ASSIGNMENT ON TEXTILE CHEMISTRY

Presentation topic: Detergent Course name: Textile Chemistry Course code: TE-215

SUBMITED BY: Asif Ahmed Department: TE ID: 131-23-3505 Section: B SUBMITED TO: Dr. A. Nayeem Faruqui Assistant Professor Department of Textile Engineering Daffodil International University. Date of Submission: 02.03.2014.

A detergent is a surfactant or a mixture of surfactants with "cleaning properties in dilute solutions." These substances are usually alkylbenzenesulfonates, a family of compounds that are similar to soap but are more soluble in hard water, because the polar sulfonate (of detergents) is less likely than the polar carboxyl (of soap) to bind to calcium and other ions found in hard water. In most household contexts, the term detergent by itself refers specifically to laundry detergent or dish detergent, as opposed to hand soap or other types of cleaning agents. Detergents are commonly available as powders or concentrated solutions. Detergents, like soaps, work because they are amphiphilic: partly hydrophilic (polar) and partly hydrophobic (nonpolar). Their dual nature facilitates the mixture of hydrophobic compounds (like oil and grease) with water. Because air is not hydrophilic, detergents are also foaming agents to varying degrees.

Chemical classification of detergents Detergents are classified into three broad groupings, depending on the electrical charge of the surfactants. Anionic Detergents: Synthetic detergents have similar molecular structures and properties as soap. Although the cleansing action is similar, the detergents do not react as readily with hard water ions of calcium and magnesium. There are over a thousand synthetic detergents available in the United States. Detergentmolecular structures consist of a long hydrocarbon chainand a water soluble ionic group. Most detergents have a negative ionic group and are called anionic detergents. The majority are alky sulfates. Others are "surfactants" (from surface active agents) which are generally known as alkyl benzene sulfonates.

Cationic Detergents: Another class of detergents have a positive ionic charge and are called "cationic" detergents. In addition to being good cleansing agents, they also possess germicidal properties which makes them useful in hospitals. Most of these detergents are derivatives of ammonia. A cationic detergent is most likely to be found in a shampoo or clothes "rinse". The purpose is to neutralize the static electrical charges from residual anionic (negative ions) detergent molecules. Since the negative charges repel each other, the positive cationic detergent neutralizes this charge. It may be surprising that it even works because the ammonium (+1) nitrogen is buried under the methyl groups as can be seen in the space filling model.

Neutral or non-ionic detergents: Nonionic detergents are used in dish washing liquids. Since the detergent does not have any ionic groups, it does not react with hard water ions. In addition, nonionic detergents foam less than ionic detergents. The detergent molecules must have some polar parts to provide the necessary water solubility. In the graphic on the left, the polar part of the molecule consists of three alcohol groups and an ester group. The non-polar part is the usual long hydrocarbon chain.

Bile Salts - Intestinal Natural Detergents: Bile acids are produced in the liver and secreted in the intestine via the gall bladder. Bile acids are oxidation products of cholesterol. First the cholesterol is converted to the trihydroxy derivative containing three alcohol groups. The end of the alkane chain at C # 17 is converted into an acid, and finally the amino acid, glycine is bonded through an amide bond. The acid group on the glycine is converted to a salt. The bile salt is called sodiumglycoholate. Another salt can be made with a chemical called taurine. The main function of bile salts is to act as a soap or detergent in the digestive processes. The major action of a bile salt is to emulsify fats and oils into smaller droplets. The various enzymes can then break down the fats and oils. QUES. Explain how bile salts work to emulsify fats. Talk about the polar and non-polar parts of the molecule.

THE DETERGENT MANUFACTURING PROCESS Detergents use a synthetic surfactant in place of the metal fatty acid salts used in soaps. They are made both in powder and liquid form, and sold as laundry powders, hard surface cleansers, dish washing liquids, fabric conditioners etc. Most detergents vhave soap in their mixture of ingredients, but it usually functions more as a foam depressant than as a surfactant. Detergent powder manufacture Step 1 - Slurry making The solid and liquid raw ingredients are dropped into a large tank known as a slurry mixer. As the ingredients are added the mixture heats up as a result of two exothermic reactions: the hydration of sodium tripolyphosphate and the reaction between caustic soda and linear alkylbenzenesulphonic acid. The mixture is then further heated to 85oC and stirred until it forms a homogeneous slurry.

