Abstract:
A process for preparing alkoxylated alkyl glyceryl ether sulfonates which comprises reacting in the presence of water and the absence of ethanol a mixture of alkoxylated glycidyl ethers having as the major quantity of alkoxylated material ##STR1## with a salt of a sulfite bisulfite salt mixture at a temperature below about 110° C. wherein R is an alkyl or alkenyl of 10 to 20 carbon atoms, inclusive, R&#39; is hydrogen or methyl and n has an average value of 1 to 10 and obtaining a sulfonated alkoxylated product having as a major quantity of the alkoxylated material a salt of 
     
       R(OCH.sub.2 CHR.sup.1).sub.n OCH.sub.2 CHOHCH.sub.2 SO.sub.3 --

Description:
This application is a continuation-in-part application of copending patent application U.S. Ser. No. 8/137,450, filed on Oct. 15, 1993 now U.S. Pat. No. 5,436,366. 
    
    
     BACKGROUND OF THE INVENTION 
     Alkyl glyceryl ether sulfonate salts, (AGES) particularly the sodium salt, have been well known for their commercial utility in detergent compositions for many years. The synthesis of these materials is relatively straight forward and also known for many years. A review article by David Whyte entitled &#34;Alkyl Glyceryl Ether Sulfonates&#34; appearing in Surfactant Science Series, Vol 7, Anionic Surfactants Part 2, 1976 provides a good summary of synthetic routes. In one synthesis a long chain alcohol is reacted with epichlorohydrin under acid catalysis to form a chlorohydrin ether. Thereafter the chlorohydrin ether is subjected to the Strecker reaction, using sodium sulfite, or bisulfite or a mixture thereof, to form the alkyl glyceryl ether sulfonate salt. Since the Strecker reaction is a two phase reaction, good interphase contact is required as well as an appropriate catalyst according to the Whyte article. The reaction product is a viscous paste and heat transfer is poor. Therefore the water content in the system is a major means of control of peak reaction temperature as well as the system processability, particularly viscosity, by means of the mixing apparatus. Excessive amounts of water lead to undesirably dilute AGES products. Low water content results in high viscosity, low thermal capacity, and poor control on temperature. For AGES with an alkyl chain in the C 12  range an overall water content of 50% or more is suggested for the sodium salt. The greater solubility of potassium sulfite and potassium salts of AGES allows somewhat higher solid levels to be about 60% employed. 
     Another route to AGES mentioned in the Whyte article is sulfonating a terminal glycidate epoxy ether of the desired structure with a mixture of sulfite and bisulfite salt as shown below. ##STR2## 
     An even higher solids content can be achieved in this sulfonation reaction of the epoxide according to the review article. However the review article states that difficulties in temperature control and excessive product viscosities make it undesirable to achieve these higher solid levels. In fact high temperatures are used to initiate the sulfonation of the epoxide with the sulfite-bisulfite mixture, 300° F. or less. The lowest temperature used for initiation of the sulfonation of the epoxy in Whyte U.S. Pat. No. 2,989,547 is 275° F., Example 6. In each of the examples in this patent, the continuing reaction is carried out at a significantly higher temperature than the initiation temperature. 
     Alkoxylated alkyl glyceryl ether sulfonates, hereinafter referred to as NEGS, have been known for many years as well and are disclosed to be useful in secondary recovery processes for increasing production in oil wells. The difference between AGES and NEGS is the presence of one or more alkoxy groups between the last carbon atom of the alkyl group and the oxygen atom of AGES. NEGS is depicted below as the ethoxylated sodium salt, 
     
         R(OCH.sub.2 CH.sub.2).sub.n OCH.sub.2 CHOH CH.sub.2 SO.sub.3.sup.- Na.sup.+(FIG. 2) 
    
