Low Density Detergent Granule Formation via Gas Injection
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Solution Overview
Problem
Conventional detergent granule processes are inflexible and limited in producing low density granules, often resulting in undesirable physical characteristics such as high density, poor solubility, and caking, while also being resource-intensive and environmentally challenging due to the use of high levels of anionic surfactants and builders like phosphate and zeolites.
Innovation Solution
A process involving the use of a hydrotrope, water-soluble polymer, and sodium silicate with a specific SiO2:Na2O ratio, along with controlled crutcher mix moisture and gas injection, to form a slurry that is free of zeolite and phosphate builders, which is then processed to create a low density detergent granule with improved flowability and solubility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spray drying processes are used with high levels of anionic surfactants and builders, then proper slurry formation and granule structure are achieved, but the granule density becomes too high and solubility is reduced
Solution Approach 1:
The patent changes the chemical composition parameters by replacing traditional anionic surfactants and phosphate/zeolite builders with a hydrotrope-based system (sodium xylenesulfonate) combined with specific polymers and sodium silicate. This parameter change enables the formation of low density granules (300-600 g/L) while maintaining proper slurry formation and granule structure, directly resolving the contradiction between reliable granule formation and excessive density.
Solution Approach 2:
The patent employs a composite material system consisting of hydrotrope (sodium xylenesulfonate), water-soluble polymers (polyacrylate, polyethylene oxide), and sodium silicate with specific SiO2:Na2O ratios. This composite approach replaces conventional single-function additives and enables simultaneous achievement of low density, good flowability, and proper granule structure through synergistic interactions among the components.
2Reliability
If high levels of organic materials (surfactants, polymers) are used in spray dried granules, then proper slurry characteristics are achieved, but the amount and type of other additives is limited and formulation flexibility is reduced
Solution Approach 1:
The patent extracts and eliminates traditional anionic surfactants and phosphate/zeolite builders from the formulation, replacing them with a hydrotrope-based system. This removal of conventional components opens up formulation flexibility, allowing the incorporation of up to 3% nonionic surfactant and other additives without causing the sticky granule problems associated with high anionic surfactant levels.
Solution Approach 2:
The hydrotrope (sodium xylenesulfonate) acts as an intermediary substance that performs the functions traditionally carried out by anionic surfactants and builders. It enables proper slurry formation and granule structure while being compatible with a wider range of additives, thus maintaining formulation flexibility and adaptability.
3Reliability
If spray dried granules contain anionic surfactants and phosphate/zeolite builders, then strong binding ability to hard metal ions is achieved, but environmental limitations and cost constraints arise
Solution Approach 1:
The patent changes the water softening mechanism by replacing phosphate and zeolite builders with a hydrotrope-based system involving sodium xylenesulfonate and sodium silicate. This parameter change maintains the ability to bind hard metal ions while eliminating the environmental limitations associated with phosphate discharge and zeolite disposal, creating a more environmentally sustainable detergent formulation.
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 achieves low density detergent granules with enhanced physical properties, including high solubility, low cake strength, and high granule strength, while reducing capital equipment requirements and minimizing environmental impact.
Implementation Method 1
injecting a gas into the slurry at a pressure of from about 6,000 kPa to about 13,000 kPa and at a rate of from about 0.01% to about 0.25% to form a low density detergent granule
Implementation Method 2
providing from about 0.1% to about 6% of a hydrotrope, mixing the hydrotrope, crutcher mix moisture, polymer, silicate, and adjunct crutcher ingredients in a crutcher to form a slurry
Implementation Method 3
providing from about 0.2% to about 8% of a water-soluble polymer with a molecular weight of at least about 10,000 g/mol
Implementation Method 4
providing from about 2% to about 20% sodium silicate having a SiO2: Na2O ratio of at least about 2:1
Implementation Method 5
mixing the hydrotrope, crutcher mix moisture, polymer, silicate, and adjunct crutcher ingredients in a crutcher to form a slurry
Data Source
AI summary
A process for forming a low density detergent granule has the steps of providing from about 0.1% to about 6% of a hydrotrope, providing from about 22% to about 50% crutcher mix moisture, providing from about 0.2% to about 8% of a water-soluble polymer with a molecular weight of at least about 10,000 g/mol, providing from about 2% to about 20% sodium silicate having a SiO2:Na2O ratio of at least about 2:1, and the balance of adjunct crutcher ingredients, mixing the hydrotrope, crutcher mix moisture, polymer, silicate, and adjunct crutcher ingredients in a crutcher to form a slurry, injecting a gas into the slurry at a pressure of from about 6,000 kPa to about 13,000 kPa, and at a rate of from about 0.01% to about 0.25% and forming the slurry into a detergent granule. The slurry is substantially free of zeolite builder and phosphate builder and the crutcher temperature is maintained at from about 40° C. to about 95° C.