US3786003A - Liquid detergent compositions - Google Patents
Liquid detergent compositions Download PDFInfo
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- US3786003A US3786003A US00195850A US3786003DA US3786003A US 3786003 A US3786003 A US 3786003A US 00195850 A US00195850 A US 00195850A US 3786003D A US3786003D A US 3786003DA US 3786003 A US3786003 A US 3786003A
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- Prior art keywords
- alcohol
- sodium
- pourable
- water
- mixture
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- 239000000203 mixture Substances 0.000 title abstract description 67
- 239000007788 liquid Substances 0.000 title abstract description 23
- 239000003599 detergent Substances 0.000 title description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 abstract description 65
- GSPKZYJPUDYKPI-UHFFFAOYSA-N diethoxy sulfate Chemical compound CCOOS(=O)(=O)OOCC GSPKZYJPUDYKPI-UHFFFAOYSA-N 0.000 abstract description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 abstract description 26
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 abstract description 15
- 239000011734 sodium Substances 0.000 abstract description 14
- 229910052708 sodium Inorganic materials 0.000 abstract description 14
- XAEFZNCEHLXOMS-UHFFFAOYSA-M potassium benzoate Chemical compound [K+].[O-]C(=O)C1=CC=CC=C1 XAEFZNCEHLXOMS-UHFFFAOYSA-M 0.000 abstract description 9
- 239000007787 solid Substances 0.000 abstract description 8
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical class C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 description 14
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 14
- 150000001298 alcohols Chemical class 0.000 description 13
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 10
- 238000006243 chemical reaction Methods 0.000 description 10
- 229910052938 sodium sulfate Inorganic materials 0.000 description 10
- 235000011152 sodium sulphate Nutrition 0.000 description 10
- 229910052799 carbon Inorganic materials 0.000 description 9
- UZABCLFSICXBCM-UHFFFAOYSA-N ethoxy hydrogen sulfate Chemical compound CCOOS(O)(=O)=O UZABCLFSICXBCM-UHFFFAOYSA-N 0.000 description 9
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 8
- IOLCXVTUBQKXJR-UHFFFAOYSA-M potassium bromide Chemical compound [K+].[Br-] IOLCXVTUBQKXJR-UHFFFAOYSA-M 0.000 description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- 125000000217 alkyl group Chemical group 0.000 description 7
- -1 anionic alcohol ethoxysulfate compound Chemical class 0.000 description 7
- 238000000034 method Methods 0.000 description 7
- KWYUFKZDYYNOTN-UHFFFAOYSA-M Potassium hydroxide Chemical compound [OH-].[K+] KWYUFKZDYYNOTN-UHFFFAOYSA-M 0.000 description 6
- 238000007046 ethoxylation reaction Methods 0.000 description 6
- 159000000000 sodium salts Chemical class 0.000 description 6
- 125000004432 carbon atom Chemical group C* 0.000 description 5
- 150000003839 salts Chemical class 0.000 description 5
- 238000009472 formulation Methods 0.000 description 4
- 239000011780 sodium chloride Substances 0.000 description 4
- 230000019635 sulfation Effects 0.000 description 4
- 238000005670 sulfation reaction Methods 0.000 description 4
- AKEJUJNQAAGONA-UHFFFAOYSA-N sulfur trioxide Chemical compound O=S(=O)=O AKEJUJNQAAGONA-UHFFFAOYSA-N 0.000 description 4
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 3
- 239000004615 ingredient Substances 0.000 description 3
- 229910052700 potassium Inorganic materials 0.000 description 3
- 239000011591 potassium Substances 0.000 description 3
- WCUXLLCKKVVCTQ-UHFFFAOYSA-M Potassium chloride Chemical compound [Cl-].[K+] WCUXLLCKKVVCTQ-UHFFFAOYSA-M 0.000 description 2
- 125000003158 alcohol group Chemical group 0.000 description 2
- 229910052783 alkali metal Inorganic materials 0.000 description 2
- 150000008044 alkali metal hydroxides Chemical class 0.000 description 2
- 150000001340 alkali metals Chemical class 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 239000003153 chemical reaction reagent Substances 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000007423 decrease Effects 0.000 description 2
- 239000012153 distilled water Substances 0.000 description 2
- 231100001261 hazardous Toxicity 0.000 description 2
