Composition and process for preparing a phosphonate and phosphate-free automatic dishwashing powder
A method for producing phosphonate in the form of a solid or a gel is provided. The solid can be prepared by neutralizing phosphonic acid as a result of mixing a neutralization composition comprising phosphonic acid and a source of alkalinity to provide phosphonate in a solid form without a step of drying. The gel can be prepared by neutralizing phosphonic acid as a result of mixing a neutralization composition comprising phosphonic acid, a source of alkalinity, and silicate to provide phosphonate in a phosphonate composition in the form of a gel. Methods for producing detergent compositions and detergent compositions are provided.
1 . A method for producing phosphonate for use in a cleaning composition, the method comprising:
(a) neutralizing phosphonic acid as a result of mixing a neutralization composition comprising the phosphonic acid and a source of alkalinity to provide phosphonate in a solid phosphonate composition without a step of drying.
2 . A method for producing phosphonate according to claim 1 , wherein the phosphonate comprises at least one of amino trimethylene phosphonate; hydroxyethylidene 1,1-diphosphonate; hexamethylene diamine tetra methylene phosphonate; diethylene triamine pentamethylene phosphonate; aminotrimethylene phosphonate; bishexamethylene triamine pentamethylene phosphonate; phosphonobutane tricarboxylate; or mixtures thereof.
3 . A method for producing phosphonate according to claim 1 , wherein the phosphonic acid comprises at least one of amino trimethylene phosphonic acid; hydroxyethylidene-1,1-diphosphonic acid; hexamethylene diamine tetra methylene phosphonic acid; diethylene triamine pentamethylene phosphonic acid; bishexamethylene triamine pentamethylene phosphonic acid; 2-phosphonobutane-1,2,4-tricarboxylic acid; phosphonomethyliminobis[2,1-ethandiyll nitrilobis(methylene)]tetrakis phosphonic acid; 2-hydroxyethyliminobis(methylenephosphonic acid) HOCH 2 CH 2 N[CH 2 PO(OH) 2 ] 2 ; or mixtures thereof.
4 . A method for producing phosphonate according to claim 1 , wherein the source of alkalinity comprises at least one of carbonate, bicarbonate, percarbonate, amine, ammonium salt, polymeric alkaline source, polyamine, copolymer of polyamine, alkaline silicate, borate, perborate, or mixtures thereof.
5 . A method for producing phosphonate according to claim 1 , wherein the molar ratio of the source of alkalinity to the phosphonic acid is about 10:1 to about 0.5:1.
6 . A method for producing phosphonate according to claim 1 , wherein the molar ratio of the source of alkalinity to the phosphonic acid is about 5:1 to about 1:1.
7 . A method for producing phosphonate according to claim 1 , wherein the molar ratio of the source of alkalinity to the phosphonic acid is about 3:1 to about 1.5:1.
8 . A method for producing phosphonate according to claim 1 , wherein the neutralization composition comprises water in an amount of about 5 wt. % to about 70 wt. %.
9 . A method for producing phosphonate according to claim 1 , wherein the composition comprises water in an amount of about 10 wt. % and about 60 wt. %.
10 . A method for producing phosphonate according to claim 1 , wherein the composition comprises water in an amount of about 20 wt. % and about 40 wt. %.
11 . A method for producing phosphonate for use in a cleaning composition, the method comprising:
(a) neutralizing phosphonic acid as a result of mixing a neutralization composition comprising the phosphonic acid, a source of alkalinity, and silicate to provide phosphonate in a phosphonate composition provided as a gel.
12 . A method for producing phosphonate according to claim 11 , wherein the phosphonate comprises at least one of amino trimethylene phosphonate; hydroxyethylidene 1,1-diphosphonate; hexamethylene diamine tetra methylene phosphonate; diethylene triamine pentamethylene phosphonate; aminotrimethylene phosphonate; bishexamethylene triamine pentamethylene phosphonate; phosphonobutane tricarboxylate; or mixtures thereof.
