a valuable tool for the detergent industry by i. adami (r ... valuable tool for the detergent...
Post on 25-Mar-2018
254 Views
Preview:
TRANSCRIPT
DRY-ANIONIC SURFACTANTSA valuable tool for the detergent industry
by
I. Adami (R&D Dept.)
BALLESTRA S.p.A.
Contents:Contents:
• SULPHONATES and THEIR IMPORTANCEin the SURFACTANTS SCENARIO
• SULPHONATES PRODUCTION TECHNOLOGY
• DRY-ANIONIC SURFACTANTS PRODUCTION
• USE and ADVANTAGES of DRY-ANIONIC SURFACTANTS
• ECONOMICAL CONSIDERATIONS
ANIONIC SURFACTANTS
are the most widely used
ACTIVE COMPONENTS
because of their
Wide spectrum of applicability Wide range of industrially available types Consolidated manufacturing technology Proven overall performances Chemical compatibility with other detergent components
ANIONIC SURFACTANTS
SULPHONATES
LABS : Linear-Alkyl-Benzene-Sulphonate
FAS : Fatty-Alcohol-Sulphates
FAES : Fatty-Alcohol-Ethoxy-Sulphates
AOS : Alpha-Olefins-Sulphonates
MES : Methylester-Sulphonate
SURFACTANTS USE SURFACTANTS USE in in
HOUSEHOLD and PERSONAL CARE PRODUCTSHOUSEHOLD and PERSONAL CARE PRODUCTS
57%
40%
2% 1%
ANIONICS
NON IONICS
CATIONICS
AMPHOTERICS
ANIONIC SURFACTANTS USE ANIONIC SURFACTANTS USE in in
HOUSEHOLD and PERSONAL CARE PRODUCTSHOUSEHOLD and PERSONAL CARE PRODUCTS
0
200
400
600
800
1000
1200
W. Europe USA Japan
MESAOSFASFAESLABS
KTY
Comparative Application Characteristics Comparative Application Characteristics of main Anionic Surfactantsof main Anionic Surfactants
DETERGENCY(*)
FOAMING(*)
SOLUBILITY
SKIN COMPATIBILITY
SENSITIVITY toH2O-HARDNESS
LABS ~ MES ~ FAS ~ FAES ~ AOS
LABS ~ AOS ~ FAES ~ FAS ~ MES
LABS > FAES > AOS > MES > FAS
MES > AOS > FAES > LABS > FAS
FAS > FAES > LABS > AOS > MES
(*) Very similar, using optimum chain length selection
SURFACTANT SELECTIONSURFACTANT SELECTION
Performance
Price
Physical shape& characteristics
SULPHONATESSULPHONATES
PRODUCTION TECHNOLOGY
FEEDSTOCK FOR SULPHONATION PROCESSFEEDSTOCK FOR SULPHONATION PROCESS(Key Parameters for Quality Processing)(Key Parameters for Quality Processing)
FEEDSTOCK PARAMETER TYPICAL FIGURES
Linear Alkylbenzene
- (High) Sulphonability- (Controlled) 2-Phenyl-Isomers Content
- (Low) Moisture- (Low) Bromine Number- (Constant) Distillation Range
98.5 - 99.0 (%)15 - 20 (%) (via HF-Alkylation)25 - 35 (%) (via AlCl3-Alkylation)0.01 - 0.02 (%)0.01 - 0.02 (gr Br2/100 gr)275 - 305 (°C)
Fatty Alcohols(Natural & Synthetic)
- (Low) Unsulphatable- (Low) Moisture- (Low) Iodine Number
0.3 - 0.5 (%)0.01 - 0.05 (%)0.05 - 0.10 (gr J2/100 gr)
Fatty Alcohol Ethoxylates(Natural & Synthetic)
- (Low) PEG content- (Low) Moisture content- (Negligible) EO content
0.5 (%) max.0.01 - 0.05 (%)2 ppm max.