- 238000007037 hydroformylation reaction Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 235000019198 oils Nutrition 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000002002 slurry Substances 0.000 description 2
- JHJLBTNAGRQEKS-UHFFFAOYSA-M sodium bromide Chemical compound [Na+].[Br-] JHJLBTNAGRQEKS-UHFFFAOYSA-M 0.000 description 2
- RZVAJINKPMORJF-UHFFFAOYSA-N Acetaminophen Chemical compound CC(=O)NC1=CC=C(O)C=C1 RZVAJINKPMORJF-UHFFFAOYSA-N 0.000 description 1
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- CPELXLSAUQHCOX-UHFFFAOYSA-M Bromide Chemical compound [Br-] CPELXLSAUQHCOX-UHFFFAOYSA-M 0.000 description 1
- VEXZGXHMUGYJMC-UHFFFAOYSA-M Chloride anion Chemical compound [Cl-] VEXZGXHMUGYJMC-UHFFFAOYSA-M 0.000 description 1
- 240000007049 Juglans regia Species 0.000 description 1
- 235000009496 Juglans regia Nutrition 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 description 1
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical class OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 1
- 239000004480 active ingredient Substances 0.000 description 1
- 150000001299 aldehydes Chemical class 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- 125000000484 butyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 235000019864 coconut oil Nutrition 0.000 description 1
- 239000003240 coconut oil Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000002425 crystallisation Methods 0.000 description 1
- 230000008025 crystallization Effects 0.000 description 1
- 229910001873 dinitrogen Inorganic materials 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 125000001495 ethyl group Chemical group [H]C([H])([H])C([H])([H])* 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 239000003925 fat Substances 0.000 description 1
- 235000019197 fats Nutrition 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 239000011344 liquid material Substances 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 125000002496 methyl group Chemical group [H]C([H])([H])* 0.000 description 1
- 125000000740 n-pentyl group Chemical group [H]C([H])([H])C([H])([H])C([H])([H])C([H])([H])C([H])([H])* 0.000 description 1
- 230000003472 neutralizing effect Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000012071 phase Substances 0.000 description 1
- 159000000001 potassium salts Chemical class 0.000 description 1
- 150000003138 primary alcohols Chemical class 0.000 description 1
- 125000001436 propyl group Chemical group [H]C([*])([H])C([H])([H])C([H])([H])[H] 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 239000000344 soap Substances 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000001180 sulfating effect Effects 0.000 description 1
- 239000012808 vapor phase Substances 0.000 description 1
- 239000012855 volatile organic compound Substances 0.000 description 1
- 235000020234 walnut Nutrition 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D3/00—Other compounding ingredients of detergent compositions covered in group C11D1/00
- C11D3/02—Inorganic compounds ; Elemental compounds
- C11D3/04—Water-soluble compounds
- C11D3/046—Salts
-
- C—CHEMISTRY; METALLURGY
- C07—ORGANIC CHEMISTRY
- C07F—ACYCLIC, CARBOCYCLIC OR HETEROCYCLIC COMPOUNDS CONTAINING ELEMENTS OTHER THAN CARBON, HYDROGEN, HALOGEN, OXYGEN, NITROGEN, SULFUR, SELENIUM OR TELLURIUM
- C07F9/00—Compounds containing elements of Groups 5 or 15 of the Periodic Table
- C07F9/02—Phosphorus compounds
- C07F9/06—Phosphorus compounds without P—C bonds
- C07F9/08—Esters of oxyacids of phosphorus
- C07F9/09—Esters of phosphoric acids
- C07F9/117—Esters of phosphoric acids with cycloaliphatic alcohols
-
- C—CHEMISTRY; METALLURGY
- C11—ANIMAL OR VEGETABLE OILS, FATS, FATTY SUBSTANCES OR WAXES; FATTY ACIDS THEREFROM; DETERGENTS; CANDLES
- C11D—DETERGENT COMPOSITIONS; USE OF SINGLE SUBSTANCES AS DETERGENTS; SOAP OR SOAP-MAKING; RESIN SOAPS; RECOVERY OF GLYCEROL
- C11D1/00—Detergent compositions based essentially on surface-active compounds; Use of these compounds as a detergent
- C11D1/02—Anionic compounds
- C11D1/12—Sulfonic acids or sulfuric acid esters; Salts thereof
- C11D1/29—Sulfates of polyoxyalkylene ethers
Definitions
- the present invention is related to the preparation of detergent formulations wherein a detergent active ingredient is an anionic alcohol ethoxysulfate compound which is normally solid at substantially room temperature.
