DEFI and ATA Mixture Process via Segmented Reaction

Solution Overview

Problem

Existing methods for producing mixtures of directly esterified fatty acyl isethionate (DEFI) and alkyl taurate amides (ATA) in a single reactor result in low yields of ATA and browning of the product, requiring high temperatures that compromise DEFI yield and cause color issues in the final mixture.

Innovation Solution

A process where taurine is combined with fatty acid at low temperatures to produce ATA first, followed by adding alkali metal isethionate to produce DEFI, allowing for higher yields of ATA and avoiding browning by maintaining lower reaction temperatures, thereby achieving higher L values and more flexible production ratios.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If high temperatures are used to drive DEFI yield, then DEFI production increases, but ATA browning occurs and product quality deteriorates

Engineering Contradiction:

ImproveDEFI yieldVSAvoidATA browning

Core Design Contradiction:

ProductivityVSObject-affected harmful factors

Solution Approach 1:

The reaction process is divided into two distinct stages: first, ATA is formed by reacting taurine with fatty acid at lower temperature (150-180°C); second, DEFI is formed by reacting isethionate with remaining fatty acid at elevated temperature (180-200°C). This segmentation allows each component to be produced under optimal conditions, preventing ATA browning while maintaining DEFI yield.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

ATA is formed first in the reaction mixture before DEFI production begins. By preliminarily forming ATA at lower temperature, the system prepares the mixture for subsequent DEFI formation without exposing ATA to high temperatures that would cause browning. The preliminary ATA formation creates favorable conditions for the second stage reaction.

Inventive Principle:

Principle #10Preliminary action

2Object-affected harmful factors

If low temperatures are used to prevent ATA browning, then product quality improves, but DEFI yield is compromised

Engineering Contradiction:

ImproveATA browningVSAvoidDEFI yield

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

The reaction process is divided into two distinct stages: first, ATA is formed by reacting taurine with fatty acid at lower temperature (150-180°C); second, DEFI is formed by reacting isethionate with remaining fatty acid at elevated temperature (180-200°C). This segmentation allows each component to be produced under optimal conditions, preventing ATA browning while maintaining DEFI yield.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The reaction temperature parameter is changed between the two stages: lower temperature (150-180°C) is used for ATA formation, then elevated temperature (180-200°C) is applied for DEFI formation. This parameter change optimizes both product quality (preventing browning) and productivity (maintaining DEFI yield).

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If DEFI and ATA are produced simultaneously in a single reactor, then process efficiency increases, but yields are low and browning occurs

Engineering Contradiction:

Improvesingle reactor processVSAvoidATA yield

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The reaction process is divided into two distinct stages: first, ATA is formed by reacting taurine with fatty acid at lower temperature (150-180°C); second, DEFI is formed by reacting isethionate with remaining fatty acid at elevated temperature (180-200°C). This segmentation allows each component to be produced under optimal conditions, preventing ATA browning while maintaining DEFI yield.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

ATA is formed first in the reaction mixture before DEFI production begins. By preliminarily forming ATA at lower temperature, the system prepares the mixture for subsequent DEFI formation without exposing ATA to high temperatures that would cause browning. The preliminary ATA formation creates favorable conditions for the second stage reaction.

Inventive Principle:

Principle #10Preliminary action

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

This process achieves yields of 75% or greater for ATA and 45-85% for DEFI with minimal browning, as measured by L values of 80 or greater, providing greater flexibility in producing desired blends and maintaining product quality.

Implementation Method 1

Another commonly used anionic surfactant are alkyl taurate amides (e.g., N-methyl taurate). Alkyl taurate amides are also well known anionic surfactants which provide good foam.

Methodology Applied

Scientific EffectAmidation: Chemical Bonding

Implementation Method 2

The acyl isethionate surfactant is commonly produced by the direct esterification of a fatty acid (e.g., C10 to C16 fatty acid such as lauric acid) and isethionate (e.g., OHCH2 CH2SO3−Na+) in a process commonly known as the 'DEFI' process.

Methodology Applied

Scientific EffectDirect esterification: Chemical Bonding

Implementation Method 3

heating triple-pressed stearic acid, sodium methyl taurate solution, and boric acid to 200° C. while stirring with a subsurface nitrogen purge and distilling off water

Methodology Applied

Scientific EffectDistillation: Distillation

Data Source

PatentUS11780806B2DEFI and taurate amide mixtures and processes thereof

Publication Date: 2023.10.10 CONOPCO INC

AI summary

The invention comprises a process for preparing mixtures of DEFI and amide taurate (ATA) having excellent yields of ATA and substantial absence of browning of final ATA and DEFI mixtures. The process permits much greater flexibility in ratios of DEFI to ATA. The invention further relates to mixtures prepared by processes of the invention.