wt% water, at least 15 wt% or at least 20 wt% water, based on the total weight of the surfactant composition.

[0112] The surfactant composition may comprise up to 40 wt% water, up to 35 wt% or up to 30 wt% water, based on the total weight of the surfactant composition.

[0113] The surfactant composition may comprise from 10 to 40 wt% water, from 20 to 35 wt%, from 25 to 32 wt% or from 25 to 30 wt% water, based on the total weight of the surfactant composition.

[0114] The surfactant composition of this first aspect is suitably flowable at temperatures relevant to handling and processing the surfactant composition to form a consumer product. Suitably the surfactant composition is flowable at 60°C, suitably flowable at 55°C, suitably flowable at 50°C. The surfactant composition may be a flowable paste at said temperatures. Suitably the surfactant composition does not form a gel or a solid at said temperatures.

[0115] Suitably the surfactant composition has a shear viscosity at 55°C of less than 10,000 cP, suitably less than 8,000 cP, less than 6,000 cP, less than 5,500 cP or less than 5,000 cP. Suitably the surfactant composition has a shear viscosity at 55°C of from 3,000 cP to 8,000 cP, from 3,000 cP to 6,000 cP or from 3,000 cP to 5,000 cP. The shear viscosity of the surfactant composition is suitably measured by a Thermo-Haake Mars 40 rheometer (conditions: Cone C35 / 1 ° Ti L, Shear Rate = 8.51 s-1 , 55°C).The surfactant compositions of this first aspect suitably have a rate of dissolution in water which is comparable to known surfactant compositions, as determined by the method described herein in the Examples. Suitably the surfactant compositions have a dissolution time in water of less than 10 minutes in said test, i.e. dilution from 70 wt% active to a 10 wt% active solution in water at 60°C, suitably to produce a transparent solution.

[0116] Other components

[0117] The surfactant composition of this first aspect may comprise minor amounts of other components, in addition to the alpha-olefin sulfonates, the halide salt and water. However, such components are suitably only present in relatively small amounts, as discussed below.

[0118] Suitably the surfactant composition comprises less than 5 wt%, less than 3 wt%, less than 2 wt% or less than 1 wt% of inorganic sulfate salts, for example sodium sulfate. Sodium sulfate may be produced as a by-product of the sulfonation reaction which forms the alpha-olefin sulfonates from the alpha-olefin composition. Suitably the surfactant composition comprises less than said amounts of sodium sulfate. In some embodiments, the surfactant composition is substantially free of sodium sulfate.

[0119] Suitably the surfactant composition comprises less than 10 wt%, less than 7 wt%, less than 5 wt% or less than 3 wt% of organic solvents which are miscible with water. Such organic solvents suitably comprise at least one hydroxy group. Such organic solvents may be selected from monohydric alcohols, polyhydric alcohols and alkoxy alcohols, such as glycols. In some embodiments, the surfactant composition is substantially free of organic solvents.

[0120] Suitably the surfactant composition comprises less than 7 wt%, less 5 wt%, less than 3 wt% or less than 1 wt% of aromatic sulfonate salts. Such aromatic sulfonate salts include alkali metal, alkaline earth metal, ammonium and alkanolamine salts of aromatic sulfonates, for example cumene sulfonates, toluene sulfonates and xylene sulfonates. In some embodiments, the surfactant composition is substantially free of aromatic sulfonate salts.

[0121] Suitably the surfactant composition comprises less than 3 wt%, less than 2 wt% or less than 1 wt% of short chain fatty alcohol sulfates, paraffins, aromatic hydrocarbons, aliphatic hydrocarbons (including aliphatic polymers, for example polyethylene), polyethylene glycols, polypropylene glycols, polyoxyethylene alkyl ethers, polyoxypropylene alkyl ethers, alkylene oxides, polyvinyl alcohols and alcohol ethers. Suitably the surfactant composition comprises less than 1 wt% of polyethylene glycols, polypropylene glycols, polyoxyethylene alkyl ethers, polyoxypropylene alkyl ethers. Suitably the surfactant composition is substantially free of polyethylene glycols, polypropylene glycols, polyoxyethylene alkyl ethers, polyoxypropylene alkyl ethers.The components discussed above may be used to modify the viscosity and / or inhibit gel formation in surfactant compositions. The surfactant composition of the present invention can achieve the desired viscosity and prevent gel formation in a highly concentrated alpha-olefin sulfonates composition without the presence of such viscosity-modifying components, which may be preferable to exclude from surfactant compositions and the consumer products which are formed using said surfactant compositions.

[0122] The surfactant composition may comprise any one or more of citric acid, sodium citrate, sodium carbonate, sodium bicarbonate and alkaline metal hydroxides. The surfactant composition suitably comprises less than 2 wt%, suitably less than 1 wt% of said components, when present.

[0123] In some embodiments, the surfactant composition of this first aspect consists essentially of the alphaolefin sulfonates, the halide salt and water.

[0124] In some embodiments, the surfactant composition comprises:

[0125] a) from 65 to 75 wt% of the alpha-olefin sulfonates;

[0126] b) from 1 to 5 wt% NaCI; and

[0127] c) from 25 to 35 wt% water.

[0128] Suitably the surfactant composition consists essentially of these components in the stated amounts.

[0129] Suitably component a) comprises:

[0130] a1) from 2 to 10 wt% of one or more C4-C12 alpha-olefin sulfonates;

[0131] a2) from 50 to 70 wt% of C14 alpha-olefin sulfonates; and

[0132] a3) from 25 to 40 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alphaolefin sulfonates present in the surfactant composition.

[0133] Suitably component a) comprises:

[0134] a1) from 2 to 10 wt% of C12 alpha-olefin sulfonates;

[0135] a2) from 50 to 70 wt% of C14 alpha-olefin sulfonates; and

[0136] a3) from 25 to 40 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alphaolefin sulfonates present in the surfactant composition.

[0137] In some embodiments, component a) comprises:a1) from 2 to 10 wt% of one or more C4-C10 alpha-olefin sulfonates;

[0138] a2) from 50 to 70 wt% of C14 alpha-olefin sulfonates; and

[0139] a3) from 25 to 40 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alphaolefin sulfonates present in the surfactant composition.

[0140] Suitably component a) consists essentially of these components in the stated amounts.

[0141] In some preferred embodiments, the surfactant composition of this first aspect comprises:

[0142] a) from 65 to 70 wt% of the alpha-olefin sulfonates;

[0143] b) from 1 to 3 wt% NaCI; and

[0144] c) from 25 to 35 wt% water;

[0145] wherein component a) comprises:

[0146] a1) from 2 to 10 wt% of C12 alpha-olefin sulfonates;

[0147] a2) from 60 to 70 wt% of C14 alpha-olefin sulfonates; and

[0148] a3) from 25 to 35 wt% of C16 alpha-olefin sulfonates,

[0149] based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0150] According to a second aspect of the present invention, there is provided a surfactant composition comprising a) 60-75 wt% of alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion, wherein the alpha-olefin sulfonates are formed by the sulfonation of an alpha-olefin composition comprising from 2 to 10 wt% of one or more C4-C12 alpha-olefins, based on the total amount of alpha-olefins present in the alpha-olefin composition.

[0151] In some embodiments, the one or more C4-C12 alpha-olefin sulfonates are provided by one or more C4-C10 alpha-olefin sulfonates. Therefore the alpha-olefin sulfonates may comprise from 2 to 10 wt% of one or more C4-C10 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. The one or more C4-C10 alpha-olefin sulfonates may comprise one or more of C4, C6, C8 or C10 alpha-olefin sulfonates, suitably one or more of C6, C8 or C10 alpha-olefin sulfonates, suitably one or more of C8 or C10 alpha-olefin sulfonates.Suitably, the second aspect of the present invention provides a surfactant composition comprising a) 60-75 wt% of alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion, wherein the alpha-olefin sulfonates are formed by the sulfonation of an alpha-olefin composition comprising from 2 to 10 wt% of C12 alpha-olefin, based on the total amount of alpha-olefins present in the alpha-olefin composition.