- a detergent active ingredient is an anionic alcohol ethoxysulfate compound which is normally solid at substantially room temperature.
- the physical state of the ingredients has an important bearing on the ease with which the formulation process may be carried out. Materials which are solid are more difficult to handle and more difficult to blend uniformly than are liquid materials.
- the alcohol ethoxysnlfates comprise sulfuric acid salts of a mixture of ethylene oxide derivatives of at least one alcohol of 11 to 15 carbon atoms wherein the average number of ethylene oxide units per molecule is from about 2 to about 5. More particularly, the alcohol ethoxysulfates are represented as a mixture of compounds of the average Formula I:
- the alcohol ethoxysulfates are deriv- 3,786,003 Patented Jan. 15, 1974 H (AB1)...
- n is a whole number from 3 to 12 inclusive selected so that the sum of m and n, i.e., the term (m;+n), is a whole number from 8 to 12 inclusive.
- the above Formula II provides for alcohols which are straight-chain or which have an alkyl branch which is methyl, ethyl, propyl, butyl or amyl, and in many instances at least a minor proportion of alcohol of each type is present. At least a substantial proportion of the alcohol of each carbon number within the 11 to 15 range is of the straight-chain structure, i.e., the compound of the above Formula H wherein m is 0, and in preferred modifications at least 70%, more preferably at least about 80% of the alcohols are straight-chain in structure. Of any alcohols that are branched, the predominant type is that having a beta-methyl branch and typically about 50% of the branched alcohols are beta-methyl alcohols with lesser amounts of the other branched-chain isomers.
- the straight-chain alcohols of Formula II are derived from fats, e.-g., coconut oils, or are synthetic. Synthetic straight-chain alcohols are produced, for example, by the oxidation of aluminum trialkyls and the hydrolysis of the resulting aluminum trialkoxides by an aqueous reagent, as disclosed in US. Pat. 3,391,175 of Davis.
- the alcohols of Formula II containing branching in the beta or 2-position, or the aldehydes corresponding thereto, are produced by the hydroformylation of straightchain olefins of 10 to 14 carbon atoms as described in, for example, US. Pats. 3,420,898 and 3,440,291.
- hydrofor-mylation processes both straight-chain and branched products are formed.
- the product mixtures within the desired range of proportions are useful as such or alternatively the individual components are separated by conventional procedures and recombined to provide a mixture of any desired proportion of alcohol types.
- the relative proportions of derivatives of alcohol of each carbon number are not critical.
- Preferred mixed compositions comprise no more than about by weight of derivatives of any one alcohol within the C to C range, more preferably, from about 10% to about 40% by weight on the same basis.
- the alcohol ethoxysulfates are produced in part by more or less conventional methods, i.e., the alcohols are reacted with 2 to 5, preferably 3, molar proportions of ethylene oxide and the resulting ethoxylate mixture is sulfated and neutralized.
- Suitable ethoxylation results are obtained by adding to the alcohol or mixture of alcohols to be ethoxylated a calculated amount, e.g., from about 0.1% by weight to about 0.6% by weight, preferably from about 0.1% to about 0.4%, based on total alcohol, of a strong base, typically an alkali metal hydroxide such as sodium hydroxide or potassium hydroxide, which serves as catalyst for the ethoxylation.
- a strong base typically an alkali metal hydroxide such as sodium hydroxide or potassium hydroxide, which serves as catalyst for the ethoxylation.
- the resulting mixture is dried, as by vapor phase removal of any water present, and an amount of ethylene oxide calculated to provide from about 2 to about moles of ethylene oxide per mole of alcohol is then introduced and the resulting mixture is allowed to react until the ethylene oxide is consumed, the course of the reaction being followed by the decrease in reaction pressure.
- the ethoxylation is conducted at an elevated tempera ture and pressure.
- Suitable reaction temperatures are from about 120 C. to about 220 C. with the range of from about 140 C. to about 160 C. being preferred.
- a suitable reaction pressure is achieved by introducing to the reaction vessel the required amount of ethylene oxide which has a high vapor pressure at the desired reaction temperature. The pressure serves as a measure of the degree of reaction and the reaction is considered to be substantially complete when the pressure no longer decreases with time.
- the ethoxylation procedure serves tointroduce a desired average number of ethylene oxide units per alcohol ethoxylate molecule.