Alpha-Olefins
- (Low) Moisture- (Low) Internal Olefins- (Low) Branched Olefins- (High) Alpha-Isomers Content- (Constant) Distillation Range
0.05 - 0.10 (%)0.5 - 2.0 (%)1.0 - 4.0 (%)94 - 98.5 (%)(depending on cut)
Fatty AcidMethylesters
- (Low) Iodine Number- (Low) Acid Value- (Low) Moisture- (Low) Glycerides Content
0.01 - 0.3 (gr J2/100 gr)0.1 - 0.5 (mg KOH/g)0.05 - 0.1 (%)0.05 - 0.1 (%)
Sulphur AIRDRYING
HEATRECOVERY
OrganicR.M.
SULPHURPRE-TREATMENT
SULPHURMELTING &
DOSING
SULPHURBURNING
SO2 / SO3PRODUCTION
SULPHONATION&
SULPHATION
AGEING &STABILIZING
LABFAFAEAOME
EXHAUST GASTREATMENT
SULPHITESOXIDATION
^atm
NEUTRALIZATION
ProcessH2O
RE-ESTERIFICATIONCaustic
Soda
BLEACHINGHYDROLYSIS
LABSO3HMESpaste
AOSpaste
DEAERATION&
STRIPPING
LABSpaste
FASpasteFAES
paste
SulphonationSulphonation ProcessProcess
SulphonationSulphonation and Neutralization Plantand Neutralization Plant
ANIONIC QUALITY SPECS.ANIONIC QUALITY SPECS.
PRODUCT AM (%) Na2 SO4(on 100% AM)
F.O.(on 100% AM)
°Klett Color(on 5% AM sol.)
LABSO3 H 97.5 - 97.7 0.5 - 0.6 ()0.8 - 1.0 10 - 20FAS (12-14 nat.) 70 - 75 0.8 - 1.20.8 - 1.0 5 - 10FAS (13-15 synt.) 70 - 73 0.9 - 1.31.0 - 1.2 15 - 25FAS (16-18 nat.) 68 - 70 1.2 - 1.71.5 - 1.8 35 - 50AES-2EO (*) 70 - 73 0.6 - 1.10.5 - 1.0 3 - 10AES-3EO (**) 70 - 73 0.6 - 1.00.8 - 1.0 5 - 15AOS (14-16/14-18) 70 - 75 1.0 - 1.51.0 - 1.6 25 - 40MES (12-14/16-18) 68 - 70 (***) 1.5 - 1.80.8 - 1.5 40 - 50 (****)() : As H2 SO4 content(*) : 1,4 Dioxane content of max. 30 ppm (on AM basis) with FO = 2% max. (on AM)(**) : 1,4 Dioxane content of max. 30 ppm (on AM basis) with FO = 2,5% max. (on AM)(***) : Di-salt content = 5% max. (on tot. AM)(****) : Color figures after bleaching
ANIONIC SURFACTANTS PHYSICAL SPECIFICATIONSANIONIC SURFACTANTS PHYSICAL SPECIFICATIONS
PRODUCT SHAPE
LABSO3H
LABSO3Na
FAS
Liquid
Liquid
LiquidPaste
FAES LiquidPaste
AOS LiquidPaste
MES LiquidPaste
VISCOSITY(mPa.s)
300 - 500
2000 - 5000
500 - 6005000 - 10.000
300 - 5005000 - 8000300 - 500
7000 - 12.000800 - 1500
5000 - 10.000
ACTIVECONTENT (%)
96,5
50 - 60
27 - 3070 - 72
2770 - 7235 - 38
7035 - 3865 - 68
SULPHONATES PRODUCTION ENERGY DEMAND and YIELDSULPHONATES PRODUCTION ENERGY DEMAND and YIELD
LABSO3 H
LABS
FAS (12-14)
FAS (16-18)
AES-2EO
AES-3EO
AOS (14-18)
MES (16-18)
Production Index
10050
Energy Demand
0250500
(Kw)
DRYDRY--ANIONIC SURFACTANTSANIONIC SURFACTANTS
PRODUCTION
SULPHONATES DRYINGSULPHONATES DRYING
LABS
FAES
FAS
AOS
MES
YES
NO
SULPHONATES DRYINGSULPHONATES DRYING
to generate products characterised by:
Optimised chemical specification (i.e.: low content of unsulphonated matter, inorganic sulphate and low color)
Regular and stable physical shape
Easy handling, storage and re-using
