Spray-Dried Detergent Granules for Alkaline Stability

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Solution Overview

Problem

Existing methods for producing powders or granules containing copolymers for detergents fail to create stable forms under high alkaline conditions without malodour formation during storage, and soil release agents based on (meth)acrylic esters cannot be crystallized for conversion into granules or powders.

Innovation Solution

A process involving the mixing of copolymers and homo- or copolymers in the presence of water, followed by spray-drying or spray granulation using a gas with an inlet temperature of at least 125°C, to produce powders or granules with specific particle size distributions and moisture content, ensuring stability under high alkaline conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If soil release agents based on (meth)acrylic esters are used, then soil release performance is improved, but the agents cannot be crystallized for conversion into granules or powders

Engineering Contradiction:

Improvesoil release performanceVSAvoidconvertibility to granules or powders

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the chemical parameters of the soil release agent by using copolymers with specific monomer compositions (Formula I and Formula II monomers in defined ratios) that enable crystallization while maintaining soil release performance. This allows the material to be converted into granule or powder form suitable for detergent applications.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention creates a composite polymer structure by copolymerizing monomers according to Formula I and Formula II in specific molar ratios (30:70 to 70:30). This composite structure provides both the desired soil release properties and the ability to form stable granules or powders, resolving the contradiction between performance and manufacturability.

Inventive Principle:

Principle #40Composite materials

2Reliability

If copolymers are processed into powders or granules for powder detergents, then stability under high alkaline conditions is required, but malodour formation and evolvement occur during storage

Engineering Contradiction:

Improvestability under high alkaline conditionsVSAvoidmalodour formation

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent optimizes the chemical composition parameters by controlling the monomer ratios (Formula I: 30-70 mol%, Formula II: 30-70 mol%) and the degree of neutralization (20-80%). These parameter adjustments ensure the copolymer remains stable under high alkaline storage conditions without decomposing to form malodours, while maintaining effectiveness in powder detergent applications.

Inventive Principle:

Principle #35Parameter changes

3Loss of energy

If granules are produced with low residual water content, then shipping costs are reduced, but the production process requires high temperature spray-drying

Engineering Contradiction:

Improveshipping costsVSAvoidenergy for spray-drying

Core Design Contradiction:

Loss of energyVSUse of energy by stationary object

Solution Approach 1:

The patent optimizes the spray-drying process parameters, specifically setting the inlet gas temperature between 125-200°C and controlling the residence time (5-60 seconds). These parameter adjustments achieve low residual water content (1-15%) in the granules, reducing shipping weight and costs, while minimizing energy consumption through efficient heat transfer and optimized process conditions.

Inventive Principle:

Principle #35Parameter changes

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 results in powders or granules that are stable under high alkaline conditions with no malodour formation during storage, suitable for use in cleaning agents, and allows for efficient production with reduced residual water content, minimizing shipping costs.

Implementation Method 1

removing most of said water by spray-drying or spray granulation using a gas with an inlet temperature of at least 125°C

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentEP3628724B1Powder and granule, process for making such powder and granule, and use thereof

Publication Date: 2021.07.28 BASF SE

AI summary

The present invention is directed towards a process for making a powder or granule containing (A) at least one copolymer obtainable by polymerization of at least one monomer according to formula (I): in an amount of 1 to 70 mole%, wherein n is ≥ 3 and at least one monomer according to formula (II): in an amount of 30 to 99 mole%, (B) at least one homo- or copolymer of (meth)acrylic acid, partially or fully neutralized with alkali, said process comprising the steps of (a) mixing the at least one copolymer (A) and the at least one homo- or copolymer (B) in the presence of water, (b) removing most of said water by spray-drying or spray granulation using a gas with an inlet temperature of at least 125°C.