- treatment of an alcohol mixture with 3 moles of ethylene oxide per mole of alcohol serves to effect the ethoxylation of each alcohol molecule with an average of 3 ethylene oxide moieties per mole alcohol moiety, although a substantial proportion of alcohol moieties will become combined with more than 3 ethylene oxide moieties and an approximately equal proportion will have become combined with less than 3.
- a typical ethoxylation product mixture there is also a minor proportion of unreacted alcohol.
- the alcohol ethoxysulfate component of the invention is sulfated with a suitable sulfating reagent such as sulfur trioxide, and the resulting sulfated product mixture is neutralized with an alkali metal solution, e.g., sodium or potassium hydroxide.
- a suitable sulfating reagent such as sulfur trioxide
- an alkali metal solution e.g., sodium or potassium hydroxide.
- the sodium or potassium salt Suitable sodium or potassium salts are NaCl, NaBr, KCl, KBr, Na SO K 80; and mixtures thereof.
- Preferred salts are sodium chloride and sodium sulfate.
- the pourable liquid compositions of the invention are prepared by mixing preselected amounts of alcohol ethoxysulfate, sodium or potassium salt and water to produce a composition having the following weight composition: about 38 to 42% alcohol ethoxysulfate, about 7 to preferably 8 to 9%, sodium or potassium salt and the balance water.
- the liquid pourable compositions are prepared by neutralizing the corresponding alcohol ethoxysulfuric acid with a solution containing preselected amounts of an alkali metal hydroxide (e.g., sodium hydroxide), as well as the sodium or potassium salt and water to produce a pourable liquid composition containing the amounts of alcohol ethoxysulfate, sodium or potassium salt and water defined above.
- an alkali metal hydroxide e.g., sodium hydroxide
- potassium or sodium salts having water of crystallizations e.g., 'Na SO -10H O, are suitably employed.
- a mixture of alcohol ethoxysulfuric acid was prepared by sulfation of a commercial alcohol ethoxylate mixture (marketed by the Shell Chemical Company as Neodol 25-3 Alcohol Ethoxylate)
- the alcohol ethoxysulfate mixture has an average of 3 ethylene oxide units per molecule and is derived from a mixture of C C C and C primary alcohols, in substantially equal proportions by weight, wherein approximately of the alcohol of each carbon number was straight-chain, approximately 10% of the alcohol of each carbon number was betamethyl branched and the remainder of the alcohol of each carbon number comprised alcohols of beta-ethyl, beta-propyl, beta-butyl or beta-amyl branching.
- the sulfation was conducted by treating the alcohol ethoxylate mixture in a continuous reactor (19 inches long) with a sulfur trioxide/ nitrogen gas mixture under the following conditions:
- EXAMPLE IV A 5.07 g. sample of a soft aqueous gel consisting of 78.9% w. of the sodium salt of the ethoxysulfuric acid prepared in Example I and 21.1% w. water was mixed by hand with 0.8 g. of sodium sulfate and 4.13 g. of distilled water. The ingredients were mixed in proportions calculated to produce a blend with the composition: 40% w. alcohol ethoxysulfate, 8% w. sodium sulfate and 52% w. water. By a similar procedure a variety of compositions were prepared. The weight concentration of alcohol ethoxysulfate and sodium sulfate and the physical state thereof at 80 F. are tabulated in Table I.
- Non-pourable stifi gel Barely pourable viscous liquid Pourable moderately viscous liquid Pourable moderately viscous liquid 12 Hazy, non-homogeneous two-phase viscous liquid 1 Pourable liquid.
- EXAMPLE V A 5.32 g. sample of a soft aqueous gel consisting of 78.9% w. of the sodium salt of the ethoxysulfuric acid prepared in Example I and 21.1% water was mixed with 0.8 g. sodium chloride and 3.88 g. of water. The resulting composition was a pourable, slightly hazy, moderately viscous liquid (80 F.) with the composition (calcu- TAB LE II Alcohol ethoxysulfate, percent w.
- the resulting pourable, clear moderately viscous liquid (at 80 F.) has a composition consisting of 40% w. alcohol ethoxysulfate, 8% w. sodium sulfate and 52% w. water.