[0152] The surfactant composition of this second aspect may have any of the suitable features and advantages described above in relation to the first aspect.

[0153] The alpha-olefin sulfonate, halide salt and alpha-olefin composition are suitably as described above in relation to the first aspect.

[0154] As described above, such alpha olefin sulfonates are typically a mixture comprising alkenyl sulfonates as the major component(s) and also comprising lesser amounts of hydroxyalkane sulfonate, alkenyl disulfonates and hydroxyalkane disulfonates.

[0155] The alpha-olefin sulfonates of the surfactant composition of this second aspect are suitably the reaction product of the sulfonation of the alpha-olefin composition. The sulfonation ofthe alpha-olefin composition is suitably followed by a neutralisation and hydrolysis step to form the alpha-olefin sulfonates. Suitably the alpha-olefin sulfonates are the direct product ofthe sulfonation ofthe alphaolefin composition and suitably the neutralisation step.

[0156] In some embodiments, the halide salt is present in a solution used in the neutralisation step and therefore the halide salt of the surfactant composition is provided by the solution used in the neutralisation step. Suitably the halide salt is present in the solution in an amount which provides the surfactant composition with the halide salt in the amounts described above in relation to the first aspect.

[0157] In such embodiments, the surfactant composition of this second aspect is suitably the direct product of the sulfonation and neutralisation of the alpha-olefin composition. Therefore this second aspect suitably provides a surfactant composition comprising a) 60-75 wt% of alpha-olefin sulfonates, and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion, wherein the surfactant composition is formed by:

[0158] A) sulfonation of an alpha-olefin composition comprising from 2 to 10 wt% of one or more C4-C12 alpha-olefins, based on the total amount of alpha-olefins present in the alpha-olefin composition;

[0159] B) neutralisation and hydrolysis of the product of step a) by addition of an aqueous solution comprising the halide salt.This second aspect preferably provides a surfactant composition comprising a) 60-75 wt% of alphaolefin sulfonates, and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion, wherein the surfactant composition is formed by:

[0160] A) sulfonation of an alpha-olefin composition comprising from 2 to 10 wt% of C12 alpha-olefin, based on the total amount of alpha-olefins present in the alpha-olefin composition;

[0161] B) neutralisation and hydrolysis of the product of step a) by addition of an aqueous solution comprising the halide salt.

[0162] In such embodiments, the surfactant composition having the advantageous properties discussed in relation to the first aspect may be provided directly and efficiently, without further steps of addition, solvent removal or purification.

[0163] The surfactant composition of this second aspect is suitably formed by a method according to the third aspect, as described below.

[0164] According to a third aspect of the present invention, there is provided a method of forming a surfactant composition comprising a) alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion, the method comprising the steps of:

[0165] 1) providing an alpha-olefin composition comprising from 2 to 10 wt% of one or more C4-C12 alpha-olefins, based on the total amount of alpha-olefins present in the alpha-olefin composition;

[0166] 2) treating the alpha-olefin composition with a sulfonating agent; and

[0167] 3) neutralising the product of step 2) with an aqueous alkaline solution;

[0168] wherein a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion is added to the surfactant composition, either in step 3) or following step 3).

[0169] In some embodiments, the one or more C4-C12 alpha-olefins are provided by one or more C4-C10 alpha-olefins. Therefore the alpha-olefins may comprise from 2 to 10 wt% of one or more C4-C10 alpha-olefins, based on the total weight of the alpha-olefins present in the alpha-olefin composition. The one or more C4-C10 alpha-olefins may comprise one or more of C4, C6, C8 or C10 alphaolefins, suitably one or more of C6, C8 or C10 alpha-olefins, suitably one or more of C8 or C10 alphaolefins.Suitably, the third aspect of the present invention provides a method of forming a surfactant composition comprising a) alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion, the method comprising the steps of:

[0170] 1) providing an alpha-olefin composition comprising from 2 to 10 wt% of C12 alpha-olefin, based on the total amount of alpha-olefins present in the alpha-olefin composition;

[0171] 2) treating the alpha-olefin composition with a sulfonating agent; and

[0172] 3) neutralising the product of step 2) with an aqueous alkaline solution;

[0173] wherein a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion is added to the surfactant composition, either in step 3) or following step 3).

[0174] Suitably the steps of the method of this third aspect are carried out in the order step 1) followed by step 2) followed by step 3).

[0175] The surfactant composition, alpha-olefin composition and halide salt of the method of this third aspect may have any of the suitable features and advantages described in relation to the first and second aspects.

[0176] The method of this third aspect suitably provides a surfactant composition according to the first and / or second aspects.

[0177] The alpha-olefin composition provided in step 1) suitably comprises one or more C4, C6, C8, C10 or C12 alpha-olefins, C14 alpha-olefins and C16 alpha-olefins in the amounts discussed above in relation to the first aspect. Suitably, the alpha-olefin composition comprises at least 85 wt% C4-C16 alpha-olefins, suitably at least 90 wt%, at least 95 wt% or at least 99 wt% C4-C16 alpha-olefins, based on the total weight of the alpha-olefins present in the mixture.

[0178] In some embodiments, the alpha-olefin composition consists essentially of C4-C16 alpha-olefins, for example one or more C4, C6, C8, C10 or C12 alpha-olefins, C14 alpha-olefins and C16 alpha-olefins, suitably in the amounts discussed above.

[0179] The alpha-olefin composition provided in step 1) suitably comprises C12, C14 and / or C16 alphaolefins in the amounts discussed above in relation to the first aspect. Suitably, the alpha-olefin composition comprises at least 85 wt% C12-C16 alpha-olefins, suitably at least 90 wt%, at least 95 wt% or at least 99 wt% C12-C16 alpha-olefins, based on the total weight of the alpha-olefins present in the mixture.

[0180] In some embodiments, the alpha-olefin composition consists essentially of C12-C16 alpha-olefins, for example C12, C14 and C16 alpha-olefins, suitably in the amounts discussed above.The alpha-olefin composition provided in step 1) may comprise C18 alpha-olefins, in addition to the C4, C6, C8, C10, C12, C14 and / or C16 alpha-olefins, in the amounts discussed above in relation to the first aspect. Suitably, the alpha-olefin composition comprises at least 85 wt% C4-C18 alphaolefins, suitably at least 90 wt%, at least 95 wt% or at least 99 wt% C4-C18 alpha-olefins, based on the total weight of the alpha-olefins present in the mixture.

[0181] In some embodiments, the alpha-olefin composition consists essentially of C4-C18 alpha-olefins, for example one or more C4, C6, C8, C10 or C12 alpha-olefins, C14 alpha-olefins, C16 alpha-olefins and C18 alpha-olefins or one or more C4, C6, C8, C10 or C12 alpha-olefins, C16 alpha-olefins and C18 alpha-olefins, suitably in the amounts discussed above and / or in amounts corresponding to the amounts of the one or more C4, C6, C8, C10 or C12 alpha-olefin sulfonates, C14 alpha-olefin sulfonates, C16 alpha-olefin sulfonates and C18 alpha-olefin sulfonates described in relation to the first aspect.

[0182] The alpha-olefin composition provided in step 1) may comprise C18 alpha-olefins, in addition to the C12, C14 and / or C16 alpha-olefins, in the amounts discussed above in relation to the first aspect. Suitably, the alpha-olefin composition comprises at least 85 wt% C12-C18 alpha-olefins, suitably at least 90 wt%, at least 95 wt% or at least 99 wt% C12-C18 alpha-olefins, based on the total weight of the alpha-olefins present in the mixture.

[0183] In some embodiments, the alpha-olefin composition consists essentially of C12-C18 alpha-olefins, for example C12, C14, C16 and C18 alpha-olefins or C12, C16 and C18 alpha-olefins, suitably in the amounts discussed above and / or in amounts corresponding to the amounts of the C12, C14, C16 and C18 alpha-olefin sulfonates described in relation to the first aspect.

[0184] Suitably the alpha-olefin composition provided in step 1) does not comprise any solvent.