Step 2 - Spray drying The slurry is deaerated in a vacuum chamber and then separated by an atomiser into finely divided droplets. These are sprayed into a column of air at 425oC, where they dry

THE DETERGENT MANUFACTURING PROCESS

Liquid detergent manufacture Step 1 - Soap premix manufacture Liquid detergent contains soap as well as synthetic surfactants. This is usually made first as a premix, then other ingredients are blended into it. This step simply consists of neutralizing fatty acids (rather than fats themselves) with either caustic soda (NaOH) or potassium hydroxide. Step 2 - Ingredient mixing All ingredients except enzymes are added and mixed at high temperature. The ingredients used in liquid detergent manufacture are typically sodium tripolyphosphate, caustic soda, sulphonic acid, perfume and water. The functions of these ingredients has been covered above. Step 3 - Enzyme addition The mixture is cooled and milled, and the enzymes added in powder form. ANCILLIARY PROCESSES Glycerine recovery As has already been stated, glycerine is more valuable than the soap itself, and so as much of it as possible is extracted from the soap. This is done in a three step process. Step 1 - Soap removal The spent lye contains a small quantity of dissolved soap which must be removed before the evaporation process. This is done by treating the spent lye with ferrous chloride. However, if any hydroxide ions remain the ferrous ions react with them instead, so these are first removed with hydrochloric acid: HCl + NaOH NaCl + H2O The ferrous chloride is then added. This reacts with the soap to form an insoluble ferrous soap: FeCl2 + 2RCOONa 2NaCl + (RCOO)2Fe This precipitate is filtered out and then any excess ferrous chloride removed with caustic: 2NaOH + FeCl2 Fe(OH)2 (s) + 2NaCl This is filtered out, leaving a soap-free lye solution. Step 2 - Salt removal Water is removed from the lye in a vacuum evaporator, causing the salt to crystallise out as the solution becomes supersaturated. This is removed in a centrifuge, dissolved

in hot water and stored for use as fresh lye. When the glycerine content of the solution reaches 80 - 85% it is pumped to the crude settling tank where more salt separates out. Step 3 - Glycerine purification A small amount of caustic soda is added to the crude glycerine and the solution then distilled under vacuum in a heated still. Two fractions are taken off - one of pure glycerine and one of glycerine and water. The glycerine thus extracted is bleached with carbon black then transferred to drums for sale, while the water/glycerine fraction is mixed with the incoming spent lye and repeats the treatment cycle.

The non-polar tails (in yellow) of tadpole shaped detergent molecules mix with grease, while the polar heads (in red) mix with water, thus forcing the grease and water to mix

Surfactants or detergents Greasy stains do not mix with water because the main interactions between water molecules are hydrogen bonding and those between molecules of oils and fats (which constitute grease) are van der Waals forces. To get water and grease to mix we use molecules called surfactants or detergents. These two terms refer to essentially the same thing - molecules that are tadpole shaped in that they have a non-polar tail and a polar or ionic head. The tail can form van der Waals bonds with non-polar grease molecules whilst the head can form hydrogen bonds with water, Figure 8. This is an example of the like dissolves like rule. There are essentially three types of surfactants - anionic, cationic and nonionic. Anionic surfactants have a negatively charged head. Common types include soaps, Figure 9, and alkylbenzene sulfonates, Figure 10.

Figure 9: Sodium stearate (a soap) - an anionic surfactant

Figure 10: Sodium dodecylbenzene sulfonate - an anionic surfactant Cationic surfactants have a positively charged head. Common types include alkyl ammonium chlorides, Figure 11.

Figure 11: Trimethylhexadecyl ammonium chloride - a cationic surfactant Non-ionic surfactants have a polar, but uncharged, head. Common types include polyethylene ethoxylates, Figure 12.

Figure 12: A polyethylene ethoxylate - a non-ionic detergent Surfactants are probably the ingredients one expects in a dishwasher product - we often call the product simply a dishwasher detergent. However, they play a relatively minor role in the product. Non-ionic polyethylene ethoxylates are chosen as the main surfactants in Finish as they produce relatively little foam. Their main function is to enable greasy soils to mix with water. Much of the soil on dishes is held there by grease. Greases and oils are chemically similar; they consist largely of esters of fatty acids - long chain carboxylic acids - with glycerol, see Figure 13. These contain long hydrocarbon chains which are essentially non-polar, and therefore do not form hydrogen bonds or dipole-dipole bonds with water molecules.

Figure 13: A typical fat or oil - which it is depends on the chain lengths of the three fatty acids and whether or not their hydrocarbon chains are branched When dissolved in water, surfactants tend to cluster at the surface (hence the name), so that their non-polar tails can stick out of the water. Surfactant molecules can form structures called micelles: these are small spheres made of surfactant that trap oil molecules and enable them to dissolve in the water. The difference between fats and oils is one of melting point - at room temperature fats are solid and oils are liquid due to their shorter hydrocarbon chains. Solid greases adhere to surfaces better than liquid oils which just tend to roll off. So a high temperature which turns fats into oils is helpful for cleaning. ENVIRONMENTAL IMPLICATIONS Soap is designed as a product to be used once then flushed down the drain, so as expected the environmental implications of its manufacture are not nearly so great as many other chemical processes. There are two main areas of concern: the safe transport and containment of th raw materials, and the minimisation of losses during manufacture. The three main components of soap by both cost and volume are oils, caustic and perfumes. Oils and perfume are immiscible in water and if spilled create havoc, although the oils do solidify at room temperature. Transport of these products is by trained carriers, and the systems for pumping from the truck to storage tanks is carefully designed. Perfumes are bought in lined steel drums which are quite robust, and flammable perfumes are not used in soaps. All storage tanks are surrounded by bunds to catch the contents of a tank should it rupture or a valve fail. When the storage system is designed, all the safety features (such as access to tank and valves) are designed in, as well as procedures to deal with the product should it end up in the bunded area. Within the plant, all the process areas are also bunded, and the trade waste from there piped to an interception tank before draining to the councils trad e waste system. The