- EXAMPLE VII A 2.58 g. sample of a soft aqueous gel, consisting of 77.5% of the sodium salt of the ethoxysulfuric acid prepared in Example I and 22.5% water, was mixed with 0.4 g. of potassium bromide and 2.02 g. distilled water. The resulting blend, consisting of 40% w. alcohol ethoxysulfate, 8% w. potassium bromide and 52% W. water, was a pourable, moderately viscous liquid (at 80 F.).
- a composition, pourable and liquid at a temperature of about 80 F. consisting essentially of (1) about 38 to 42% by weight, based on total composition, of a nonionic alcohol ethoxysulfate (2) about 7 to 10% by weight, based on total composition, of a salt selected from NaCl, KBr, Na SO or a mixture thereof and (3) the balance water, said alcohol ethoxysulfate being a solid at a temperature of about F.
- M is sodium or potassium
- X is a number from 2 to 5 representing an average of the ethylene oxide units per molecule
- R is alkyl of from 11 to 15 carbon atoms of the formula wherein m is a whole number from 0 to 5 inclusive and n is a whole number from 3 to 12 inclusive so that the sum of mi+n is a whole number from. 8 to 12 inclusive.
- composition of claim 1 wherein the salt is a sodium salt.
- composition of claim 4 wherein the percentage by Weight of salt is about 8 to 9% and the percentage by weight of alcohol ethoxysulfate is about 40%.
- composition of claim 5 wherein R is alkyl of from C12 to C15.
- composition of claim 2 wherein m is 0 in essentially of said alkyls, x is 3 and M is sodium.
- composition of claim 7 wherein the percentage by weight of salt is about 8 to 9% and the percentage of alcohol ethoxysulfate is about 40%.
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Abstract
POURABLE, LIQUID ALCOHOL ETHOXYSULFATE COMPOSITIONS ARE PREPARED FROM SOLID ALCOHOL ETHOXYSULFATES BY COMBINING WITH SELCTED AMOUNTS OF WATER AND A SODIUM OR POTASSIUM SALT.
Description
United States Patent O 3,786,003 LIQUID DETERGENT COMPOSITIONS Leon Hunter, Walnut Creek, Calif., assignor to Shell Oil Company, Houston, Tex. No Drawing. Filed Nov. 4, 1971, Ser. No. 195,850 Int. Cl. C11d N14 US. Cl. 252-551 8 Claims ABSTRACT OF THE DISCLOSURE Pourable, liquid alcohol ethoxysulfate compositions are prepared from solid alcohol ethoxysulfates by combining with selected amounts of water and a sodium or potassium salt.
BACKGROUND OF THE INVENTION The present invention is related to the preparation of detergent formulations wherein a detergent active ingredient is an anionic alcohol ethoxysulfate compound which is normally solid at substantially room temperature. In the preparation of detergent formulations, the physical state of the ingredients has an important bearing on the ease with which the formulation process may be carried out. Materials which are solid are more difficult to handle and more difficult to blend uniformly than are liquid materials.
It is known in the art that normally solid anionic alcohol ethoxy sulfates can be converted to pourable liquids by blending therewith selected amounts of aqueous ethanol solutions. However, the presence of ethanol precludes the use of such pourable liquid alcohol ethoxy sulfate formulations in the manufacture of dry particulate detergent compositions which are generally dried by spraying an aqueous slurry of the desired composition into a hot gas stream, heated at a temperature of 350- 750 F. The use of ethanol-containing aqueous slurry in such a spray drying operation would create potentially hazardous explosions.
The conversion of normally solid nonionic alcohol ethoxylates into pourable liquids without the use of potentially hazardous volatile organic compounds is disclosed in US. Pat. 3,419,500 of Rytter et al.
SUMMARY OF THE INVENTION It has now been found that certain normally solid anionic alcohol ethoxysulfates can be blended with preselected amounts of water and a sodium or potassium salt selected from chloride, bromide, sulfate or mixture thereof to produce a composition which is pourable and liquid at 80 F. and contains about 38 to 42% by weight of the alcohol ethoxysulfate, about 7 to by weight, preferably 8 to 9% by weight, of the sodium or potassium salt and the balance water.
DESCRIPTION OF PREFERRED EMBODIMENTS The alcohol ethoxysnlfates.The alcohol ethoxysulfate components of the invention comprise sulfuric acid salts of a mixture of ethylene oxide derivatives of at least one alcohol of 11 to 15 carbon atoms wherein the average number of ethylene oxide units per molecule is from about 2 to about 5. More particularly, the alcohol ethoxysulfates are represented as a mixture of compounds of the average Formula I:
RO{-C H O) SO M (I) wherein R is primary alkyl of from 11 to 15 carbon atoms, M is an alkali metal, preferably sodium or potassium, x is a number from about 2 to about 5 representing an average of the ethylene oxide units per alcohol ethoxysulfate molecule.