     n is an average value of one or more. 
     R is an alkyl or alkenyl group 
     The synthesis of AGES outlined above involves functional group transformation, the conversion of an epoxide to a hydroxy sulfonate. Since the same functional group transformation occurs in the preparation of NEGS, the advantages and disadvantages occurring in the AGES synthesis outlined above would also be expected in a NEGS synthesis using the same process. 
     Surprisingly this does not occur to the extent expected. Rather, several significant advantages occur when the ethoxylated alkyl terminal epoxy is reacted preferably with a mixture of sulfite-bisulfite salt. 
     Firstly, the reaction can be carried out at room temperature or elevated temperature below 100° C., the boiling point of water, without the use of elevated pressure. This brings about lower processing costs and allows the surfactant to be made in the same type of &#34;kettle&#34; or &#34;crutcher&#34; like equipment in which a personal cleansing composition can be prepared. For the synthesis of AGES, a substantially elevated temperature, below about 300° F., is used to initiate the sulfonation conversion of the glycidate to the hydroxy sulfonate structure via the sulfite-bisulfite reaction. However this present conversion of the NEGS glycidate is initiated and proceeds to completion at temperatures which are at or below the boiling point of water. In fact, even though the reaction is exothermic, the reaction temperature can be maintained at or below about 110° C., preferably at or below 100° C. Such lower temperatures eliminates the need for pressure reactors or the addition of water. 
     Secondly, when converting the glycidate of AGES with alkali metal sulfite-bisulfite, the viscosity increases as the percent solids of products increases according to the cautionary statements of the Whyte article. However, when preparing NEGS from a terminal glycidate (epoxy) starting material the viscosity of the reaction mass measured at completion of the reaction, greater than about 50 wt % to about 75 wt % solids content remains essentially unchanged or is reduced from the viscosity at or about 50 wt %. This is an important factor in allowing preparation of a higher percentage NEGS product in water. Such a high solids content provides major advantages in handling, cost savings in transport, and processing the NEGS through adequate mixing into a cleansing composition. 
     Thirdly, the sodium salt(s) of a sulfite-bisulfite mixture can be employed and still see the higher solids, processable composition. Such higher solids content was previously thought to be achievable or potentially achievable only through the use of the potassium salt according to the review article. However potassium salts of a surfactant brings about a much softer and difficult to process solid personal cleansing composition than a sodium salt composition. 
     Fourthly, a catalytic quantity of an emulsifying agent, in the NEGS reaction brings about a shorter induction time and shortened total reaction time than the similar or same agent employed in a comparable AGES reaction. 
     SUMMARY OF THE INVENTION 
     In accordance with the invention, there is a process for preparing an alkoxylated alkyl glyceryl ether sulfonate which comprises reacting in the presence of water and the absence of ethanol a mixture of an alkali metal sulfite and bisulfite with a mixture of alkoxylated glycidyl ethers comprising a major quantity of ##STR3## at a temperature at or below about 110° C. wherein R is an alkyl or alkenyl of 10 to 20 carbon atoms, inclusive, R&#39; is hydrogen or methyl and has an average value of 1 to 10 and obtaining the sulfonated alkoxylated product comprising a major quantity of: ##STR4## 
     DETAILED DESCRIPTION OF THE INVENTION 
     The preparation of a salt of an alkoxylated, preferably ethoxy, alkyl glyceryl ether sulfonate from a terminal glycidate (epoxy) starting material by the use of a sulfite bisulfite salt mixture proceeds smoothly, economically and with significant advantages over the preparation of AGES from the comparable terminal glycidate starting material. The NEGS can be prepared in a high solids concentration at a lower temperature over a shorter time period and with a shorter induction period than AGES. 
     In the terminal glycidate starting material and product above, R&#39; is preferably hydrogen, n is preferably 1 to 4, more preferably 1 to 2, and R is preferably 12 to 15 carbon atoms, inclusive and is preferably normal than branched. AIkyl is preferred. The major portion of the alkoxylated starting material is that shown in FIG. 3. However, there are minor portions of &#34;dimer&#34; as shown below: ##STR5## wherein R, R&#39; and n are as previously defined and X is halo, preferably chloro or hydroxy. This material is sulfonated as well and is part of the alkoxylated sulfonated product. Trimeric and small quantities of tetrameric materials similar to that shown in U.S. Pat. No. 3,024,273 can also be present and sulfonated. The chlorohydrin analgous materials are shown in U.S. Pat. No. 2,989,547. 
     It should also be noted that when the average value of n is low, for example 1 or 2, there can be a significant amount of non alkoxylated starting material which will provide non alkoxylated sulfonated product. 
     The reaction is performed in the presence of water. The presence of any solvent other than water, particularly an organic solvent is not preferred. Further purification steps would be necessary and such substance, for example, ethanol, would interfere with the end surfactant use. Ethanol is a known lather depressant. 
     The temperature at which the sulfonation reaction of the glycidate occurs is at a temperature at or below 100° C., the boiling point of water. Temperatures can be as low as room temperature, if desired, however, the uncatalyzed reaction is quite slow at that point. Generally, a temperature range of about 50° to 99° C., preferably about 75° to 95° C. brings about a well-controlled, speedy reaction for maximum yields in a minimum amount of time. 
     Temperatures as high as 110° C. can be employed, particularly if the water amount is to be reduced somewhat. In Whyte U.S. Pat. No. 2,989,547 the temperature used to promote the sulfonation of the AGES glycidate was disclosed to be about 149° C. (300° F.) in general. The lowest temperature for initiation of the reaction was reported to be 135° C. (275° F.); see Example 6, column 7. After the induction of reaction, the temperature always increased due to the exothermic nature of the reaction. The preparation of NEGS is also exothermic but temperatures can be easily maintained at or below 110° C., preferably at or below 100° C. 
