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Sulfonation/Sulfation Processing Technology for Anionic Surfactant Manufacture 273

Fig. 5. Reactions of alfa-olefin sulfonation (adapted from de Groot, 1991)

oligomerisation of ethylene. The physical, detergency and biodegradation characteristics of
alfa-olefins are affected by the carbon chain length distribution and therefore each new
supply may require testing to determine whether the desired properties for the new chosen
application can be achieved. The Lion Corporation, Japan, is one of the principal producers
and users of alfa-olefin sulfonates. In addition to fabric washing powders, they also market
fabric washing liquid, shampoos, tooth paste and foam bath products containing this active.
In the USA, Minnetonka has utilized AOS in hand cleaners/liquid soaps. AOS is a potential
replacement for alkyl benzene sulfonates in dish wash detergent liquids formulations with
performance peaking at C 16 chain length (de Groot., 1991).

2.5 Fatty acid methyl esters sulfonates (FAMES)
FAMES are called to be the main feedstock for detergent formulating in the future due to
their applicability in detergent formulations (Ingegar & Martin, 2001; Johansson & Svensson,
2001; Roberts & Garrett, 2000; Satsuki, 1998). Moreover, when it is derived from palm oil
presents special biodegradable properties that place them over the surfactants derived from
petrochemicals compounds. To date, the application of FAMES is under development in
various detergent products, and their presence on the market is still highly restricted. The
typical cut of FAMES (C 16-C 18) shows interesting surface activity (about 90% compared to
LABS), high detergent, dispersing and emulsifying power in hard water, high lime soap
dispersion and moderate foam levels. FAMES show high stability to pH and temperature
hydrolysis. Therefore, they can be easily spray dyer and/or incorporated in detergent bars.
Methyl ester sulfonates have a wide range of application and important biological
properties. As aggregated value the FAMES can be used in cosmetics, as auxiliary agents in
the production of fibers, plastics, and rubber, and in leather manufacture (Cohen et al., 2008;
de Groot, 1991; Roberts et al., 2008; Stein & Baumann, 1975).

3. Sulfonation process used for the manufacturing of anionic surfactants
Sulfonation reactions can be carried out in different configurations, either liquid-liquid
contact, or gas-liquid contact reactors, and a diversity of sulfonating reagents can be applied
for the sulfonation process, such as: Sulfuric acid, SO 3 from stabilized liquid SO 3, SO 3 from
sulfur burning and subsequent conversion of the SO 2 formed, SO 3 from boiling concentrated
oleum and chlorosulfonic acid. However some reasons why SO 3/air in gas-liquid contactor
(sulfonator) is becoming the predominant process for the manufacture of anionic surfactants
are (Foster, 1997):

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