[0185] Step 2) is suitably carried out using known sulfonation methods, suitably using SO3 as the sulfonating agent. Suitably an excess of sulfonating agent is used, compared to the amount of alpha-olefins present in the alpha-olefin composition. For example, step 2) may be carried out using from 1 to 1.5 equivalents of sulfonating agent, suitably from 1 to 1.25 or 1 to 1.10 equivalents of sulfonating agent, suitably SO3.

[0186] Step 2) is suitably carried out using a standard sulfonation method known in the art, for example using a mixture of 2-4% gaseous SO3 in dry air at a temperature in the range 35-60°C.

[0187] In step 3) the aqueous alkaline solution is provided in an amount and a pH / concentration sufficient to neutralise and hydrolyse the sulfonation product of step 2). Suitably the aqueous alkaline solution is an aqueous solution of a hydroxide salt, suitably NaOH. Step 3) may be carried out at an elevated temperature, for example of up to 140°C. Suitably a slight excess of alkaline solution remains in the surfactant composition after step 3).Suitably the aqueous alkaline solution provides sufficient water to provide the desired amount of water in the surfactant composition, as described in relation to the first aspect, and therefore provide the desired wt% the alpha-olefin sulfonates in the surfactant composition.

[0188] Suitably step 3) additionally involves adding the halide salt to the surfactant composition. The halide salt may be comprised in the aqueous alkaline solution and so be added in one feed with the aqueous alkaline solution. Alternatively, the halide salt may be added in a separate feed.

[0189] Suitably the aqueous alkaline solution comprises sufficient base to neutralise and hydrolyse the products of the sulfonation step 2), sufficient water to provide the desired amount of water in the surfactant composition and sufficient halide salt to provide the desired amount of the halide salt. Therefore the surfactant composition may be directly provided after step 3), without further additions or removals of alkaline species, halide salt and I or water.

[0190] In some embodiments, step 3) is not followed by any purification, dilution or concentration steps. Suitably the surfactant composition is provided directly after step 3).

[0191] In some embodiments, step 3) may be followed by a further addition of a halide salt, for example in an aqueous solution, in order to achieve a desired concentration of the surfactant composition. For example, step 3) may be followed by an addition of an aqueous NaCI solution, to obtain the final surfactant composition product.

[0192] Suitably the method provides a surfactant composition having 60-75 wt% of alpha-olefin sulfonates.

[0193] According to a fourth aspect of the present invention, there is provided a use of one or more C4-C12 alpha-olefin sulfonates to lower the viscosity of a surfactant composition comprising C14-C20 alphaolefin sulfonates, wherein the one or more C4-C12 alpha-olefin sulfonates are used in the surfactant composition in an amount of from 2 to 10 wt%, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0194] In some embodiments, the one or more C4-C12 alpha-olefin sulfonates are provided by one or more C4-C10 alpha-olefin sulfonates. Therefore the alpha-olefin sulfonates may comprise from 2 to 10 wt% of one or more C4-C10 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. The one or more C4-C10 alpha-olefin sulfonates may comprise one or more of C4, C6, C8 or C10 alpha-olefin sulfonates, suitably one or more of C6, C8 or C10 alpha-olefin sulfonates, suitably one or more of C8 or C10 alpha-olefin sulfonates.

[0195] Suitably, the fourth aspect of the present invention provides a use of C12 alpha-olefin sulfonates to lower the viscosity of a surfactant composition comprising C14-C20 alpha-olefin sulfonates, wherein the C12 alpha-olefin sulfonates are used in the surfactant composition in an amount of from 2 to 10 wt%, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.The alpha-olefin sulfonates and surfactant composition may have any of the suitable features and advantages described above in relation to the first and second aspects.

[0196] The use of this fourth aspect suitably lowers the viscosity of the surfactant composition compared to an otherwise identical surfactant composition which does not comprise the one or more C4-C12 alpha-olefin sulfonates.

[0197] The use of this fourth aspect suitably lowers the viscosity of the surfactant composition compared to an otherwise identical surfactant composition which does not comprise C12 alpha-olefin sulfonates.

[0198] Suitably the alpha-olefin sulfonates comprise C14 and C16 alpha-olefin sulfonates.

[0199] According to a fifth aspect of the present invention, there is provided a use of a halide salt of an alkali metal, an alkaline earth metal or an ammonium ion to lower the viscosity of a surfactant composition comprising C12, C14 and C16 alpha-olefin sulfonates.

[0200] The halide salt, alpha-olefin sulfonates and surfactant composition may have any of the suitable features and advantages described above in relation to the first and second aspects.

[0201] The use of this fifth aspect suitably lowers the viscosity of the surfactant composition compared to an otherwise identical surfactant composition which does not comprise the halide salt.

[0202] Suitably the halide salt is an alkali metal chloride, suitably NaCI.

[0203] According to a sixth aspect of the present invention, there is provided a use of a combination of one or more C4-C12 alpha-olefin sulfonates and a halide salt of an alkali metal, an alkaline earth metal or an ammonium ion to lower the viscosity of a surfactant composition comprising C14-C20 alphaolefin sulfonates.

[0204] In some embodiments, the one or more C4-C12 alpha-olefin sulfonates are provided by one or more C4-C10 alpha-olefin sulfonates. Therefore the alpha-olefin sulfonates may comprise from 2 to 10 wt% of one or more C4-C10 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition. The one or more C4-C10 alpha-olefin sulfonates may comprise one or more of C4, C6, C8 or C10 alpha-olefin sulfonates, suitably one or more of C6, C8 or C10 alpha-olefin sulfonates, suitably one or more of C8 or C10 alpha-olefin sulfonates.

[0205] Suitably, the sixth aspect of the present invention provides a use of a combination of C12 alphaolefin sulfonates and a halide salt of an alkali metal, an alkaline earth metal or an ammonium ion to lower the viscosity of a surfactant composition comprising C14-C20 alpha-olefin sulfonates.

[0206] The halide salt, alpha-olefin sulfonates and surfactant composition may have any of the suitable features and advantages described above in relation to the first and second aspects.The use of this sixth aspect suitably lowers the viscosity of the surfactant composition compared to an otherwise identical surfactant composition which does not comprise the one or more C4-C12 alpha-olefin sulfonates or said halide salt.

[0207] The use of this sixth aspect suitably lowers the viscosity of the surfactant composition compared to an otherwise identical surfactant composition which does not comprise the C12 alpha-olefin sulfonates or said halide salt.

[0208] Suitably the one or more C4-C12 alpha-olefin sulfonates are used in the surfactant composition in an amount of from 2 to 10 wt%, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0209] Suitably the C12 alpha-olefin sulfonates are used in the surfactant composition in an amount of from 2 to 10 wt%, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

[0210] Suitably the halide salt is an alkali metal chloride, suitably NaCI.

[0211] In the use of the fifth and sixth aspects, the halide salt is suitably used in the surfactant composition in an amount of from 1 to 5 wt%, based on the total weight of the surfactant composition.

[0212] In the use of the fourth, fifth and sixth aspects, the surfactant composition suitably comprises 60-75 wt% of the alpha-olefin sulfonates.

[0213] The inventors have surprisingly found that the inclusion of one or more C4-C12 alpha-olefin sulfonates, suitably C12 alpha-olefin sulfonates and / or the halide salt in a surfactant composition having a relatively high proportion of alpha-olefin sulfonates can lower the viscosity of the surfactant composition to the extent that processing and formulation is facilitated, as described above, which would otherwise be difficult or impossible due to the high viscosity of such surfactant compositions comprising high concentrations of alpha-olefin sulfonates.