     The sulfonating agent employed is a sulfite salt, bisulfite salt or a mixture of sulfite and bisulfite salts. The sulfite salt present is from about 0.1 to 35 wt %, the remainder being bisulfite, preferably about 15 to 30 wt % of the sulfite. The cation of the salt is any alkali metal which brings about water solubility for the sulfite-bisulfite mixture. Examples of such cations are sodium and potassium. An excess of the salt is preferably used in the reaction. Potassium sulfite-bisulfite salts are more soluble in an aqueous media than the sodium salts according to the Whyte review article. However, the potassium salts of a surfactant, in this case the ethoxylated alkyl glyceryl ether sulfonate, when used in a solid cleansing composition, poses a severe challenge in processing and causes the bar to be soft. The sodium salt is preferred. 
     Still further, it has been surprisingly found that very high solids content of sulfonated product in water can be achieved. The viscosity of a sulfonated product reaction mass increases as the reaction progresses and more sulfonated product is produced. However this viscosity increase surprisingly levels off or goes down at a certain sulfonated product content. For example, when n equal an average value 1, that certain solids content is about 50%. The term &#34;sulfonated product&#34; in this instance refers to any molecule which is sulfonated and thereby includes the sulfonated glycidyl ether of FIG. 3, the sulfonated &#34;dimer&#34; previously alluded to above as well as the small quantities of trimer and tetramet present. It also includes the sulfonated material wherein there are no alkoxy groups. Although the maximum point wherein viscosity of the reaction mass will significantly increase once more can vary, generally a quantity of sulfonated product of about 73-75 wt %, preferably about 70 wt % or above 65 wt % is where the viscosity can begin to significantly rise above the point where it began to fall or level off. A preferred range is above 50 to about 70 wt % of sulfonated product. Such a high solid content but still workable reaction mass provides major advantage in handling, cost savings in transport, and processing the sulfonated product into cleansing composition, particularly personal care cleansing composition. Processability (stirrability) of the reaction mass and proper control of the exothermic reaction is readily maintained. 
     As noted in the Whyte review article relating to the synthesis of AGES, above 60% solids content can be achieved with potassium salt but difficulties in temperature control and excessive product viscosities make it undesirable to achieve these higher solids levels. Such product solids content levels are achieved with this invention while maintaining readily processable reaction viscosities and good temperature control. These high solids contents are obtained while using the sodium salt of the sulfite-bisulfite mixture. 
     Although the rates of the reaction are generally satisfactory, the presence of a catalyst to overcome or shorten the initial induction period is preferred. It has been found that a material that brings about an emulsification of the aqueous phase of the salt and the organic phase of the glycidate (epoxy) starting materials substantially shortens the overall time period of the synthesis and the induction period as well. In fact, surprisingly an uncatalyzed NEGS synthesis proceeds to completion at a faster rate than a NEGS catalyzed AGES synthesis. Interestingly AGES synthesis catalyzed by NEGS proceeds faster than an AGES synthesis catalyzed by AGES, both being slower than an uncatalyzed NEGS synthesis. Of course the catalyzed NEGS process is even faster. Any material which aids in the forming of an emulsion of the phases can be used as a catalyst. Examples of such materials include the product of the reaction or analogue (NEGS), AGES, soap, anionic surfactant such as a sulfate, sulfonate, sarcosinate and the like. Nonionic surfactants which are emulsifiers can also be employed. Quantities of the catalyst are not unduly significant and, by definition a catalytic quantity is effective. This may vary from at least 0.1 to about 15 wt % of the reaction mass, preferably about 1-5 wt %. Even more emulsifier can be used at the start of the reaction. The exact amount of emulsifying agent will be a compromise between reaction rate and quantity of product desired from the batch reaction. 
     A further benefit of the mild conditions of this process is that the NEGS can be synthesized in the same equipment that personal cleansing compositions are prepared. A simple crutcher or kettle can be employed as the reaction vessel. Readily available steam can be employed as the heating medium. Thereafter the usual soap making procedures can be followed for making a liquid or solid cleansing composition containing NEGS. As stated previously the use of the sodium salts allows the preparation of a solid cleansing composition. Additional surfactants can be added to the cleansing composition preparation process such as soap, anionic, nonionics, zwitterionics, amphoterics and the like. 
     Below are examples and data of the invention and comparative examples showing the advantages of the inventive process and composition. These examples are intended to exemplify the broad inventive concept and not limit such concept. 
     In these examples, the glycidate employed is a mixture of glycidates wherein the major portion of the alkoxylated glycidate is of the structure FIG. 3 wherein R is alkyl of fourteen to fifteen carbons. R&#39; is hydrogen and n has an average value of 1. These materials are sulfonated and make up the &#34;sulfonated product&#34;. The percent &#34;sulfonated product&#34; is the solids content. After synthesis was complete, a 0.4g sample of acid mixture was accurately weighed in a 100 ml beaker and dissolved in deionized water. The solution was transferred to a volumetric flask and made up to 100 ml with deionized water. An aliquot (10 ml) of this solution was mixed with 25 ml of methylene blue indicator and 15 ml of chloroform in a 100 ml glass stoppered mixing cylinder. The mixture was titrated with Benzethonium Chloride solution (Hyamine 1622) while using vigorous agitation. The end point was reached when the aqueous layer was more blue than the organic layer (upon the addition of a 0.05 ml increment). The sample size was apportioned such that 6-14 ml of 0.004842N Benzethonium Chloride solution was required for the titration. 
     Sulfonated product solids content in the samples were calculated using the following equation: ##EQU1## 
     An additional benefit of the reaction is that the amount of &#34;free oil&#34;, nonionic material, at the end of the reaction is quite low. 
    
