Spray-Drying Process Using Acid Surfactant Precursor
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Solution Overview
Problem
The spray-drying process in laundry detergent production is often the rate-determining step, leading to capacity constraints in existing facilities, necessitating additional equipment or complex formulations to increase capacity.
Innovation Solution
Introducing the acid precursor of anionic detersive surfactant to the alkaline slurry after mixing and carefully controlling moisture levels, allowing for increased spray-drying capacity without additional equipment or process aids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If additional spray-drying equipment is invested in to increase capacity, then productivity increases, but device complexity and investment cost increase
Solution Approach 1:
The patent changes the chemical form of the surfactant from its conventional salt form to its acid precursor form, and adjusts the moisture level parameter of the alkaline slurry to a specific range (10-20%). This allows the spray-drying process to handle higher concentrations of surfactant precursor without compromising powder quality, thereby increasing capacity without additional equipment
Solution Approach 2:
The patent performs a preliminary chemical transformation by converting the anionic detersive surfactant to its acid precursor form before the spray-drying step. This preliminary action enables the subsequent spray-drying process to operate at higher capacities because the acid precursor has different physical properties that are more suitable for high-rate spray-drying
2Productivity
If process aids are incorporated to increase capacity, then productivity increases, but formulation complexity increases
Solution Approach 1:
The patent extracts and removes the need for process aids by fundamentally changing the surfactant form to an acid precursor. This extraction of the problem (need for capacity enhancement) is solved by taking out the conventional surfactant salt form and replacing it with the acid precursor, which inherently enables higher spray-drying capacity without requiring additional process aids
Solution Approach 2:
By changing the surfactant to its acid precursor form and adjusting the moisture level parameter, the patent creates a formulation that naturally supports higher spray-drying rates. This parameter change eliminates the need for process aids that would otherwise be required to achieve similar capacity increases
3Productivity
If spray-drying rate is increased to meet demand, then productivity increases, but manufacturing precision deteriorates
Solution Approach 1:
The patent changes the chemical form of the surfactant to an acid precursor and optimizes the moisture level parameter to a specific range (10-20%). These parameter changes result in a slurry that maintains its physical and chemical properties even at higher spray-drying rates, ensuring that powder quality metrics such as flowability, dissolution, and surfactant content remain within specification
Solution Approach 2:
The preliminary conversion to acid precursor form prepares the surfactant in a state that is more tolerant of high spray-drying rates. This preliminary action ensures that even when spray-drying capacity is increased to meet growing demand, the resulting powder maintains the required manufacturing precision and quality standards
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
Significantly enhances the capacity of the spray-drying process, maintaining product quality and reducing formulation complexity, thereby optimizing production efficiency.
Implementation Method 1
contacting an acid anionic detersive surfactant precursor to the alkaline slurry after the mixer and before the spray pressure nozzle
Implementation Method 2
spray-drying the mixture to form a spray-dried powder
Data Source
AI summary
The present invention relates to a process for preparing a spray-dried powder comprising (i) anionic detersive surfactant; (ii) from 0 wt % to 10 wt % zeolite builder; (iii) from 0 wt % to 10 wt % phosphate builder; and (iv) optionally from 0 wt % to 15 wt % silicate salt; wherein the process comprises the steps of: (a) forming an alkaline slurry in a mixer, the slurry comprising: (v) from 0 wt % to 15 wt % anionic detersive surfactant; (vi) from 0 wt % to 35 wt % water; and (b) transferring the alkaline slurry from the mixer through at least one pump to a spray pressure nozzle; (c) contacting an acid anionic detersive surfactant precursor to the alkaline slurry after the mixer and before the spray pressure nozzle to form a mixture; (d) spraying the mixture through the spray pressure nozzle into a spray-drying tower; (e) spray-drying the mixture to form a spray-dried powder; and (f) optionally, contacting an alkalinity source with the alkaline slurry and/or the acid anionic detersive surfactant precursor, and/or the mixture.