Broadly speaking, the alcohol ethoxysulfates are deriv- 3,786,003 Patented Jan. 15, 1974 H (AB1)...
3 A (II) where m is a whole number from 0 to 5 inclusive and n is a whole number from 3 to 12 inclusive selected so that the sum of m and n, i.e., the term (m;+n), is a whole number from 8 to 12 inclusive.
The above Formula II provides for alcohols which are straight-chain or which have an alkyl branch which is methyl, ethyl, propyl, butyl or amyl, and in many instances at least a minor proportion of alcohol of each type is present. At least a substantial proportion of the alcohol of each carbon number within the 11 to 15 range is of the straight-chain structure, i.e., the compound of the above Formula H wherein m is 0, and in preferred modifications at least 70%, more preferably at least about 80% of the alcohols are straight-chain in structure. Of any alcohols that are branched, the predominant type is that having a beta-methyl branch and typically about 50% of the branched alcohols are beta-methyl alcohols with lesser amounts of the other branched-chain isomers.
The straight-chain alcohols of Formula II (where m is 0) are derived from fats, e.-g., coconut oils, or are synthetic. Synthetic straight-chain alcohols are produced, for example, by the oxidation of aluminum trialkyls and the hydrolysis of the resulting aluminum trialkoxides by an aqueous reagent, as disclosed in US. Pat. 3,391,175 of Davis.
The alcohols of Formula II containing branching in the beta or 2-position, or the aldehydes corresponding thereto, are produced by the hydroformylation of straightchain olefins of 10 to 14 carbon atoms as described in, for example, US. Pats. 3,420,898 and 3,440,291. In the hydrofor-mylation processes, both straight-chain and branched products are formed. The product mixtures within the desired range of proportions are useful as such or alternatively the individual components are separated by conventional procedures and recombined to provide a mixture of any desired proportion of alcohol types.
In terms of the above Formulas I and II, the preferred derivatives are represented by the Formula III:
wherein m, n, M and x have the previously stated significance. It should be appreciated that there will be present ethoxysulfate derivatives of at least one alcohol of a carbon number of 11, 12, 13, 14 or 15, that is, ethoxysulfate derivatives of one or more C to C alcohols. In the case of mixtures of derivatives of alcohols of differing carbon number, the relative proportions of derivatives of alcohol of each carbon number are not critical. Preferred mixed compositions comprise no more than about by weight of derivatives of any one alcohol within the C to C range, more preferably, from about 10% to about 40% by weight on the same basis.
The alcohol ethoxysulfates are produced in part by more or less conventional methods, i.e., the alcohols are reacted with 2 to 5, preferably 3, molar proportions of ethylene oxide and the resulting ethoxylate mixture is sulfated and neutralized.
Suitable ethoxylation results are obtained by adding to the alcohol or mixture of alcohols to be ethoxylated a calculated amount, e.g., from about 0.1% by weight to about 0.6% by weight, preferably from about 0.1% to about 0.4%, based on total alcohol, of a strong base, typically an alkali metal hydroxide such as sodium hydroxide or potassium hydroxide, which serves as catalyst for the ethoxylation. The resulting mixture is dried, as by vapor phase removal of any water present, and an amount of ethylene oxide calculated to provide from about 2 to about moles of ethylene oxide per mole of alcohol is then introduced and the resulting mixture is allowed to react until the ethylene oxide is consumed, the course of the reaction being followed by the decrease in reaction pressure.
The ethoxylation is conducted at an elevated tempera ture and pressure. Suitable reaction temperatures are from about 120 C. to about 220 C. with the range of from about 140 C. to about 160 C. being preferred. A suitable reaction pressure is achieved by introducing to the reaction vessel the required amount of ethylene oxide which has a high vapor pressure at the desired reaction temperature. The pressure serves as a measure of the degree of reaction and the reaction is considered to be substantially complete when the pressure no longer decreases with time.