    
     EXAMPLE 1 
     Synthesis of NEGS wherein n is an average value of one, R&#39; is hydrogen, and R is normal alkyl of fourteen or fifteen carbon atoms (approx. 3% NEGS catalyst). 
     A mixture of sodium sulfite (14.4 g, 0.114 moles) and sodium bisulfite (35.68 g. 0.243 moles) was dissolved in 72.5 gms of distilled water in a thick walled glass reactor equipped with a water cooled condenser. To the above solution glycidate (epoxy) (157.1 g, 0.42 moles) was added. An anionic surfactant, alkylethoxylatedglycerylethersulfonate, having the same values of R and n as the glycidate (30 g, 33% active ingredient, moisture 58.4%, approx. 3wt %) was added as the catalyst to intitiate the reaction. The reaction mixture was heated to 95° C., 1 atm. pressure and stirred at 200-300 rpm. The reaction was monitored along its course by the earlier identified titration method. Under these reaction conditions, it took 4 hours for the completion of the reaction, and 95% of the glycidate was converted to the sodium salt of sulfonated product (NEGS). 
     Analysis: % sulfonated products 62.3,% Moisture 29 and % free oil 9.4 (based on 100% sulfonated product) 
     EXAMPLE 2 
     Synthesis of NEGS (Uncatalyzed) 
     Sodium sulfite (14.4 g, 0.114 moles), sedium bisfulfite (35.7 g, 0.343 moles) glycidate identified in Example 1 (157.0 g, 0.424 moles) and 90 g of distilled water were weighed and added to the reaction. The same procedure as mentioned above in Example 1 was used except no NEGS catalyst was used. It took more than 6 hours for the completion of the reaction and 93% of the glycidate was converted to sulfonated product. 
     Analysis: % sulfonated product 59.7, % moisture 30 and % free oil 9.98 (based on 100% sulfonated product) 
     Comparative Example 1 
     Synthesis of AGES (Product Solids, Approx. 3% NEGS Catalyst) 
     Sodium sulfite (14.4 g, 0.114 moles), sodium bisulfite (35.7 g, 0.343 moles) were dissolved in 72.2 g of distilled water. Nonethoxylated Glycidate (with an alkyl chain of 14 and 15 carbon atoms (137.3 g, 0.425 moles) was added. NEGS as defined in Example 1 (32.3 g, %A1 33.3,% moisture 58.4, approx. 3% by weight) was added as the catalyst. The reaction rate was substantially slower than the catalyzed NEGS reaction of Example 1. It took 7 hours for the reaction to complete, and 95% of the glycidate was converted to sulfonated product, primarily alkylglycerylethersulfonate (AGES). 
     Analysis: % sulfonated product 59, moisture 31% and % free oil 9.2 (based on 100% sulfonated product). 
     Comparative Example 2 
     Synthesis of AGES (Uncatalyzed) 
     Sodium sulfite (14.4 g, 0.114 moles), sodium bisulfite (35.7 g, 0.343 moles) were dissolved in 90.9 g of distilled water and glycidate as in comparative Example 1 (137.3g, 0.125 mole) was added. The same procedure as described in Example 1 was used. The reaction was very slow and in 7 hours only 2% of the glycidate was converted into AGES. 
     Analysis: % sulfonated product 2.02, % moisture 32 and free oil 65.9% (based on 100% sulfonated product). 
     EXAMPLE 3 
     NEGS (3% Soap 85/15 Tallow/Coco as Catalyst) 
     Sodium sulfite (14.4 g, 0.114 moles), sodium bisulfite (35.7 g, 0.343 moles) were dissolved in 85.5 g of distilled water. Glycidate of example 1(157 g, 0.424 moles) was added. Soap (85/15, tallow/coco; moisture 30%, approx. 3% by weight) was added as the catalyst. The reaction was faster than the uncatalyzed NEGS reaction; however it was slower than the NEGS catalyzed reaction. After 7 hours, 86.2% of the glycidate was converted to sulfonated product. 
     Analysis: % sulfonated product 53.5 and % moisture 29. 
     The results are summarized in the Table below. 
     