contents of the interception tank are continuously monitored for acidity or alkalinity, and is designed to settle out excess solids or light phase chemicals. If a spill is detected in the plant itself, a portion of the interception tank can be isolated off and the effects of the spill neutralized before the waste is dumped. In most cases, however, potential problems are identified and stopped before they happen. Often an off-spec product can be reprocessed and blended rather than dumped, and even washout water can be reprocessed to minimised the discharges from the plant. Finally, the manufacturing process itself is closely monitored to ensure any losses are kept to a minimum. Continuous measurements of key properties such as electrolyte levels and moisture both ensure that the final product is being made to spec, and ensures the manufacturing process is working as it was designed to. Hence the losses in the plant will indirectly be minimised because the process itself is being monitored.

Synthetic detergent biodegradability There has recently been a strong move away from the environmentally hazardous biologically stable detergents used in the past to biodegradable ones. The sulphonic acid and nonionic detergents used in New Zealand to produce both liquid and powder detergents are fully biodegradable and comply with the relevant Australian standard. The sulphonic acid is made from a highly linear alkylbenzene, mainly dodecylbenzene, and the nonionics are ethoxylated long chain alcohols. The sodium lauryl ether sulphates also used in liquid detergents and shampoos are highly biodegradable, being made from either natural or synthetic linear C12 - C15 alcohols. Phosphates from detergent products used in New Zealand are independently monitored and have been found to not be an environmental hazard. Detergent powder Detergent powder manufacture has some specific environmental issues associated with it that are not present in other areas of the industry. These are dust control and volatile organic emissions. Dust present during delivery and transfer of bulk powdered detergent (and powdered raw materials) is a potential problem. Dry and wet cyclones are used to filter out most of the dust, and all emissions are monitored. If the dust level in these does exceed acceptable limits, appropriate remedial action is taken. Dust levels in emissions must be keptbelow 50 mg m-3. The spray drying tower also releases volatile organics. These emissions are minimised by having tight specifications on what can be added as primary detergent active material. An potentially hazardous material is added with the secondary actives after the tower so that it is not heated. Spot checks are done on the total hydrocarbon content of the exhaust gases using a flame ionisation detector. ROLE OF THE LABORATORY The laboratory monitors the formulation and specification of products from raw material to finished goods. Many soaps are formulated locally, and the laboratory tests a range of formulations for stability and manufacturing practicality. The trial formulations are aged in a warm oven to simulate a couple of years of shelf life, then checked for

perfume loss or alteration, base odour, colour stability and any general rancidity. Formulations are also constantly checked for cost effectiveness, and soaps are frequently reformulated for cost and supplier considerations. When a new formula has been agreed the laboratory will lay down the specifications that the finished soap and its intermediary stages must meet. These could be colour, odour, moisture or electrolyte concentrations, or the concentrations of impurities or additives. These specifications are also constantly being revised as the production equipment is improved, or consumer demands change. The laboratory lays down all the specifications for raw materials to be purchased against. These specifications become the basis for the supplier to quote against. The materials are constantly tested against these specifications, either on a shipment basis or suppliers batch size. In some cases the manufacturing plant is inspected and approved, and if the supplier can validate their process then the need for many routine or expensive tests can be reduced or eliminated. In most cases quality testing is performed at the process, by the process operators. The laboratory hold samples of every batch of finished goods for twelve months, so that if there are any consumer complaints, an original sample can be tested against the defect sample to determine the cause of the complaint. Tests carried out on some particular products are listed below.

Batch process soap The incoming tallow and coconut oil are tested for colour (after bleaching) and free fatty acid content. The neat liquid soap is tested for free alkali, salt content and glycerol content, while the soap chips are tested to moisture and fatty acid content. Detergent powder On-line tests are continuously carried out on density and moisture. The laboratory also tests for the concentrations of active detergent, sodium tripolyphosphate, moisture, soda ash, enzymes and bleach, and monitors physical properties such as dynamic flow rate, compressibility, particle size, colour and perfume.

Liquid detergent The product is typically tested for viscosity, pH, cationic detergent (fabric conditioner) content, enzyme content, conductivity (a measure of detergent stability), colour and perfume. Compiled by Heather Wansbrough from two articles, one from Ralph Laing (Colgate- Palmolive) and the other from Paul Milson (Lever Rexona) and with reference to: The Enclyclopdia Britannica (15th ed.); Encyclopdia Britannica, Inc.; 1979 Selinger, Ben; Chemistry in the Marketplace (3rd ed.); Harcourt Brace Jovanovich; 1986

Liquid detergent