It should be understood that the ethoxylation procedure serves tointroduce a desired average number of ethylene oxide units per alcohol ethoxylate molecule. For example, treatment of an alcohol mixture with 3 moles of ethylene oxide per mole of alcohol serves to effect the ethoxylation of each alcohol molecule with an average of 3 ethylene oxide moieties per mole alcohol moiety, although a substantial proportion of alcohol moieties will become combined with more than 3 ethylene oxide moieties and an approximately equal proportion will have become combined with less than 3. In a typical ethoxylation product mixture, there is also a minor proportion of unreacted alcohol.
To prepare the alcohol ethoxysulfate component of the invention, the alcohol ethoxylate products are sulfated with a suitable sulfating reagent such as sulfur trioxide, and the resulting sulfated product mixture is neutralized with an alkali metal solution, e.g., sodium or potassium hydroxide. Suitable sulfation procedures are disclosed in U.S. Pats. 3,259,645 and 3,350,428.
The sodium or potassium salt.Suitable sodium or potassium salts are NaCl, NaBr, KCl, KBr, Na SO K 80; and mixtures thereof. Preferred salts are sodium chloride and sodium sulfate.
The pourable liquid compositions of the invention are prepared by mixing preselected amounts of alcohol ethoxysulfate, sodium or potassium salt and water to produce a composition having the following weight composition: about 38 to 42% alcohol ethoxysulfate, about 7 to preferably 8 to 9%, sodium or potassium salt and the balance water.
In a preferred modification, the liquid pourable compositions are prepared by neutralizing the corresponding alcohol ethoxysulfuric acid with a solution containing preselected amounts of an alkali metal hydroxide (e.g., sodium hydroxide), as well as the sodium or potassium salt and water to produce a pourable liquid composition containing the amounts of alcohol ethoxysulfate, sodium or potassium salt and water defined above.
In preparing the pourable compositions potassium or sodium salts having water of crystallizations, e.g., 'Na SO -10H O, are suitably employed.
EXAMPLE I A mixture of alcohol ethoxysulfuric acid was prepared by sulfation of a commercial alcohol ethoxylate mixture (marketed by the Shell Chemical Company as Neodol 25-3 Alcohol Ethoxylate) The alcohol ethoxysulfate mixture has an average of 3 ethylene oxide units per molecule and is derived from a mixture of C C C and C primary alcohols, in substantially equal proportions by weight, wherein approximately of the alcohol of each carbon number was straight-chain, approximately 10% of the alcohol of each carbon number was betamethyl branched and the remainder of the alcohol of each carbon number comprised alcohols of beta-ethyl, beta-propyl, beta-butyl or beta-amyl branching. The sulfation was conducted by treating the alcohol ethoxylate mixture in a continuous reactor (19 inches long) with a sulfur trioxide/ nitrogen gas mixture under the following conditions:
Reaction temperature C. 50
S0 gram/min. a 2.5
80 alcohol ethoxylate mole ratio 1.04
N /SO volume ratio 40/1 EXAMPLE II A 765.5 g. sample of the free ethoxysulfuric acid prepared as described in Example I was added to a mixture of 72 g. sodium hydroxide, 147.4 g. sodium sulfate and 862.1 g. water at a temperature of 50-60" C. The resulting mixture was a moderately viscous liquid which could be stirred efiiciently throughout the entire addition period. The ingredients were contacted in proportions calculated to produce a blend having 40% w. alcohol ethoxysulfate, 8% w. sodium sulfate and 52% w. water. Analysis of the blend showed 40.3% w. alcohol ethoxylate. The blend had a Klett (5%) color of 23 and was a pourable liquid at a temperature of 80-85 F.
'EXAMPLE III A 745.7 g. sample of the free alcohol ethoxysulfuric acid prepared as described in Example I was neutralized by adding it to a mixture of 62 g. sodium hydroxide, 147.4 g. of sodium sulfate and 862.1 g. of water. The amounts of reactants was calculated to produce a blend of 42% w. alcohol ethoxysulfate, 8% w. sodium sulfate and 50% w. water. Analysis of the blend showed 41.7% w. alcohol ethoxysulfate. The blend had a pH of 8.5, a Klett (5%) color of 25 and was a pourable moderately viscous liquid at a temperature of 80-85" F.