[0214] The use of the fourth, fifth and sixth aspects suitably lowers the shear viscosity of the surfactant composition at 55°C, compared to an otherwise identical surfactant composition which does not comprise the one or more C4-C12 alpha-olefin sulfonates, suitably the C12 alpha-olefin sulfonates, or said halide salt. The shear viscosity of the surfactant is suitably measured as described above in relation to the first aspect. The shear viscosity at 55°C of the surfactant composition is suitably lowered to less than 10,000 cP, suitably less than 8,000 cP, less than 6,000 cP, less than 5,500 cP or less than 5,000 cP. Such shear viscosities at 55°C suitably facilitate handling of the surfactant composition and processing into consumer products.According to a seventh aspect of the present invention, there is provided a use of a surfactant composition according to the first or second aspects in a personal care product, a laundry product, a dishwashing product, a surface cleaning product, a toilet cleaning product, a firefighting product, an agrochemical composition, an oil field chemical product, a textile or leather processing composition, a construction composition or in an emulsion polymerisation process.

[0215] In embodiments wherein the use is in a personal care product, the personal care product may be selected from a liquid body wash, a bubble bath, a liquid hand wash, a hand sanitiser, a foaming hand wash, a liquid shampoo, an intimate wash, a bar soap, a syndet bar, a facial cleanser, a face wipe, a cleansing paste, a cleansing butter, a cleansing stick, a toothpaste, a mouthwash, pet shampoo, a pet wipe or a pet bar soap.

[0216] In embodiments wherein the use is in a laundry product, the laundry product may be selected from a laundry powder, a laundry additive composition, a laundry tablet, a laundry liquid, a laundry sheet, a laundry pod, a solid laundry detergent, a laundry bar or a laundry pre-spotter.

[0217] In embodiments wherein the use is in a dishwashing product, the dishwashing product may be selected from a manual dishwashing powder, a manual dishwashing liquid, a manual dishwashing mousse, a manual dishwashing bar, a manual dishwashing concentrate, a manual dishwashing paste, an automatic dishwashing powder, an automatic dishwashing liquid, an automatic dishwashing tablet, an automatic dishwashing rinse-aid liquid, an automatic dishwashing concentrate or an automatic dishwashing paste.

[0218] In embodiments wherein the use is in a surface cleaning product, the surface cleaning product may be selected from a surface cleaning liquid, a surface cleaning tablet, a surface cleaning powder, a surface cleaning sheet, a liquid floor cleaner, a floor cleaning sheet, a carpet cleaner, a glass cleaner, a vehicle shampoo or a vehicle windscreen cleaner.

[0219] In embodiments wherein the use is in a toilet cleaning product, the toilet cleaning product may be selected from a toilet bowl freshener, a solid toilet block, a liquid toilet block, a toilet bowl cleaner, an effervescent toilet cleaner or a toilet self-adhesive gel.

[0220] In embodiments wherein the use is in an oil field chemical product, the surfactant composition is suitably used to reduce the surface tension of drilling fluids and / or to stabilize drilling fluids and / or to improve drilling efficiency.

[0221] In embodiments wherein the use is in a textile or leather processing composition, the surfactant composition is suitably used as a wetting agent and / or to improve penetration of dyes / pigments into a textile or leather material.

[0222] In embodiments wherein the use is in a construction composition, the surfactant composition is suitably used as a density and / or foaming improver in concrete, cement or wallboard.In embodiments wherein the use is in an agrochemical composition, the surfactant composition is suitably used as an emulsifier, suitably for a pesticide.

[0223] According to an eighth aspect of the present invention, there is provided a product comprising the surfactant composition according to the first or second aspects, wherein the product is selected from a personal care product, a laundry product, a dishwashing product, a surface cleaning product, a toilet cleaning product, a firefighting product, an agrochemical composition, an oil field chemical product, a textile or leather processing composition, a construction composition or an emulsion polymerisation process additive.

[0224] The product of the eighth aspect may have any of the suitable features and advantages described in relation to the seventh aspect.

[0225] The product of the seventh or eighth aspects may be a solid product or a liquid product at room temperature (for example at 25°C). In some embodiments the product is in the form of a gel or paste at room temperature (for example at 25°C). Preferably the product is in the form of a paste, such as a flowable paste, at room temperature (for example at 25°C).

[0226] The use of the surfactant composition of the first or second aspects of the present invention in the products of the seventh or eighth aspects may advantageously provide products which are flowable, for example as flowable pastes (as defined herein), especially products which are flowable pastes at a temperature of 25°C. Products which are flowable may be easier to process and may be easier for the consumer to use. The use of the surfactant composition of the first or second aspects may allow such an advantageous, lower viscosity of the product to be obtained, compared to an otherwise identical product which does not comprise the one or more C4-C12 alpha-olefin sulfonates, suitably the C12 alpha-olefin sulfonates, or said halide salt. Such flowable compositions may be particularly advantageous when the product is a dishwasher product or a laundry product, as described further herein.

[0227] Suitably the product of this eighth aspect has a shear viscosity at 30°C of less than 10,000 cP, suitably less than 8,000 cP, less than 6,000 cP, less than 5,500 cP, less than 5,000 cP or less than 4,000 cP. Suitably the surfactant composition has a shear viscosity at 30°C of from 1 ,000 cP to 10,000 cP, from 1,000 cP to 6,000 cP or from 1 ,500 cP to 4,000 cP. The shear viscosity of the surfactant composition is suitably measured by a Thermo-Haake Mars 40 rheometer (conditions: Cone C35 / 1 ° Ti L, Shear Rate = 8.51 s-1 , 30°C).

[0228] The product of this eighth aspect suitably comprises at least 1 wt% of the of the surfactant composition according to the first or second aspects, suitably at least 5 wt%, based on the total weight of the productThe product of this eighth aspect suitably comprises upto 80 wt% of the of the surfactant composition according to the first or second aspects, suitably up to 70 wt%, based on the total weight of the product

[0229] The product may comprise from 1 to 80 wt% of the surfactant composition according to the first or second aspects, suitably from 5 to 70 wt%, based on the total weight of the product.

[0230] The product of the seventh or eighth aspects preferably comprises one or more further ingredients, in addition to the surfactant composition according to the first or second aspects.

[0231] The product may comprise one or more further surfactants, such as one or more amphoteric, anionic cationic and / or non-ionic surfactants (in addition to those defined in the surfactant composition according to the first or second aspects).

[0232] Suitable anionic surfactants for use herein include salts of: fatty acids; alkoxylated carboxylic acids; ester carboxylates; ethoxylated ester carboxylates; mono- or dialkyl sulfates; mono- or dialkyl ether sulfates; lauryl ether sulfates; alkyl sulfonates; alkyl aryl sulfonates; primary alkane disulfonates; alkene sulfonates; hydroxyalkane sulfonates; internal olefin sulfonates; alkyl ester sulfonates; isethionates, alkyl isethionates, acyl isethionates, acyl alkyl isethionates, alkyl glyceryl ether sulfonates; alkyl phosphates; sulfonates of alkylphenolpolyglycol ethers; alkyl sulfopolycarboxylic acid esters; alkyl sulfosuccinates; alkyl ether sulfosuccinates; taurates; acyl taurates, N-alkyl acyl taurates; products of condensation of fatty acids with oxy- and aminoalkanesulfonic acids; sulfated derivatives of fatty acids and polyglycols; alkyl and acyl sarcosinates; sulfoacetates; acyl lactylates; alkyl phosphates; alkyl phosphate esters; acyl lactylates; alkanolamides of sulfated fatty acids, lipoamino acids and acyl amino acids, for example acyl glycinates and acyl glutamates, acyl alaninates and acyl aspartates. Particularly exemplary salts, where applicable, are the sodium, potassium, ammonium, magnesium and triethanolamine salts.

[0233] Preferred anionic surfactants include one or more of alkyl or alkenyl sulfates, alkyl or alkenyl ether sulfates, alkyl benzene sulfonates, acyl taurates, acyl isethionates, N-alkyl acyl taurates, acyl alkyl isethionates, acyl amino acids and sulfosuccinates, especially acyl alkyl isethionates (such as sodium cocoyl methyl isethionate).