         ______________________________________                      Reaction % Glycidate             3%       Time,    ConvertedExample  Product    Catalyst Hours    to Product______________________________________1      NEGS       Yes      4        952      NEGS       No        6+      93Comp 1 AGES       Yes      7        95Comp 2 AGES       No       7         2______________________________________ 
    
     The superiority of the process for preparing NEGS over the same process parameters in preparing AGES is clear. Even the uncatalyzed NEGS reaction is faster than the catalyzed AGES reaction. 
     EXAMPLE 4 
     Various NEGS reactions were carried out to provide differing concentrations of sulfonated product in the reaction mass. This concentration of sulfonated product is also referred to as percent solids content. At the completion of the reaction the sulfonated product (% solid content) was assayed and the viscosity of the reaction mass measured on a Carrimed Rheometer by TA Instrument. The viscosity was measured at various shear rates, the shear rates being varied by the Rheometer. Below are the results. 
     
         ______________________________________Solids Content %        Shear Rate, sec.sup.-1                       Viscosity, Pa · s.______________________________________33           22.76          5.3344           23.17          11.2850           23.19          13.9865           24.49          6.5533           43.85          3.6444           43.99          7.9750           44.17          8.3365           43.47          4.9433           74.21          2.4844           69.83          3.7350           71.60          5.3665           72.56          4.94______________________________________ 
    
     This data shows that as the solids content increases at the same shear rate, the viscosity increases until about 50%; thereafter, up to at least 65% solids content, the viscosity is reduced or at least levels off.