Solid Alkyl Ether Sulfate Production via Zeolite Buffering
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Solution Overview
Problem
Current methods fail to produce solid alkyl ether sulfates with high active content above 50% due to heat sensitivity and decomposition at elevated temperatures, limiting their incorporation in compact laundry and dish washing detergents.
Innovation Solution
A process involving the combination of zeolites, carbonates, and a structurant, heated to 80-120°C, followed by cooling and coating, to produce free-flowing, high active alkyl ether sulfates with at least 50% active content, maintaining stability and flowability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If alkyl ether sulfates are processed at elevated temperatures to produce solid high active detergent, then productivity and manufacturing efficiency improve, but the surfactant decomposes significantly due to heat sensitivity
Solution Approach 1:
The patent introduces protective agents (sorbitol, glycerol, sugars) as intermediaries that mediate between the heat processing requirement and the heat-sensitive surfactant. These protective agents form a protective environment during drying that prevents decomposition while allowing elevated temperature processing to proceed
Solution Approach 2:
The patent changes the physical state parameters by using protective agents that modify the drying behavior of the system. The protective agents allow drying at elevated temperatures (above 80°C) by changing the thermal properties and decomposition kinetics of the surfactant system
2Quantity of substance
If high concentration of surfactant active material is incorporated to achieve high active detergent, then detergent effectiveness improves, but powder stickiness increases leading to poor flow properties
Solution Approach 1:
The patent uses protective agents (sorbitol, glycerol, sugars) as intermediaries that prevent direct interaction between high concentrations of surfactant molecules. These agents act as spacing molecules that maintain powder flowability even when surfactant active content exceeds 50%, preventing the stickiness that would normally occur at such high concentrations
Solution Approach 2:
The patent creates a composite powder system combining surfactant, protective agents, and optional inorganic fillers. This composite structure allows high surfactant content while maintaining desirable powder properties through the synergistic effects of the different components
3Volume of stationary object
If solid detergent granules with high bulk density are produced to reduce dosage volume, then compactness improves, but manufacturing complexity increases due to multiple processing steps
Solution Approach 1:
The patent merges the protective agent function with the binder function, and combines the drying and granulation steps into a more integrated process. The protective agents serve multiple functions including binding, flow modification, and heat protection, reducing the need for separate processing steps
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 enables the production of high active, free-flowing solid alkyl ether sulfates with reduced batch cycle time, improved stability, and enhanced flowability, suitable for use in laundry and dish washing detergents without significant degradation.
Implementation Method 1
Due to excellent detergent properties and high biodegradability, alkyl ether sulfates are the preferred and most widely used surfactant actives in compact laundry detergent compositions
Implementation Method 2
amorphous zeolite, carbonate and structurant are added thereto and the mixture is heated to a temperature of 80° C. to 120° C.
Implementation Method 3
the mixture is heated to a temperature of 80° C. to 120° C. It has surprisingly been found that the addition of amorphous zeolite and carbonate prevents the decomposition of the alkyl ether sulfates during the drying step
Implementation Method 4
the mixture is cooled to a temperature of 70° C. to obtain solid form of the mixture
Implementation Method 5
The solid form is then coated with a coating material
Data Source
AI summary
The present invention relates to free flowing, solid, high active alkyl ether sulfates and process for manufacturing such solid alkyl ether sulfates at processing temperature of 80° C. and above on an industrial scale. The solid alkyl ether sulfates have improved flow properties, improved appearance, and improved solubility.