[0234] Suitable non-ionic surfactants include alcohol alkoxylates (such as alcohol ethoxylates, alcohol propoxylates, and ethylene oxide / propylene oxide cocomposition derived surfactants), aliphatic esters, aromatic esters, sugar esters (such as sorbitan esters), fatty acid alkoxylates (such as fatty acid ethoxylates and fatty acid propoxylates), or polyethylene glycol esters (including partial esters), glycerol esters (including glycerol partial esters and glycerol triesters), fatty alcohols (such as cetearyl alcohol, lauryl alcohol, stearyl alcohol, behenyl alcohol), and alkanolamides. Preferred non-ionic surfactants include alcohol ethoxylates, for example ethoxylated C9-11 alcohols (such as C9-11 Pareth-8).Suitable amphoteric surfactants include surfactants referred to as betaines, sultaines or zwitterionic surfactants or other amphoteric surfactants, for example those based on fatty nitrogen derivatives or amine oxides. By amphoteric surfactants, we mean to include any surfactants having the ability to exhibit both positive and negative sites. Suitable amphoteric surfactants include betaines (for example alkyl betaines or alkylamidopropyl betaines), amino oxides, alkylamidopropyl hydroxy sultaines, alkylamphoacetates, alkylamphodiacetates, alkylamphopropionates, alkylamphodipropionates, alkyliminodipropionates and alkyliminodiacetate.

[0235] Preferred acetate-based amphoteric surfactants for use herein include sodium lauroamphocaetate, sodium cocoamphoacetate and mixtures thereof.

[0236] Preferred betaine surfactants for use herein are amido betaines. Preferred amido betaines include lauryl amidopropyl betaine and cocoamidopropyl betaine (CAPB). Especially preferred compounds include cocoamidopropyl betaine.

[0237] Preferred amine oxide surfactants for use herein include lauramine oxide.

[0238] The product may comprise a chelating agent such as a chelating agent selected from MGDA, GLDA, IDS, EDTA, DTPA, DETPMP, HEIDA, EDDS, citric acid and salts and mixtures thereof, or a chelating agent selected from MGDA, GLDA, EDTA, EDDS, citric acid and salts and mixtures thereof.

[0239] The product may further comprise a filler. The filler suitably comprises a carbonate salt, a sulfate salt, a halide salt, a phosphate salt, a silicate, or a combination thereof. The filler may comprise an alkali metal or alkaline earth metal carbonate salt, an alkali metal or alkaline earth metal sulfate salt, an alkali metal or alkaline earth metal halide salt, an alkali metal or alkaline earth metal phosphate salt, or a combination thereof. Suitable fillers include sodium sulfate, sodium chloride, sodium carbonate, and sodium silicate. Suitable fillers may be anhydrous or hydrated. Preferably, the filler is anhydrous.

[0240] The present invention may provide products comprising in total greater than 40 wt%, preferably greater than 50 wt% active surfactants. Such “super-concentrated” products have reduced transport and packaging costs and can be packaged in environmentally friendly packaging and water soluble films.

[0241] In some embodiments, the product of the seventh and eighth aspects is a personal care product, such as a personal care product as defined above.

[0242] Personal care products typically comprise ingredients such as surfactants (including anionic, amphoteric, nonionic and cationic surfactants); conditioning agents (including quaternary ammonium compounds, cationic polymers, cationic conditioning polymers, silicones, synthetic or natural oils or resins etc), fatty alcohols, electrolytes or other rheology modifiers, opacifying / pearlising agents, scalp benefit agents, fragrances, dyes, UV filters, penetration enhancers (eg, propylene carbonate,benzyl alcohol etc), preservatives, antioxidants, emulsifiers, pH adjusting agents and buffers and styling polymers (eg, polyvinylpyrrolidone etc).

[0243] The personal care product may comprise one or more of the surfactants previously defined herein. The personal care product may also comprise a cationic surfactant, such as a cationic polymer. Suitable cationic polymers will be known to those skilled in the art and include multiple quaternary ammonium residues bonded to a polymeric backbone. Suitable cationic polymers include those known as polyquaterniums on the list of International Nomenclature for Cosmetic Ingredients (INCI list).

[0244] Preferred cationic polymers for use herein are polysaccharide compounds which have been functionalised with a cationic residue, such as quaternary ammonium group. Especially preferred cationic polymers are based on cellulose or guar gum. Compounds of this type will be known to the person skilled in the art.

[0245] Personal care products suitably comprise one or more ingredients selected from a sodium acyl isethionate (such as sodium lauroyl isethionate or sodium cocoyl isethionate), a sodium acyl alkyl isethionate (such as sodium lauroyl methyl isethionate or sodium cocoyl methyl isethionate), a sodium alkyl amphoacetate, disodium cocoamphodiacetate, an alkyl betaine, an alkamidopropyl betaine, an alkamidopropyl hydroxyl sultaine, an alkyl propionate, an alkyl sulfate, an alkyl ether sulfate, an alkyl sulfosuccinate, an alkyl ether sulfosuccinate, an acyl taurate (such as sodium lauroyl methyl taurate), an acyl glycinate, an acyl glutamate, an acyl sarcosinate, an alkyl polyglucoside, an acyl lactylate, a sodium acyl sulfoacetate, an aliphatic ester, an aromatic ester, a glycerol ester, an alcohol alkoxylate, a fatty acid alkoxylate, a biosurfactant (such as a sophorolipid), a fatty acid, or a mixture thereof.

[0246] In some embodiments the personal care product is a shampoo composition.

[0247] In such embodiments wherein the product is a personal care product, such as a shampoo composition, the product may comprise from 2 to 15 wt% of the surfactant composition according to the first or second aspects, suitably from 4 to 12 wt% of the surfactant composition, suitably from 6 to 10 wt% of the surfactant composition, based on the total weight of the product. Such products may be formulated with further components as described herein and as known in the art.

[0248] In some embodiments, the product of the seventh and eighth aspects is a laundry product, such as a laundry product as defined above.

[0249] Laundry products may comprise further additional components known to the person skilled in the art and including, for example, chelating agents, fillers, builders, bleaching agents, bleach activators, pigments, dispersants, polymeric dispersing agents, dyes, dye transfer inhibitors, fragrances, fragrance delivery systems, enzyme stabilizers, biocides, probiotics, preservatives, pH adjustingagents, phosphates, silicates, zeolites, peroxide based compounds (especially hydrogen peroxide, chlorine based bleaches), perborate compounds, percarbonate compounds, bleach activators and catalysts, cationic surfactants, redeposition additives, brighteners, sud suppressors, fabric softeners, anti-redeposition agents, wash performance boosting polymers, dissolution promoters and hydrotropes. As the skilled person would appreciate, the further additional components will be selected according to the particular form of the laundry detergent composition.

[0250] In such embodiments wherein the product is a laundry detergent composition, the product may comprise from 5 to 80 wt% of the surfactant composition according to the first or second aspects, suitably from 5 to 50 wt% or from 5 to 30 wt%, based on the total weight of the product. In some embodiments, the laundry detergent composition may comprise from 30 to 80 wt% of the surfactant composition according to the first or second aspects, suitably from 40 to 75 wt% of the surfactant composition, suitably from 50 to 70 wt% of the surfactant composition, based on the total weight of the product. Such products may be formulated with further components as described herein and as known in the art. In some embodiments, the product of the seventh and eighth aspects is a dishwashing product, such as a dishwashing product defined above.

[0251] Suitable additional components for inclusion in such dishwashing compositions will be known to the person skilled in the art. For example, the dishwashing product may comprise an amphoteric surfactant as described herein, for example sodium lauroamphoacetate, and / or a betaine surfactant such as cocamidopropyl betaine.

[0252] The dishwashing product may be an automatic dishwashing composition or a manual dishwashing detergent composition. Suitably the dishwashing product is in a flowable form, suitably in the form of a flowable paste.

[0253] In such embodiments wherein the product is a dishwashing product, the product may comprise from 20 to 65 wt% of the surfactant composition according to the first or second aspects, suitably from 30 to 55 wt% of the surfactant composition, suitably from 35 to 50 wt% or from 40 to 50 wt% of the surfactant composition, based on the total weight of the product. Such products may be formulated with further components as described herein and as known in the art.