13 . A method for producing phosphonate according to claim 11 , wherein the phosphonic acid comprises at least one of amino trimethylene phosphonic acid; hydroxyethylidene-1,1-diphosphonic acid; hexamethylene diamine tetra methylene phosphonic acid; diethylene triamine pentamethylene phosphonic acid; bishexamethylene triamine pentamethylene phosphonic acid; 2-phosphonobutane-1,2,4-tricarboxylic acid; phosphonomethyliminobis[2,1-ethandiyll nitrilobis(methylene)]tetrakis phosphonic acid; 2-hydroxyethyliminobis(methylenephosphonic acid) HOCH 2 CH 2 N[CH 2 PO(OH) 2 ] 2 ; or mixtures thereof.
14 . A method for producing phosphonate according to claim 11 , wherein the silicate comprises at least one of sodium silicate, potassium silicate, and mixtures of sodium silicate and potassium silicate.
15 . A method for producing phosphonate according to claim 11 , wherein the silicate has a tendency to polymerize at a pH below about 10.7.
16 . A method for producing phosphonate according to claim 11 , wherein the phosphonate composition is substantially free of non-silicate thickening agents.
17 . A method for producing phosphonate according to claim 11 , wherein the phosphonate composition has a viscosity of at least about 100 centipoise and less than about 100,000 centipoise when measured using a Brookfield RVT viscometer.
18 . A method for producing phosphonate according to claim 11 , wherein the molar ratio of the source of alkalinity to the phosphonic acid is about 10:1 to about 0.5:1.
19 . A method for producing phosphonate according to claim 11 , wherein the neutralization composition comprises water in an amount of about 5 wt. % to about 70 wt. %.
20 . A method for producing phosphonate according to claim 11 , wherein the source of alkalinity comprises at least one of carbonate, bicarbonate, percarbonate, amine, ammonium salt, polymeric alkaline source, polyamine, copolymer of polyamine, borate, perborate, and mixtures thereof.
21 . A method for producing a detergent composition, the method comprising:
(a) neutralizing phosphonic acid as a result of mixing a neutralization composition comprising the phosphonic acid and a source of alkalinity to provide phosphonate in a solid form without a step of drying; and
(b) mixing components to form the detergent composition, the components comprising:
(i) at least 10 wt. % of the phosphonate;
(ii) source of alkalinity in an amount sufficient to provide a use composition at a 1 wt. % concentration of the detergent composition having a pH of greater than 7.0; and
(iii) wherein the composition contains less than about 0.1 wt. % phosphate.
22 . A method according to claim 21 , wherein the phosphonate comprises at least one of amino trimethylene phosphonate; hydroxyethylidene 1,1-diphosphonate; hexamethylene diamine tetra methylene phosphonate; diethylene triamine pentamethylene phosphonate; aminotrimethylene phosphonate; bishexamethylene triamine pentamethylene phosphonate; phosphonobutane tricarboxylate; or mixtures thereof.
23 . A method according to claim 21 , wherein the phosphonic acid comprises at least one of amino trimethylene phosphonic acid; hydroxyethylidene-1,1-diphosphonic acid; hexamethylene diamine tetra methylene phosphonic acid; diethylene triamine pentamethylene phosphonic acid; bishexamethylene triamine pentamethylene phosphonic acid; 2-phosphonobutane-1,2,4-tricarboxylic acid; phosphonomethyliminobis[2,1-ethandiyll nitrilobis(methylene)]tetrakis phosphonic acid; 2-hydroxyethyliminobis(methylenephosphonic acid) HOCH 2 CH 2 N[CH 2 PO(OH) 2 ] 2 ; or mixtures thereof.
24 . A method according to claim 20 , wherein the phosphonate comprises a polymeric phosphonate.
25 . A method according to claim 21 , wherein the detergent composition comprises about 10 wt. % to about 90 wt. % of the phosphonate.
26 . A method according to claim 21 , wherein the detergent composition comprises about 15 wt. % to about 65 wt. % of the phosphonate.
27 . A method according to claim 21 , wherein the detergent composition comprises about 35 wt. % to about 60 wt. % hydroxyethylidene 1,1-diphosphonate; aminotrimethylene phosphonate; or mixture thereof.