EXAMPLE IV A 5.07 g. sample of a soft aqueous gel consisting of 78.9% w. of the sodium salt of the ethoxysulfuric acid prepared in Example I and 21.1% w. water was mixed by hand with 0.8 g. of sodium sulfate and 4.13 g. of distilled water. The ingredients were mixed in proportions calculated to produce a blend with the composition: 40% w. alcohol ethoxysulfate, 8% w. sodium sulfate and 52% w. water. By a similar procedure a variety of compositions were prepared. The weight concentration of alcohol ethoxysulfate and sodium sulfate and the physical state thereof at 80 F. are tabulated in Table I.
Non-pourable stifi gel Barely pourable viscous liquid Pourable moderately viscous liquid Pourable moderately viscous liquid 12 Hazy, non-homogeneous two-phase viscous liquid 1 Pourable liquid.
EXAMPLE V A 5.32 g. sample of a soft aqueous gel consisting of 78.9% w. of the sodium salt of the ethoxysulfuric acid prepared in Example I and 21.1% water was mixed with 0.8 g. sodium chloride and 3.88 g. of water. The resulting composition was a pourable, slightly hazy, moderately viscous liquid (80 F.) with the composition (calcu- TAB LE II Alcohol ethoxysulfate, percent w.
ilh ivi as 40 42 Non-pourable stifi gel Barely pourable viscous liquid Pourable moderately viscous liquid Pourable moderately viscous liquid Hazy, non-homogeneous two-phase viscous liquid 1 Pourable liquid EXAMPLE VI By a procedure similar to that of Example I a mixture of alcohol ethoxysulfuric acid was prepared by sulfation of a commercial alcohol ethoxylate mixture (marketed by Continental Oil Company as Alfonic 1412-40 Ethoxylate) having the structural formula CH (CH CH (OCH CH OH wherein the approximate value of a is 11 and b is 3.
A 3.39 g. sample of a soft aqueous gel, consisting of 59% of the sodium salt of the above ethoxysulfuric acid and 41% water, was mixed with 0.4 g. sodium sulfate and 1.21 g. water. The resulting pourable, clear moderately viscous liquid (at 80 F.) has a composition consisting of 40% w. alcohol ethoxysulfate, 8% w. sodium sulfate and 52% w. water.
EXAMPLE VII A 2.58 g. sample of a soft aqueous gel, consisting of 77.5% of the sodium salt of the ethoxysulfuric acid prepared in Example I and 22.5% water, was mixed with 0.4 g. of potassium bromide and 2.02 g. distilled water. The resulting blend, consisting of 40% w. alcohol ethoxysulfate, 8% w. potassium bromide and 52% W. water, was a pourable, moderately viscous liquid (at 80 F.).
I claim as my invention:
1. A composition, pourable and liquid at a temperature of about 80 F., consisting essentially of (1) about 38 to 42% by weight, based on total composition, of a nonionic alcohol ethoxysulfate (2) about 7 to 10% by weight, based on total composition, of a salt selected from NaCl, KBr, Na SO or a mixture thereof and (3) the balance water, said alcohol ethoxysulfate being a solid at a temperature of about F. and being represented by the formula wherein M is sodium or potassium, X is a number from 2 to 5 representing an average of the ethylene oxide units per molecule and R is alkyl of from 11 to 15 carbon atoms of the formula wherein m is a whole number from 0 to 5 inclusive and n is a whole number from 3 to 12 inclusive so that the sum of mi+n is a whole number from. 8 to 12 inclusive.
2. The composition of claim 1 wherein the salt is a sodium salt.
3. The composition of claim 2 wherein m is 0 in about 80% of said alkyls and no more than 75% by weight of R is alkyl of any one number of carbon atoms.
4. The composition of claim 3 wherein M is sodium and x is 3.
5. The composition of claim 4 wherein the percentage by Weight of salt is about 8 to 9% and the percentage by weight of alcohol ethoxysulfate is about 40%.
6. The composition of claim 5 wherein R is alkyl of from C12 to C15.
7. The composition of claim 2 wherein m is 0 in essentially of said alkyls, x is 3 and M is sodium.
8. The composition of claim 7 wherein the percentage by weight of salt is about 8 to 9% and the percentage of alcohol ethoxysulfate is about 40%.
References Cited UNITED STATES PATENTS 2,766,212 10/1956 Grifo 252-541 2,970,964 2/1961 Krumrei et a1. 252-551 3,440,171 4/1969 Warren 252-558 X OTHER REFERENCES Gohlke et al.: Soap and Chem. Spec., Alkyl Ether U.S. Cl. X.R. 252550
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