[0254] Examples

[0255] Comparative examples 1-4 and Examples 5-7, as shown in Table 1, were prepared using the following procedures.

[0256] A C12-C16 alpha-olefin composition was prepared with the following distribution of alpha-olefin carbon chain lengths: C12 alpha-olefin = 5 wt%; C14 alpha-olefin = 62 wt%; C16 alpha-olefin = 33 wt%. This alpha-olefin composition was used to prepare Comparative Example 4 and Examples 5-7.A C14-C16 alpha-olefin composition was prepared with the following distribution of alpha-olefin carbon chain lengths: C14 alpha-olefin = 65 wt%; C16 alpha-olefin = 35 wt%. This alpha-olefin composition was used to prepare Comparative Examples 1-3.

[0257] The alpha-olefin compositions were sulfonated using a mixture of 2-4% gaseous SO3 in dry air at a temperature in the range 35-60°C. Sulfonation was followed by neutralisation and hydrolysis of the sulfonated reaction mixture using an aqueous solution of NaOH at a temperature of 120-140°C under a pressure between 4-6 barg. This provided a range of alpha-olefin sulfonates surfactant compositions comprising the varying amounts of halide salt shown in Table 1 (Comparative Examples 1-4 and Examples 5-7). Each of the Comparative Examples 1-4 and the Examples 5-7 were prepared at wt%s of active material in the range 66-70 wt%, which was achieved by varying the amount of water included in the composition, to provide samples having varying wt% active material for subsequent testing, for example 66 wt%, 68 wt% and 70 wt%. The examples comprising NaCI were formed by using an aqueous solution of NaOH and NaCI of the appropriate concentration in the neutralisation step. The surfactant compositions were obtained as solid compositions at room temperature, in the form of non-flowable pastes.

[0258] This procedure was varied to provide Comparative Examples 1-4 and Examples 5-7 with amounts of active material (AOS) of from 66 to 70 wt%, as shown in Table 1.

[0259] Table 1 - Composition of Examples

[0260]

[0261] AOS = alpha-olefin sulfonates.

[0262] The distribution of the different carbon chain lengths of alpha-olefin sulfonates in the example compositions were determined by HPLC using an HPLC Agilent 1200 Series equipped with UV detector, column: C18 (Thermo scientific ODS hypersil, 150x4.6 mm, Part size: 5 pm), using gradient analysis with eluents acetonitrile and 0.5% aq. sol. of NaCIO4, carried out at 30°C.Examples 4-7 were determined to comprise approximately: C12 alpha-olefin sulfonates = 5%; C14 alpha-olefin sulfonates = 65%; C16 alpha-olefin sulfonates = 30%, based on the total amount of AOS present.

[0263] The shear viscosity of Comparative Examples 1-4 and Examples 5-7 at varying wt% active material from 66 to 70 wt% were measured under the following conditions: Rheometer Thermo-Haake Mars 40 equipped with a Cone C35 / 1 ° Ti L, Shear Rate = 8.51 s-1 , 55°C. The results are shown in Table 2.Table 2 - shear viscosity measurements (cP) at varying wt% active material and varying halide salt content

[0264]

[0265] The results in Table 2 show that the inclusion of C12 alpha-olefin sulfonates and / or halide salt in the surfactant compositions of Examples 4-7 may lower the shear viscosity of said compositions at relatively high wt% of active material (66-70 wt%), compared to Comparative Examples 1 , 2, 3 and 4, which do not contain both the C12 alpha-olefin sulfonates and a halide salt. This lowering of the viscosity may provide a concentrated alpha-sulfonate surfactant composition with a viscosity which is suitable for processing, for example a shear viscosity of less than 8,000 cP at 55°C. In particular, the use of both the C12 alpha-olefin sulfonates and the halide salt in the surfactant composition may provide an especially beneficial viscosity of less than 4,000 cP at 55°C, suitably less than 3,500 cP, at 66-68 wt% active material, as demonstrated by the results with Examples 7.

[0266] Examples - Dissolution testing

[0267] The example surfactant compositions were tested to determine their dissolution rate compared to the commercially available surfactant compositions SLE1S (sodium laureth sulfate, 78% active) and SLE2S (sodium laureth-2 sulfate, 70% active) and Comparative Example 1 (at 70 wt% active material), which have dissolution rates suitable for formulation into consumer products. Examples 6 and 7 (at wt% active material indicated in Table 3) were diluted to 10 wt% solutions in water at 60°C with stirring at 250 rpm. The times for the surfactant compositions to dissolve into a homogeneous solution were measured. Table 3 shows the results of these dissolution experiments. The results show that the dissolution times for the Example surfactant compositions were not significantly different to the comparative surfactant compositions. Therefore the inclusion of the viscositymodifying C12 alpha-olefin sulfonates and the halide salt do not adversely affect this property of the surfactant composition.

[0268] Table 3 - Dissolution testing

[0269]

[0270] SLE1S - sodium laureth sulfate (C12-16 fatty alcohol 1 EO moles ethoxylate sodium sulphate ester) SLE2S - sodium laureth-2 sulfate (C12-16 fatty alcohol 2 EO moles ethoxylate sodium sulphate ester)

[0271] Examples - Laundry performance

[0272] A further Example surfactant composition, Example 8, was prepared as described above. Example 8 comprised 2.5 wt% NaCI and 66 wt% active AOS material (5wt% C12 AOS and 95 wt% C14-C16 AOS, based on total AOS present). The composition of Example 8 (66 wt% active material) had a shear viscosity of 3,300 cP at 55°C, measured according to the procedure described above for obtaining the results in Table 2.

[0273] Example 8:

[0274]

[0275] Example 8 was tested to determine whether the inclusion of the C12 alpha-olefin sulfonates and the halide salt viscosity-modifying additives affect the laundry performance of the compositions. The percentage soil removal of common stains on samples of different fabrics was measured by the Linitest procedure, as described below.

[0276] This Linitest procedure evaluates the ability of detergent formulations to remove applied soils from fabrics. Soiled fabric swatches are washed in a laboratory washer (Linitest, SDL Atlas) under specific conditions of temperature, detergent solution, washing time and water hardness. The Linitest machine rotates closed cannisters (8 x 500 mL) in a thermostatically controlled water bath at 40 ± 2 RPM.

[0277] The washing conditions for the washing tests were as follows:

[0278] AOS testing solution (ppm): 1000 (as Active)

[0279] Wash Time (min): 30

[0280] Temperature (°C): 25

[0281] Water Hardness (°f - French degrees): 30

[0282] For each run, four of the same type of swatches were placed in each closed cannister within the Linitest washer. The swatches were each 6 cm x 6 cm in size and simulate different types of fabricsand soil stains. The stain types and the different materials of the swatches are given in Table 4. The swatches are commercially available from CFT CenterforTest Materials (Vlaardingen, Netherlands). After the washing cycle, the washing liquors were emptied and the swatches rinsed under running cold tap water, then dried on a clothesline within a fume hood (in the dark and with the fume hood air flow switched on).

[0283] The effectiveness of the test detergent against a given type of swatch (e.g. specific fabric and stain type) was assessed by reflectometry. A Datacolor 400 high performance, reflectance only bench top spectrophotometer was used. The spectrophotometer had a D65 light source and a UV cut-off filter (400 nm). Reflectance measurements were taken by the spectrophotometer using the Y-value of the Y, x, y colour coordinates measurement (according to AISE protocol standard for laundry washing tests).

[0284] Measurements were taken of the soiled swatch before the wash and of the cleaned swatch after the wash. The measurements were taken with each swatch in a defined set of different positions and an average value used to generate the results. The results discussed herein were generated by averaging the measurements (before and after the wash) for the four swatches used in each test. The following formula was used to calculate detergency as the percentage change in reflectance, compared to the initial reflectance before the washing cycle.

[0285] Detergency = 100 x (R? - Ri)

[0286] Ri

[0287] where:

[0288] Ri = reflectance of soiled cloth before wash

[0289] R2 = reflectance of soiled cloth after wash

[0290] A positive value for the above detergency calculation means that the swatch material has become more reflective after washing. This signifies that the stain has been removed or partially removed from the swatch by the detergent composition during the test.

