Production process of non-ionic surfactants

3.3.2.1 Process flow of MES/AES The production units of MES include production processes such as SO3 sulfonation, esterification, continuous bleaching, continuous neutralization, and flash drying; details are shown in Figure 1 below. Figure 1: Schematic diagram of the MES production process. The reaction raw material, SO3 gas, is fed into the bottom of the multi-tube membrane spray reactor (R101), and then distributed evenly into each reaction tube. The other raw material, methyl palmitate, enters from the top of the reactor, forming a film on the inner surface of the reaction tube as it flows together with the gas. The reactor distribution head has a special structure. This structure ensures an accurate feed rate, maintains a consistent molar ratio between the reactant and sulfonation gas in each reaction tube, and allows the sulfonation reaction to take place within the tubes. The heat of reaction is removed by the cooling water in the shell side, and the temperature of this cooling water is automatically adjusted depending on the raw materials being processed. The fatty acid methanesulfonic acid coming out of the bottom of the sulfonation reactor, after having the entrained SO3 gas removed, enters the esterification tank (R102), where methanol is added to carry out the esterification reaction; the resulting methyl ester sulfonic acid then goes into the decolorization tank (R103). The esterified methanesulfonic acid is thoroughly mixed with hydrogen peroxide in the decolorization tank (R103) to carry out decolorization; after that, it enters the neutralization tank (R104), where 30% liquid alkali is added for neutralization. A vacuum pump (P101) is then activated to perform vacuum dehydration, thereby removing any unreacted residual methanol and other impurities as well. Hydrated MES can be sold as a product, but transportation costs will increase. Such aqueous products are then fed into a spray dryer (G101) to be converted into powder. The powdered product is collected at the bottom of the dryer, and after packaging, it becomes the final product. 3.3.2.2 Process flow of alcohol ether surfactants The production equipment for alcohol ethers includes processes such as dehydration, addition reaction, neutralization, and filtration; details are shown in Figure 2 below. Figure 2: Schematic diagram of the alcohol ether production process. The raw material EO from the raw material tank area enters the EO metering tank for storage. The reactants and catalyst are added to reactor R201; then pump P203 is started, and steam from heat exchanger E201 is turned on to heat the mixture to a certain temperature. Vacuum pump P202 is then started to remove water, followed by purging with nitrogen. Once the starting material is heated to the specified temperature, the steam heating for E201 is switched to water cooling; the EO feed pump is started, and EO is gradually added. Once EO enters the reactor, it reacts with the starting material under the action of the catalyst, releasing a large amount of heat which is transferred by the external heat exchanger. As more EO is added, the molecular weight of the reaction products also increases continuously. When a certain amount of EO is added, P204 and E202 are activated, and the mixture enters R202; EO is also transferred to the reaction in R202 until the reaction products reach the desired molecular weight. The reaction products are discharged into the neutralization tank R203 for further processing. The reactants are neutralized with phosphoric acid in the neutralization tank, and then dehydrated using the pump P205. After dehydration, the material is sent to the closed filter L201 via P204 for filtering out the salts formed during neutralization; once filtered, it is packaged to become the final product. Once the neutralization tank is emptied, the next production cycle can begin.

Non-ionic surfactants mainly include: polyoxyethylene types, such as fatty alcohol polyoxyethylene ethers； Polyoxypropylene type, such as fatty alcohol polyoxypropylene ether ； Polyol type, sorbitan fatty acid esters ； Alkylolamide type, such as Ninaral ； Polyether type, such as block polyethers. Non-ionic surfactants possess high surface activity and have functions such as emulsification, wetting, dispersion, detergency, and solubilization. They also offer benefits like antistatic properties, softness, sterilization, lubrication, corrosion inhibition, rust prevention, color uniformity, and anti-corrosion effects. It is widely used in various industries, including textiles, papermaking, food processing, plastics, leather, glass, chemical fibers, pharmaceuticals, pesticides, paints, dyes, fertilizers, film and photography, metal processing, mineral processing, building materials, environmental protection, firefighting, and more. Its main use is still in various detergents and cosmetics. Its current production volume ranks second, only behind anionic surfactants.

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