DryDry--Anionic Surfactants Production StepsAnionic Surfactants Production Steps
ANIONIC SURFACTANT
PASTE (70% AM)
FLASHPRE-CONCENTRATION DRYING COOLING and
FLAKING
PHYSICAL SHAPE MODIFICATION
POWDER NEEDLES GRANULES
: FLASH-PRECONCENTRATOR
: SCRAPED FILM DRYER
: ROLL-FLAKER
DRY-FLAKES
CW
STE
AM
CW
W ET SCRUBBING
VACUUM PUMP
HYDRO LYSISNEUTRALIZATION
ACID
H2O/NaOH
FAS/MESPRE HEATING
AOS
SULPHONIC
ANIONIC SURFACTANT DRYING UNITANIONIC SURFACTANT DRYING UNIT
SURFACTANS UPGRADING
DRYING PHYSICAL SHAPEMODIFICATION
FLAKES > POWDER > NEEDLES > GRANULES
PROCESSING DEMAND
Product Shape Processing DemandProduct Shape Processing Demand
DRY SURFACTANT FLAKESDRY SURFACTANT FLAKES
MILLINGMILLING
BLENDINGBLENDING
CLASSIFYINGCLASSIFYING
EXTRUSIONEXTRUSION
COOLING&
CUTTING
COOLING&
CUTTING
DRYINGDRYING
PULVERIZINGPULVERIZING
GRANULATIONGRANULATION
CONDITIONINGCONDITIONING
COATINGCOATING
SIEVINGSIEVING
DRY SURFACTANTPOWDER
DRY SURFACTANTPOWDER
DRY SURFACTANTNEEDLES
DRY SURFACTANTNEEDLES DRY SURFACTANT
GRANULESDRY SURFACTANT
GRANULES
SIEVING &CLASSIFYINGSIEVING &
CLASSIFYING
SOLID/LIQUIDADDITIVES
SOLID/LIQUIDADDITIVES
SOLID/LIQUIDADDITIVES
SOLID/LIQUIDADDITIVES
Surfactants Shape Modification ProcessesSurfactants Shape Modification Processes
DRY SURFACTANTS PHYSICAL CHARACTERISTICSDRY SURFACTANTS PHYSICAL CHARACTERISTICS
POWDER NEEDLES GRANULES
BD = 500 - 550 BD = 450 - 500 BD = 450 - 700
Particle size = 100 - 1000 Diameter = 0,7 - 1,5 mm Particle size = 500 - 1500
DFR
80 Length = 5 - 15 mm DFR =
120
DRY-ANIONIC SURFACTANTS
GLYCOL
GLYCOL
DRY POWDER
NITROGEN
ATM
DRY FLAKES
: COOLING BATTERY
: DEDUSTING AND COOLING FAN
: DEDUSTING FILTER
: CENTRIFUGAL MILL
DRYDRY--ANIONIC POWDER PRODUCTIONANIONIC POWDER PRODUCTION
DRY-FLAKES
DRY NEEDLES
COOLINGFLUID
CONDITIONED AIR
: PNEUMATIC TRANSPORT FAN
: EXTRUDER AND CUTTER
: PNEUMATIC TRANSPORT FILTER
DRYDRY--NEEDLES PRODUCTIONNEEDLES PRODUCTION
COARSES
FINES
DRY-GRANULES
NITROGEN
: GRANULATOR
: CLASSIFIER
: COARSES/FINES RECOVERY SYSTEM
: MILL
AIR
DRY-FLAKES
DRYDRY--GRANULES PRODUCTIONGRANULES PRODUCTION
DRYDRY--ANIONIC SURFACTANTSANIONIC SURFACTANTS
USES and ADVANTAGES
DRYDRY--SULPHONATESSULPHONATES allow to produce formulated detergents by:
• Simple Plant Configuration
• Low Energy-demanding equipment
• Reduced production cost
Main applications of DRY ANIONIC SURFACTANTSMain applications of DRY ANIONIC SURFACTANTS
XX = Good/Suitable = Possible ApplicationX - = Not Used/Not Suitable
SURFACTANTTYPE
POWDERS
HD LD DW
LIQUIDS
HD LD DW
SYNDET BARS
HD LD
FAS
AOS
MES
X
XX
XX
XX
X
-
-
-
-
-
X
X
X
-
X
XX
-
-
X
X
X
-
-X
THERMOSENSITIVECOMPONENTS
AGGLOMERATEDDETERGENT
(COARSE)
PERFUME
LIGHT-SILICATE
LIQUID BINDER
HOT AIR
LABS
FFA
NI
ADDIT.
