Alkyl Polyalkoxy Sulphate Salts Flowability
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Solution Overview
Problem
Concentrated alkyl ether sulphate compositions often form non-flowable and non-pumpable liquid crystalline structures at high surfactant concentrations, limiting their use in industrial applications, particularly in the oil and gas sector, where high emulsifying effects and low viscosity are required without the use of organic solvents or viscosity reducers.
Innovation Solution
Developing highly-concentrated alkyl polyalkoxy sulphate compositions with at least 75% by weight alkyl polyalkoxy sulphates, where 2/3 of alkoxy units are propoxy groups, and 1-25% by weight water, allowing for flowability at room temperature, easy solubility in water and oils, and a low pour point, achieved through specific sulphation and neutralization processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If alkyl ether sulphate compositions are concentrated to high surfactant concentrations (above 70% by weight), then the active content is improved, but the composition becomes non-flowable and non-pumpable due to liquid crystalline structure formation
Solution Approach 1:
The patent changes the chemical composition parameters by incorporating specific polyalkylene glycol ethers (with 2-20 oxyalkylene units) and using branched alkyl groups (C12-C20) to modify the molecular structure. This alters the liquid crystalline phase behavior, allowing the composition to remain flowable at concentrations of 70-95% active substance without forming solid-like structures.
Solution Approach 2:
The patent creates a composite surfactant system combining alkyl ether sulphates with specific polyalkylene glycol ethers and optional co-surfactants. This composite formulation synergistically prevents liquid crystalline phase separation while maintaining high active content, achieving both high concentration and flowability simultaneously.
2Ease of operation
If organic solvents or viscosity reducers are added to maintain flowability at high concentrations, then the ease of operation is improved, but the purity and environmental compatibility deteriorate due to solvent content
Solution Approach 1:
The patent extracts and eliminates the need for organic solvents and viscosity reducers by using specifically designed ethoxylated/propoxylated surfactant molecules. The molecular structure itself provides the necessary flow properties at high concentrations without requiring additional solvent components, achieving solvent-free formulations with 70-95% active content.
3Reliability
If conventional alkyl ether sulphates are used, then the emulsifying effect is adequate, but the viscosity becomes too high for industrial applications in the oil and gas sector
Solution Approach 1:
The patent modifies the molecular parameters by incorporating 2-20 oxyalkylene units (ethylene oxide and/or propylene oxide) into the surfactant structure. This increases the hydrophilic-lipophilic balance (HLB) and reduces intermolecular associations, thereby lowering viscosity while preserving emulsifying performance for industrial oil and gas applications.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting compositions are flowable, pumpable, and easily dilutable, with a pour point below -5°C, maintaining high active content and avoiding organic solvents, making them suitable for industrial applications such as tertiary oil recovery and metal working.
Implementation Method 1
Alkyl polyalkoxy sulphates... are used as surfactants or emulsifiers... Structurally they have a lipophilic alkyl group and a hydrophilic area composed of the polar ether groups and the chemically bonded sulphate anion. These physical properties make these compounds surfactants and allow them to emulsify fats and oils.
Implementation Method 2
The hydroxyether is then converted to an ester with sulphur trioxide which results in a sulphuric acid monoester or a sulphuric acid semiester. This acid is unstable and is converted into a salt with the use of alkali hydroxide or ammonia.
Implementation Method 3
Concentration ranges between approximately 30% by weight and below approximately 70% by weight active content (anionic active substance) result in non-flowable and non-pumpable compositions, as liquid crystalline structures in the form of hexagonal or cubic phases with a very high viscosity are formed.
Implementation Method 4
highly-concentrated compositions of salts of alkyl polyalkoxy sulphates, wherein in total at least 2/3 of all alkoxy units of the salts of alkyl polyalkoxy sulphates are proproxy units... The resulting compositions are flowable, pumpable, and easily dilutable, with a pour point below -5°C
Data Source
AI summary
The subject matter of the present invention relates to highly-concentrated compositions of salts of alkyl polyalkoxy sulphates, whereby in total at least 2/3 of all alkoxy unit of the alkyl polyalkoxy sulphates are propoxy units, a method of their production as well as their use in oil and gas field applications.