28 . A method according to claim 21 , wherein the source of alkalinity comprises at least one carbonate, bicarbonate, sulfate, citrate, borate, silicate, percarbonate, perborate, amine, or mixtures thereof.
29 . A method according to claim 21 , wherein the source of alkalinity comprises polymeric amine.
30 . A method according to claim 21 , wherein the detergent composition comprises about 10 wt. % to about 70 wt. % of the source of alkalinity.
31 . A method according to claim 20 , wherein the source of alkalinity comprises an alkaline gas.
32 . A method according to claim 31 , wherein the alkaline gas comprises at least one of amine, ammonia, and mixture thereof.
33 . A method according to claim 21 , wherein the detergent composition comprises a secondary builder.
34 . A method according to claim 20 , wherein the secondary builder comprises at least one of polycarboxyamine derivative; aluminosilicate, hydroxy acid, carboxylate, aluminosilicate, alkylamine, nitriloacetate, or mixtures thereof.
35 . A method according to claim 21 , wherein the detergent composition further comprises at least one of silicate, bleach, enzyme, surfactant, glass-etch inhibitor, anti-redeposition agent, pH modifier, antimicrobial agent, sheeting agent, flow aid, corrosion inhibitor, defoamer, bleach activator, filler, dye, or fragrance.
36 . A method according to claim 21 , wherein the detergent composition is provided in the form of a powder, an agglomerate molded solid, or an extruded solid.
37 . A method according to claim 21 , further comprising:
(a) packaging within a water-soluble or water-dispersible packaging.
38 . A method for producing a detergent composition, the method comprising:
(a) neutralizing phosphonic acid as a result of mixing a neutralization composition comprising the phosphonic acid, a source of alkalinity, and silicate to provide phosphonate in a phosphonate composition provided as a gel; and
(b) mixing components to form the detergent composition, the components comprising:
(i) at least 10 wt. % of the phosphonate;
(ii) source of alkalinity in an amount sufficient to provide a use composition at a 1 wt. % concentration of the detergent composition having a pH of greater than 7.0; and
(iii) wherein the composition contains less than about 0.1 wt. % phosphate.
39 . A method according to claim 38 , wherein the detergent composition is provided in the form of a gel.
40 . A method according to claim 38 , wherein the composition has a viscosity of about 100 centipoise to about 100,000 centipoise when measured using a rotary viscometer.
41 . A method according to claim 38 , wherein the detergent composition is substantially free of a non-silicate thickening agent.
42 . A method according to claim 38 , wherein the detergent composition comprises about 2 wt. % to about 14 wt. % of the silicate.
43 . A method according to claim 38 , wherein the detergent composition comprises a secondary builder.
44 . A solid detergent composition comprising:
(a) at least about 9 wt. % phosphonate;
(b) at least about 10 wt. % source of alkalinity;
(c) at least about 0.5 wt. % surfactant; and
(d) wherein the composition is substantially free of phosphate.
45 . A solid detergent composition according to claim 44 , wherein the solid is provided in the form of a powder, an agglomerate, a tablet, a pellet, a block, or mixture thereof.
46 . A gel detergent composition comprising:
(a) at least about 3 wt. % phosphonate;
(b) at least about 2 wt. % source of alkalinity;
(c) at least about 2 wt. % silicate;
(d) at least about 0.5 wt. % surfactant; and
(e) wherein the composition is substantially free of phosphate.
47 . A gel detergent composition according to claim 46 , wherein the gel has a viscosity of about 100 centipoise to about 100,000 centipoise when measured using a Brookfield RVT viscometer.
48 . A gel detergent composition according to claim 46 , wherein the detergent composition contains no greater than 0.5 wt. % non-silicate polymer thickening agent.
49 . A gel detergent composition according to claim 46 , wherein the detergent composition contains no greater than 2 wt. % clay thickening agent.
50 . A gel detergent composition according to claim 46 , wherein the composition contains no non-silicate thickening agent.