[0291] For comparison, the laundry performance of a sample of C12 alpha-olefin sulfonates (C12 AOS) was also tested, in addition to samples of Comparative Example 1 (C14-C16 AOS, no halide salt) and Comparative Example 4 (C12-C16 AOS, no halide salt). The results for detergency of the test compositions, as determined using the method described above, are shown in Table 4. The last column “total” shows the sum of the detergency result of each swatch type.Table 4 - Laundry performance test results

[0292]

[0293] These results show that the use of approximately 5 wt% C12 alpha-olefin sulfonates (based on the total weight of AOS present) in Example 8 did not significantly decrease laundry performance, whereas the use of C12 AOS alone did significantly decrease laundry performance, compared to a standard grade C14-C16 AOS surfactant composition (Comp. Ex. 1). The inclusion of the halide salt also does not adversely affect the laundry performance of the surfactant composition, as demonstrated by the comparison of Example 8 with Comparative Example 4 and Comparative Example 1.

[0294] This data demonstrates that the present invention can provide surfactant compositions comprising relatively high amounts of alpha-olefin sulfonate active material with sufficiently low viscosity at relevant temperatures to allow efficient handling and formulation into consumer products, by including C12 alpha olefin sulfonates and / or a halide salt in said compositions. Furthermore, the use of the C12 alpha olefin sulfonates, at the specific concentrations defined herein, and / or the use of the halide salts in said compositions does not adversely affect desired properties such as dissolution rate and detergency. The surfactant compositions of the present invention may therefore be used effectively in a wide range of consumer products, to replace ethoxylated surfactants and so enable consumer products such as personal care products to meet the regulatory limits to 1 ,4-dioxane content.

[0295] Formulation examples

[0296] Example 8 as described in the laundry performance example above (2.5 wt% NaCI and 66 wt% active C12-16 AOS material) was used to prepare the following formulations:Formulation Example 1: Super concentrated blend:

[0297] C9-11 pareth-8, lauramine oxide and citric acid were mixed and stirred at 60°C until homogeneous. The high active AOS from example 8 was combined and stirred until homogeneous, while keeping the temperature constant at 60°C. The mixture was left to cool down to room temperature and perfume was added. The product obtained was a flowable paste with a shear viscosity of 1800 cP at 25°C, and a pH of 7 at 25°C (when diluted into a 10% aqueous solution). Shear viscosity was measured using the Rheometer device and parameters described in the previous examples.

[0298] Table 5 shows the composition of the super concentrated blend based on amounts of the products added. The concentrated blend had a total active surfactant concentration of about 60 wt% based on the total weight of the composition.

[0299] Table 5 - composition of Formulation Example 1

[0300]

[0301] [1] C9-11 Pareth-8 is a C9-11 alcohol having a degree of ethoxylation of about 8, which was commercially provided as a 100 wt% active liquid.

[0302] [2] Lauramine oxide was commercially provided as a 30 wt% active aqueous composition.

[0303] Formulation Example 2: Dishwashing Detergent Paste

[0304] A flowable dishwashing detergent paste was obtained by mixing and stirring the components in Table 6 at room temperature until homogeneous. The sodium C12-16 olefin sulfonate from Example 8 was added in its flowable state by heating it previously to 55-60°C. The product obtained had a shear viscosity of 3000 cP at 30°C, and a pH of 7 at 25°C (when diluted into a 10% aqueous solution). Table 6 shows the composition of the dishwashing detergent paste based on amounts of the products added.Table 6 - composition of Formulation Example 2

[0305]

[0306] [3] Sodium Lauroamphoacetate was commercially provided as a 25 wt% active aqueous composition.

[0307] [4] Cocamidopropyl Betaine was commercially provided as a 34 wt% active aqueous composition.Formulation Example 3: Shampoo Composition

[0308] A pearlescent shampoo composition was prepared with the following ingredients:

[0309]

[0310] * The amount of Sodium C12-16 Olefin Sulfonate from Example 8 is based on the product added (the 66 wt% active C12-16 AOS material). This provides 5.37 wt% of active C12-16 AOS in the shampoo composition.This data demonstrates that the present invention can provide formulated products comprising the surfactant composition according to the first or second aspects compositions in the form of flowable pastes by incorporating the alpha-olefin sulfonates of the first aspect. Such products may be formulated to be suitable for a wide range of applications, such as personal care (shampooing) and dishwashing.

[0311] Although a few preferred embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention, as defined in the appended claims.

[0312] Throughout this specification, the term “comprising” or “comprises” means including the component(s) specified but not to the exclusion of the presence of other components. The term “consisting essentially of’ or “consists essentially of’ means including the components specified but excluding other components except for materials present as impurities, unavoidable materials present as a result of processes used to provide the components, and components added for a purpose other than achieving the technical effect of the invention. Typically, when referring to compositions, a composition consisting essentially of a set of components will comprise less than 5% by weight, typically less than 3% by weight, more typically less than 1 % by weight of non-specified components.

[0313] The term “consisting of’ or “consists of’ means including the components specified but excluding addition of other components.

[0314] Whenever appropriate, depending upon the context, the use of the term “comprises” or “comprising” may also be taken to encompass or include the meaning “consists essentially of’ or “consisting essentially of’, and may also be taken to include the meaning “consists of’ or “consisting of’.

[0315] The optional features set out herein may be used either individually or in combination with each other where appropriate and particularly in the combinations as set out in the accompanying claims. The optional features for each aspect or exemplary embodiment of the invention as set out herein are also to be read as applicable to any other aspect or exemplary embodiments of the invention, where appropriate. In other words, the skilled person reading this specification should consider the optional features for each exemplary embodiment of the invention as interchangeable and combinable between different exemplary embodiments.

[0316] Attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.All of the features disclosed in this specification (including any accompanying claims, and drawings), and / or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and / or steps are mutually exclusive.

[0317] Each feature disclosed in this specification (including any accompanying claims, and drawings) may be replaced by alternative features serving the same, equivalent or similar purpose, unless expressly stated otherwise. Thus, unless expressly stated otherwise, each feature disclosed is one example only of a generic series of equivalent or similar features.

[0318] The invention is not restricted to the details of the foregoing embodiment(s). The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Claims

Claims1. A surfactant composition comprising a) 60-75 wt% of alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion ora substituted ammonium ion; wherein the alpha-olefin sulfonates comprise from 2 to 10 wt% of one or more C4-C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

2. The surfactant composition according to claim 1 , wherein the alpha-olefin sulfonates comprise from 2 to 10 wt% of C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

3. The surfactant composition according to claim 1 , wherein the alpha-olefin sulfonates comprise from 2 to 10 wt% of one or more C4-C10 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

4. The surfactant composition according to claim 1 or claim 2, wherein the alpha-olefin sulfonates comprise C12, C14 and C16 alpha-olefin sulfonates.

5. The surfactant composition according to any preceding claim, wherein the alpha-olefin sulfonates comprise C18 alpha-olefin sulfonates.

6. The surfactant composition according to any of claims 1 , 2 or 4, wherein the alpha-olefin sulfonates consist essentially of C12-C16 alpha-olefin sulfonates.

7. The surfactant composition according to any preceding claim, comprising from 1 to 5 wt% of the halide salt.

8. The surfactant composition according to any preceding claim, wherein the halide salt is a halide salt of an alkali metal, preferably wherein the halide salt is NaCI.

9. The surfactant composition according to any preceding claim, wherein the alpha-olefin sulfonates comprise from 50 to 70 wt% of the C14 alpha-olefin sulfonates, based on the total amount of alphaolefin sulfonates present in the surfactant composition.

10. The surfactant composition according to any preceding claim, wherein the alpha-olefin sulfonates comprise from 20 to 70 wt% of the C16 alpha-olefin sulfonates, based on the total amount of alphaolefin sulfonates present in the surfactant composition.

11. The surfactant composition according to any preceding claim, comprising from 65 to 75 wt% of the alpha-olefin sulfonates.

