Detergent Granule Production via Double Salt Formation
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Solution Overview
Problem
Current detergent manufacturing processes face challenges in producing spray-dried detergent granules with anionic detergent content of 40 wt% or higher, leading to poor drying rates, energy inefficiency, and handling issues due to high viscosity and moisture content, which result in low bulk density and increased energy costs and safety risks.
Innovation Solution
A process involving the neutralization of an anionic surfactant precursor with a source of alkali, followed by the addition of Na2SO4 and Na2CO3 to form a slurry with a molar ratio of 1:0.9 to 1:1.3, incorporating a polycarboxylate polymer, and then spray-drying to produce granules with a high anionic surfactant content, forming the double salt Na2SO4·Na2CO3, which enhances specific surface area and flow properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the anionic detergent content is increased to 40 wt% or higher, then the washing effectiveness is improved, but the drying rate deteriorates and energy consumption increases
Solution Approach 1:
The patent changes the physical-chemical parameters of the slurry by controlling the water content to 20-40 wt% (optimizing moisture level) and adjusting the slurry temperature to 65-140°C before spray-drying. These parameter changes enable the formation of granules with 40-70 wt% anionic surfactant content while achieving acceptable drying rates and energy consumption levels.
2Quantity of substance
If the anionic detergent content is increased to 40 wt% or higher, then the washing effectiveness is improved, but the slurry viscosity increases causing handling and transportation problems
Solution Approach 1:
The patent maintains slurry temperature at 65-140°C to reduce viscosity and improve flowability. Additionally, the water content is carefully controlled at 20-40 wt%, and polycarboxylate polymers are added as viscosity modifiers to enable handling of high-concentration slurries with 40-70 wt% anionic surfactant content.
3Productivity
If high drying temperatures are used to remove excess water, then the drying rate is improved, but energy consumption increases and fire safety risks arise
Solution Approach 1:
The patent optimizes the slurry water content to 20-40 wt% before spray-drying, reducing the amount of water that needs to be evaporated. The spray-drying tower operates with inlet air temperature of 250-400°C and outlet air temperature of 80-120°C, achieving efficient drying while minimizing fire risks through proper temperature control and reduced moisture content.
4Ease of operation
If the bulk density is reduced to improve flow properties, then the handling is improved, but the packaging costs increase
Solution Approach 1:
The spray-drying process creates granules with a porous structure and bulk density of 426 g/l or less. This porous structure improves flow properties and handling characteristics while the granule morphology maintains reasonable packaging efficiency, balancing flow performance with packaging cost considerations.
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 process enables the production of detergent granules with greater than 50% anionic surfactant content, improving energy efficiency, reducing packaging costs, and achieving excellent flow properties and storage stability, while minimizing environmental impact.
Implementation Method 1
drying these in a counter-current spray-drying tower
Implementation Method 2
atomising slurry under high pressure to form droplets
Data Source
AI summary
There is provided a process for the production of a detergent granule comprising at least 40% by weight of an anionic surfactant and suitable for use as a granular detergent composition or a component thereof, which comprises the steps of (i) neutralising an anionic surfactant precursor with a source of alkali, (ii) adding Na2SO4 and Na2CO3 to form a slurry and (iii) spray-drying the obtained slurry to form a granule, whereby the molar ratio of Na2SO4 to Na2CO3 is in range of 1 : 0.9 to 1 : 1.3, and whereby the double salt Na2SO4.Na2CO3 is formed and whereby the slurry comprises a polycarboxylate polymer. There is also provided a spray-dried detergent carrier granule comprising at least 40% by weight of an anionic surfactant and suitable for use as a granular detergent composition or a component thereof, comprising (i) linear alkylbenzene sulphonate (LAS), soap and mixtures thereof, and (ii) the double salt Na2SO4.Na2CO3 obtainable by the process of the present invention. A third aspect is a detergent composition comprising such granules.