harcros narrow range ethoxylation technology
DESCRIPTION
Harcros Narrow Range Ethoxylation Technology. Patent Approved August 2006, “Method of Preparing Alkoxylation Catalysts and their use in Alkoxylation Reactions” (US 7,119,236). Presented by Dr. Peter Radford President, Organics Division Harcros Chemicals Inc. Narrow Range Ethoxylation. - PowerPoint PPT PresentationTRANSCRIPT
Harcros Narrow Range Ethoxylation Technology
Presented by
Dr. Peter Radford
President, Organics Division
Harcros Chemicals Inc
Patent Approved August 2006, “Method of Preparing Alkoxylation Catalysts and their use in Alkoxylation
Reactions” (US 7,119,236)
Narrow Range Ethoxylation
For Alcohol Substrates, this results in• a broad ethoxymer distribution• higher free, un-reacted alcohol• increased PEG’s• lower overall concentration of surfactant range
ethoxymers
Typical ethoxylation processes rely upon KOH, NaOH, or Methylate Catalysts.
Narrow Range Ethoxylation
Narrow Range Alcohol Ethoxylates (NRE’s) have• a compressed ethoxymer curve similar to the distribution
of alkylphenol ethoxylates
• lower free alcohol = lower VOC’s
• increased concentration of surfactant range adducts
• lower PEG levels
• In some cases, an improved aquatic toxicity profile
Narrow range processes utilize unique catalyst systems to produce a tighter ethoxymer distribution.
Ethoxymer Distribution Comparison
0 2 4 6 8 10 12 14 16
Moles EO
Mo
le %
NP-8
NRE6 mole
BRE6 mole
Unreacted Alcohol
Surfactant Range
Ethoxylates
Free Alcohol Comparisons
0
5
10
15
20
25
30
35
C1216
-2.5
C1216
-6
C1216
-9.5
TDA-2.5
TDA-6
TDA-9.5
% F
ree
Alc
oh
ol
BRE
NRE
None Detected for NRE
Linear Alc. Ethoxylate Branched Alc. Ethoxylate
Branched substrates contain higher levels of un-reacted alcohol due to the steric bulk of the hydrophobe.
Wetting Time Comparison
0
5
10
15
20
25
30
35
40
45
C1216-6 C1216-9.5 Isodecyl-6
Wet
tin
g T
ime
(sec
)
BR
E
NP-9.5, 8 sec.
NR
E
5.8 mole NRE
8.6 mole NRE
5.8 mole NRE
Wetting Time Comparison (Skein Test) 25 C
42ºC 37ºC 37ºC
87ºC 86ºC
72ºC
43ºC 36ºC 36ºC
NRE’s display a higher cloud point versus the BRE of the same EO level. When comparing certain properties, it is necessary to match cloud points, not moles of EO.
NRE’s show better wetting times if cloud point is matched.
Ethoxylate NRE BREC1216-6 42 37C1216-5.8 37C1216-9.5 87 86C1216-8.6 72Isodecyl-6 43 36Isodecyl-5.8 36NP-9.5 58
Cloud Point ( C )
Foam Height Comparison
0
2
4
6
8
10
12
14
C1216
-6
C1216
-9.5
C1216
-8.6
C1216
-6
C1216
-9.5
Fo
am H
eig
ht
(cm
)
NRE BRE
1min
5 min
1min
5 min
Less stable foam for NRE’s
Less high mole adducts and lower free alcohol lead to decreased foam stability for NRE’s.
Interfacial Surface TensionInterfacial Surface Tension
00.5
11.5
22.5
3
C1216
-6
C1216
-9.5
TDA-9.5
C1012
-6
C1012
-9.5
(d
ynes
/cm
)
NRE BRE
NP-9.5
8.6 Mole NRE
NRE’s display higher surface tensions than BRE’s due to increased hydrophilicity. If the EO level is adjusted to match surface tension of the BRE (8.6 mole NRE), a much lower IFT is achieved. Even with higher surface tensions, NRE’s show better wetting times than BRE’s.
NRE/BRECMC
(ppm)Sur. Ten
(dynes/cm)Wet. (sec)
C1216-9.5 32.5/35 35/33.5 41/40C1216-8.6 32.5 33.5 23
Narrow Range Technology
Acid Catalyst Systems • Limited to low-mole adducts
• Produce high levels of 1,4 dioxane which must be scrubbed
Metal Cyanide• Used predominately for polyol production
Calcium Based Systems• Milder catalyst yields neutral pH ethoxylate, no neutralization step required
• Higher catalytic activity, lower levels required (100 ppm Ca+ vs 350 ppm K+)
• Catalyst residue is water soluble
• Ethoxylation of alternative substrates possible – Soybean Oil, Methyl Esters, etc.
• Commercial products – Harcros NR series,
General Summary of NRE Benefits
• Tailored wetting performance
• Lower CMC’s and IFT’s
• Less un-reacted alcohol = lower VOC’s and Ether Sulfates with lower irritation indices (less alcohol sulfate)
• Greater concentration of surfactant range ethoxymers
• Decreased foam stability
• Reduced PEG’s
Formulators seeking to replace Alkyl Phenol Ethoxylates can turn to Narrow Range Ethoxylates as performance alternatives.
Narrow Range Ethoxylation technology utilizes a milder, higher active catalyst to produce robust ethoxylates of alcohol, ester, and other hydrophobes yielding
Products used in Energy Recovery- NRE Benefits
• Fatty alcohol ethoxylates – Lower interfacial surface tensions for lower
mole adducts• Mutual Solvents (short chain ethoxylates)
– Perform considerably more efficiently at higher temperature, in the presence of electrolytes.
Products Used in Energy Recovery- NRE Benefits (Continued)
• Foamer Products (short chain ether sulfates)– Retain form density better than their NRE
counterparts– Perform very well in higher brine systems.
• Soap Sticks (highly ethoxylated NPE’s): – High mole NPE’s are considerably more
crystalline, and have higher melt points when prepared with the NRE catalyst.
Mutual Solvents – Improved efficiency under real world conditions
BRE in Brine 50C
98.8
38.330
39.1 40
49.2
0
10
20
30
40
50
60
70
80
90
100
110
2.8 3.1 3.5 4.5 5.5 6
EO Level
mL
Etho
xyla
te
BRE Brine, 50C
NRE in Brine 50C
78.2
60
30.9
19 21.625
0
10
20
30
40
50
60
70
80
90
2.57 2.95 3.5 4.5 5.5 6
EO Levelm
L Et
hoxy
late
NRE Brine, 50C
Graphs show milliliters of ethoxylate required to reach one single phase at the indicated temperature –note the improvement with the NRE version
Foamers - Foam Heights for Linear Ether Sulfates (NRE vs. BRE)
470
480
490
500
510
520
530
540
550
560
NRE Linear Ether Sulfate BRE Linear Ether Sulfate
DeionizedWater(mL)
10%NACEbrine (mL)
•NRE Based Foamers have Improved Brine Foam Height
Height, mm
Foamers- Foam Stability and Branched Ether Sulfates
(NRE vs. BRE )
0:00
0:28
0:57
1:26
1:55
2:24
2:52
3:21
3:50
4:19
NRE BranchedEther Sulfate
BRE BranchedEther Sulfate
Deionized Water
5% CaCl2
10% CaCl2
Hal
f L
ife
(min
utes
)
Foamers – Foam Density on Standing
(NRE vs. BRE)
0
0.05
0.1
0.15
0.2
Foam Density (g/cc)
Broad Range Narow Range
Ethoxylate Type
Foam 'Wetness" for NRE and BRE ether sulfates
30 secs
240 secs