12. The surfactant composition according to any preceding claim, comprising from 20 to 35 wt% water.

13. The surfactant composition according to any preceding claim, comprising at least 85 wt% of linear alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

14. The surfactant composition according to any preceding claim, comprising less than 2 wt% of inorganic sulfate salts.

15. The surfactant composition according to any preceding claim, comprising less than 5 wt% of organic solvents.16 The surfactant composition according to any preceding claim, comprising less than 5 wt% of aromatic sulfonate salts.

17. The surfactant composition according to any preceding claim, comprising less than 1 wt% of short chain fatty alcohol sulfates, paraffins, aromatic hydrocarbons, aliphatic hydrocarbons (including aliphatic polymers, for example polyethylene), polyethyleneglycol, polyoxypropylene glycols, alkylene oxides, polyvinyl alcohols and alcohol ethers.

18. The surfactant composition according to any preceding claim; consisting essentially of the alphaolefin sulfonates, the halide salt and water.

19. The surfactant composition according to any preceding claim, comprising:a) from 65 to 75 wt% of the alpha-olefin sulfonates;b) from 1 to 5 wt% NaCI; andc) from 25 to 35 wt% water.

20. The surfactant composition according to claim 19, wherein a) comprises:a1) from 2 to 10 wt% of C12 alpha-olefin sulfonates;a2) from 50 to 70 wt% of C14 alpha-olefin sulfonates; anda3) from 25 to 40 wt% of C16 alpha-olefin sulfonates, based on the total weight of the alphaolefin sulfonates present in the surfactant composition.

21. A surfactant composition comprising a) 60-75 wt% of an alpha-olefin sulfonates and b) a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion, wherein the alpha-olefin sulfonates are formed by the sulfonation of an alpha-olefin composition comprising from 2 to 10 wt% of one or more C4-C12 alpha-olefins, based on the total amount of alpha-olefins present in the alpha-olefin composition.

22. The surfactant composition according to claim 21, wherein the alpha-olefin sulfonates comprise from 2 to 10 wt% of C12 alpha-olefin sulfonates, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

23. The surfactant composition according to any preceding claim, wherein the composition has a shear viscosity at 55°C of less than 8,000 cP.

24. The surfactant composition according to any preceding claim, wherein the composition is a solid at20°C.

25. A method of forming a surfactant composition comprising alpha-olefin sulfonates and a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion ora substituted ammonium ion, the method comprising the steps of:1) providing an alpha-olefin composition comprising from 2 to 10 wt% of one or more C4-C12 alpha-olefins, based on the total amount of alpha-olefins present in the alpha-olefin composition;2) treating the alpha-olefin composition with a sulfonating agent; and3) neutralising the product of step 2) with an aqueous alkaline solution;wherein a halide salt of an alkali metal, an alkaline earth metal, an ammonium ion or a substituted ammonium ion is added to the surfactant composition, either in step 3) or following step 3).

26. The method according to claim 25, wherein the alpha-olefin composition comprises from 2 to 10 wt% of C12 alpha-olefin, based on the total amount of alpha-olefins present in the alpha-olefin composition27. The method according to claim 25 or 26, wherein the method provides a surfactant composition having 60-75 wt% of alpha-olefin sulfonates.

28. The method according to any of claims 25 to 27, wherein the method provides a surfactant composition according to any of claims 1 to 24.

29. Use of one or more C4-C12 alpha-olefin sulfonates to lower the viscosity of a surfactant composition comprising C14-C20 alpha-olefin sulfonates, wherein the one or more C4-C12 alphaolefin sulfonates are used in the surfactant composition in an amount of from 2 to 10 wt%, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

30. The use according to claim 29, wherein the one or more C4-C12 alpha-olefin sulfonates are C12 alpha-olefin sulfonates.

31. The use according to claim 29 or claim 30, wherein the C14-C20 alpha-olefin sulfonates comprise C14 and C16 alpha-olefin sulfonates.

32. Use of a halide salt of an alkali metal, an alkaline earth metal or an ammonium ion to lower the viscosity of a surfactant composition comprising C12, C14 and C16 alpha-olefin sulfonates.

33. Use of a combination of one or more C4-C12 alpha-olefin sulfonates and a halide salt of an alkali metal, an alkaline earth metal or an ammonium ion to lower the viscosity of a surfactant composition comprising C14-C20 alpha-olefin sulfonates.

34. The use according to claim 33, wherein the one or more C4-C12 alpha-olefin sulfonates are C12 alpha-olefin sulfonates.

35. The use according to claim 34, wherein the C12 alpha-olefin sulfonates are used in the surfactant composition in an amount of from 2 to 10 wt%, based on the total weight of the alpha-olefin sulfonates present in the surfactant composition.

36. The use according to any of claims 32 to 35, wherein the halide salt is used in the surfactant composition in an amount of from 1 to 5 wt%, based on the total weight of the surfactant composition.

37. The use according to any of claims 29 to 36, wherein the surfactant composition comprises 60-75 wt% of the alpha-olefin sulfonates.

38. The use according to any of claims 29 to 37, which lowers the shear viscosity of the surfactant composition at 55°C.

39. Use of a surfactant composition according to any of claims 1 to 24 in a personal care product, a laundry product, a dishwashing product, a surface cleaning product, a toilet cleaning product, a firefighting product, an agrochemical composition, an oil field chemical product, a textile or leather processing composition, a construction composition or in an emulsion polymerisation process.

40. The use according to claim 39 in a personal care product, wherein the personal care product is selected from a liquid body wash, a bubble bath, a liquid hand wash, a hand sanitiser, a foaminghand wash, a liquid shampoo, an intimate wash, a bar soap, a syndet bar, a facial cleanser, a face wipe, a cleansing paste, a cleansing butter, a cleansing stick, a toothpaste, a mouthwash, pet shampoo, a pet wipe or a pet bar soap.

41. The use according to claim 39 in a laundry product, wherein the laundry product is selected from a laundry powder, a laundry additive composition, a laundry tablet, a laundry liquid, a laundry sheet, a laundry pod, a solid laundry detergent, a laundry bar or a laundry pre-spotter.

42. The use according to claim 39 in a dishwashing product, wherein the dishwashing product is selected from a manual dishwashing powder, a manual dishwashing liquid, a manual dishwashing mousse, a manual dishwashing bar, an automatic dishwashing powder, an automatic dishwashing liquid, an automatic dishwashing tablet or an automatic dishwashing rinse-aid liquid.

43. The use according to claim 39 in a surface cleaning product, wherein the surface cleaning product is selected from a surface cleaning liquid, a surface cleaning tablet, a surface cleaning powder, a surface cleaning sheet, a liquid floor cleaner, a floor cleaning sheet, a carpet cleaner, a glass cleaner, a vehicle shampoo or a vehicle windscreen cleaner.

44. The use according to claim 39 in a toilet cleaning product, wherein the toilet cleaning product is selected from a toilet bowl freshener, a solid toilet block, a liquid toilet block, a toilet bowl cleaner, an effervescent toilet cleaner or a toilet self-adhesive gel.

45. The use according to claim 39 in an oil field chemical product, wherein the surfactant composition is used to reduce the surface tension of drilling fluids and / or to stabilize drilling fluids and / or to improve drilling efficiency.

46. The use according to claim 39 in a textile or leather processing composition, wherein the surfactant composition is used as a wetting agent and / or to improve penetration of dyes / pigments into a textile or leather material.

47. The use according to claim 39 in a construction composition, wherein the surfactant composition is used as a density and / or foaming improver in concrete, cement or wallboard.

48. The use according to claim 39 in an agrochemical composition, wherein the surfactant composition is used as an emulsifier, suitably for a pesticide.

49. A product comprising the surfactant composition according to any of claims 1 to 24, wherein the product is selected from a personal care product, a laundry product, a dishwashing product, a surface cleaning product, a toilet cleaning product, a firefighting product, an agrochemical composition, an oil field chemical product, a textile or leather processing composition, a construction composition or an emulsion polymerisation process additive.

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