Industrial Cleaning Agent Formulation & Surfactant Selection Guide

Abstract

As the global industrial economy grows, the industrial cleaning sector is expanding rapidly. The success of industrial cleaning depends on both the process and the choice of cleaning agents. With increasing environmental regulations, selecting the right raw materials is critical. This article focuses on selecting water-based surfactants by comparing key parameters to achieve high-efficiency and eco-friendly results.

What is Industrial Cleaning?

Industrial cleaning is the process of removing physical, chemical, or biological contaminants (soil) from a substrate surface. The goal is to restore the surface to its original state.

The effectiveness of this process is influenced by three main factors:

1. Cleaning Technology

2. Cleaning Equipment

3. Cleaning Agents

Primary Cleaning Technologies

• Chemical Cleaning: This includes common methods like acid washing, alkaline washing, and solvent cleaning. These methods are cost-effective and convenient, making them a dominant force in the industry.

• Physical Cleaning: This involves high-pressure water jets, air turbulence, ultrasonic cleaning, and dry ice blasting. While highly efficient, the equipment is often expensive.

• Biological Cleaning: This uses microbial catalysis, often for textiles or pipeline cleaning. However, it is limited by the specific catalytic requirements of biological enzymes.

Classification of Cleaning Agents

Industrial cleaning agents are generally classified into three types: water-based, semi-water-based, and solvent-based. Due to environmental concerns, solvent-based agents are being phased out. Water-based agents—categorized by pH as acidic, alkaline, or neutral—are gaining significant market share.

The Shift Toward Green Chemistry

Modern cleaning agents must be eco-friendly, efficient, and economical. Key industry requirements include:

• Replacing solvents with water-based alternatives.

• Formulating products that are phosphate-free, low-nitrogen, and free of heavy metals.

• Developing concentrated formulas to reduce transportation costs.

• Ensuring effectiveness at ambient temperatures (room temperature) to save energy.

Principles of Water-Based Formulation Design

Before designing a formulation, we must classify the target contaminants. Understanding the nature of the soil determines the choice of surfactants and additives.

1. Acid/Alkali/Enzyme Soluble Contaminants: These are easily removed using specific pH-adjusted solutions.

2. Water-Soluble Contaminants: Substances like soluble salts, sugars, and starch can be dissolved through immersion or spraying.

3. Water-Dispersible Contaminants: Materials like cement, lime, and dust require mechanical force combined with wetting agents and dispersants to remain suspended in water.

4. Insoluble Soils: Oils and waxes require emulsification or saponification. Surfactants are essential here to detach the soil from the substrate and form a stable dispersion.

The Four Steps of the Cleaning Process

Most industrial soils are complex mixtures. Regardless of whether the bond is chemical or physical, a successful cleaning process follows these four critical steps:

• Dissolution: Breaking down the soluble parts of the soil.

• Wetting: Lowering surface tension to allow the cleaning solution to penetrate the soil.

• Emulsification & Dispersion: Breaking oils into small droplets and preventing solid particles from re-settling.

• Chelation: Binding metal ions to prevent interference with the cleaning action.