High productivity process for alkylphenol ethoxylates

摘要

The present invention provides a process for the production of an alkylphenol ethoxylate involving charging a portion of product from a previous preparation (a "heel") or an ethoxylate to a reactor, optionally, charging from about 0.2 wt.% to an amount equal to or greater than the weight of the heel of an alkylphenol starter to the reactor, charging ethylene oxide to activate a double metal cyanide ("DMC") catalyst, adding the alkylphenol starter simultaneously with ethylene oxide for a portion of the process and continuing ethylene oxide addition following completion of the simultaneous alkylphenol starter and ethylene oxide addition. The process of the present invention provides significant improvements in cycle time and safety in producing ethoxylates which may find use in or as surfactants.