STPP/ZEOLITENa2CO3Na2SO4
: HIGH-SHEAR AGGLOMERATOR
: FLUIDIZED BED CONDITIONER
: 1st AIR FILTER and DUST RECOVERY
: POST-AGGLOMERATOR
: FINAL MIXER/SIEVE
: 2nd AIR FILTER and DUST RECOVERY
COLD AIR
FAS
AOS
MES
POWDERDRY
POWDER
NONNON--TOWER DETERGENT PRODUCTION PLANTTOWER DETERGENT PRODUCTION PLANT
DRYDRY--SULPHONATES in POWDER FORMSULPHONATES in POWDER FORM
are the optimum “tool” to obtain:
- Extension of the total Active Matter content
- Improvement of the product bulk density control
- Increase of the formulation flexibility
- Reduction of the overall process energy input
FAS AOS MES
Active (%)Additional
Energy Demand(%)
Active (%)Additional
Energy Demand(%)
Active (%)Additional
Energy Demand(%)
30 ± 35 35 - 38 35
70 - 75 (70 - 75) (65 - 70)
>90 + 38-40 >90 + 23-25 >90 + 34-36
>92 + 50-55 >94 + 34-36 >90 + 50-52
>90 + 65-68 - - - -
>85 + 70-72 - - - -
Surfactantcommercial
shape
LIQUID
PASTE
DRY-FLAKES
DRY-POWDER
DRY-NEEDLES
DRY-GRANULES
SURFACTANT UPGRADING ENERGY DEMANDSURFACTANT UPGRADING ENERGY DEMAND
200100 150
Liquid/Paste
Dry-granules
Dry-needles
Dry-powder
(%) + Product Added Value
DRYDRY--FAS ADDED VALUEFAS ADDED VALUE
DRYDRY--ANIONIC SURFACTANTSANIONIC SURFACTANTS
• ADVANTAGES for MANUFACTURERS
- Workable in processes where liquid Surfactant cannot be used- Increased range of product formulations and relevant performance- Easiness in handling and dosing
• ADVANTAGES for MANUFACTURERS
- Easy and safe production process- Add value to the production- Easy storage, handling and transportation- Increased production range/variety- Offer additional marketing opportunities
DETERGENT
SURFACTANT
MANUFACTURING PROCESSESMANUFACTURING PROCESSES
INCREASED USE OF DRYDRY--ANIONIC SURFACTANTSANIONIC SURFACTANTS
DISPLAY OF THE CAPABILITY OF THE
SURFACTANTS & DETERGENTS INDUSTRYSURFACTANTS & DETERGENTS INDUSTRY
to developLESS ENERGYLESS ENERGY--INTENSIVEINTENSIVE
MORE EFFICIENTMORE EFFICIENT
OPTIMIZATION OF
DETERGENT MANUFACTURING TECHNOLOGYDETERGENT MANUFACTURING TECHNOLOGY
top related