Abstract. Process Economics Program Report No. 168 NONIONIC SURFACTANTS. (March 1984)

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1 Abstract Process Economics Program Report No. 168 SRI INTERNATIONAL Menlo Park, California NONIONIC SURFACTANTS (March 1984) This report covers the technology and costs of manufacturing three types of nonionic surfactants: alcohol ethoxylates, alkylphenol ethoxylates, and fatty amine oxides. Also covered is the manufacture of alkylphenols. Alcohol ethoxylates are used In household detergents. Alkylphenol ethoxylates are used in industrial cleaning applications. Both types are manufactured by a batch process in which the alcohol or alkylphenol is reacted with ethylene oxide. Amine oxides are used as foam promoters in dishwashing detergents and shampoos. They are manufactured by the hydrobromination of a linear alpha olefin, followed by reactions with dimethylamine and hydrogen peroxide. Alkylphenols are intermediates in alkylphenol ethoxylate production. They are made by reaction of branched CB-Cl2 olefins with phenol. PEP'83 MAr

2 Report No. 168 NONIONIC SURFACTANTS by MICHAEL ARNI! E 0 I I m A private report by the March 1984 PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

3 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii

4 CONTENTS INTRODUCTION SUMMARY... 3 Alcohol and Alkylphenol Ethoxylates... 5 Alkylphenols INDUSTRY STATUS RawMaterials Operating Characteristics of Ethoxylate Producers Supply/Demand Balance End-Use Breakdown Present and Future Growth ALCOHOL AND ALKYLPHENOL ETHOXYLATES Chemistry... Ethylene Oxide Chain Distribution Alcohol Ethoxylates... Alkylphenol Ethoxylates... Physical Properties... Biodegradability... Process Review... Process Description... Process Discussion... Cost Estimates... Capital Costs... Production Costs NONYLPHENOL BY AN ION EXCHANGE CATALYZED PROCESS Chemistry Process Review Process Description Process Discussion Cost Estimates Capital Costs Production Costs iii

5 CONTENTS 6 NONYLPHENOL BY A BF3 CATALYZED PROCESS Chemistry Process Review Process Description Process Discussion Cost Estimates Capital Costs Production Costs FATTY AMINE OXIDES Chemistry Process Review Process Description Process Discussion Cost Estimates Capital Costs Production Costs CITED REFERENCES PATENT REFERENCES IV

6 ILLUSTRATIONS Primary Alcohols Product Values ,.,,.. 10 Ethylene Oxide Distribution for Dodecyl Alcohol Ethoxylate (Weibull-Nyeander Distribution) ,,,..., 32 Ethylene Oxide Adduct Distribution for Nonylphenol Ethoxylate (A Poisson Distribution)..., , Primary Biodegradation Mechanisms of Biodegradation ,, Ethoxylation FlowSheet...., h Dodecyl Alcohol Nine Mol Ethoxylate on Product Value.,.., b, Nonylphenol Nine Mol Ethoxylate on Product Value Nonylphenol by an Ion Exchange Catalyzed Process FlowSheet..* , on Product Value FlowSheet %. 131 on Product Value Hydrobromination Reactor ,., Fatty Amino Oxides FlowSheet a, on Production Cost, V

7 TABLES Summary of Ethoxylate Economics... 4 Summary of Alkylphenol Economics... 6 Summary of Amine Oxide Economics... 7 U.S. Producers of Nonylphenol U.S. Producers of Linear Alcohol Ethoxylates U.S. Ethoxylate Supply/Demand Balance U.S. Detergent Alcohol Ethoxylate Demand Ethoxylate End Uses Ethoxylates Patent Summary Ethoxylation Design Bases Alcohol Ethoxylates Major Equipment Alcohol Ethoxylates Stream Flows Alkylphenol Ethoxylates Stream Flows Alcohol Ethoxylates Total Capital Investment Alcohol Ethoxylates Production Costs Alkylphenol Ethoxylates Production Costs PatentSummary DesignBases Major Equipment Stream Flows Total Capital Investment Vii

8 TABLES Production Costs Nonylphenol by BF 3 Catalyzed Processes Patentsummary... DesignBases Major Equipment Stream Flows Nonylphenol by a BF Catalyzed Process Capital Investment a y Section Production Costs Patent Summary DesignBases... Major Equipment :..... from Alpha-Olefins Stream Flows Total Capital Investment Production Costs Viii

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