A method of producing a polyether polyol that includes reacting a low molecular weight initiator with one or more monomers in the presence of a polymerization catalyst, the low molecular weight initiator having a number average molecular weight of less than 1,000 g/mol and a nominal hydroxyl functionality at least 2, the one or more monomers including at least one selected from propylene oxide and butylene oxide, and the polymerization catalyst being a Lewis acid catalyst having the general formula M(R.sup.1).sub.1(R.sup.2).sub.1(R.sup.3).sub.1(R.sup.4).sub.0 or 1. Whereas, M is boron, aluminum, indium, bismuth or erbium, R.sup.1, R.sup.2, and R.sup.3 each includes a same fluoroalkyl-substituted phenyl group, and optional R.sup.4 includes a functional group or functional polymer group. The method further includes forming a polyether polyol having a number average molecular weight of greater than the number average molecular weight of the low molecular weight initiator in the presence of the Lewis acid catalyst.

A process for transitioning a reactor from base-catalyzed polyol production to double metal cyanide (DMC)-catalyzed polyol production is described. The process includes discharging a base-catalyzed and un-neutralized product mixture from a reactor, and adding an acidified polyether polyol starter and DMC catalyst mixture to the reactor. A DMC-catalyzed polyol production reaction can then be conducted in the reactor without intermediate washing or rinsing of the reactor, and without catalyst deactivation from base or alkaline hold-up.

A method of producing a polyether polyol that includes reacting a low molecular weight initiator with ethylene oxide in the presence of a polymerization catalyst, the low molecular weight initiator having a number average molecular weight of less than 1,000 g/mol and a nominal hydroxyl functionality at least 2, and the polymerization catalyst being a Lewis acid catalyst having the general formula M(R.sup.1)1(R.sup.2)1(R.sup.3)1(R.sup.4)0 or 1. Whereas, M is boron, aluminum, indium, bismuth or erbium, R.sup.1, R.sup.2, and R.sup.3 each includes a same fluoroalkyl-substituted phenyl group, and optional R.sup.4 includes a functional group or functional polymer group. R.sup.1, R.sup.2, and R.sup.3 are the same fluoroalkyl-substituted phenyl group. The method further includes forming a polyether polyol having a number average molecular weight of greater than the number average molecular weight of the low molecular weight initiator in the presence of the Lewis acid catalyst.

A method of producing an alcohol ethoxylate surfactant or lubricant includes reacting a low molecular weight initiator with ethylene oxide in the presence of a polymerization catalyst, the low molecular weight initiator having a nominal hydroxyl functionality at least 1, and the polymerization catalyst being a Lewis acid catalyst having the general formula M(R.sup.1)1(R.sup.2)1(R.sup.3)1(R.sup.4).sub.0 or 1, whereas M is boron, aluminum, indium, bismuth or erbium, R.sup.1, R.sup.2 and R.sup.3 each includes a same fluoroalkyl-substituted phenyl group, and optional R.sup.4 includes a functional group or functional polymer group. R.sup.1, R.sup.2, and R.sup.3 are the same fluoroalkyl-substituted phenyl group. The method further includes forming the alcohol ethoxylate surfactant or lubricant having a number average molecular weight of greater than the number average molecular weight of the low molecular weight initiator in the presence of the Lewis acid catalyst.

A method of producing a polyether polyol that includes reacting a low molecular weight initiator with ethylene oxide in the presence of a polymerization catalyst, the low molecular weight initiator having a number average molecular weight of less than 1,000 g/mol and a nominal hydroxyl functionality at least 2, and the polymerization catalyst being a Lewis acid catalyst having the general formula M(R.sup.1)1(R.sup.2)1(R.sup.3)1(R.sup.4)0 or 1. Whereas, M is boron, aluminum, indium, bismuth or erbium, R.sup.1, R.sup.2, and R.sup.3 each includes a same fluoroalkyl-substituted phenyl group, and optional R.sup.4 includes a functional group or functional polymer group. R.sup.1, R.sup.2, and R.sup.3 are the same fluoroalkyl-substituted phenyl group. The method further includes forming a polyether polyol having a number average molecular weight of greater than the number average molecular weight of the low molecular weight initiator in the presence of the Lewis acid catalyst.

A method of producing a polyether polyol that includes reacting a low molecular weight initiator with one or more monomers in the presence of a polymerization catalyst, the low molecular weight initiator having a number average molecular weight of less than 1,000 g/mol and a nominal hydroxyl functionality at least 2, the one or more monomers including at least one selected from propylene oxide and butylene oxide, and the polymerization catalyst being a Lewis acid catalyst having the general formula M(R.sup.1)1(R.sup.2)1(R.sup.3)1(R.sup.4)0 or 1. Whereas, M is boron, aluminum, indium, bismuth or erbium, R.sup.1, R.sup.2, and R3 each includes a same fluoroalkyl-substituted phenyl group, and optional R.sup.4 includes a functional group or functional polymer group. The method further includes forming a polyether polyol having a number average molecular weight of greater than the number average molecular weight of the low molecular weight initiator in the presence of the Lewis acid catalyst.

A method of producing an alcohol ethoxylate surfactant or lubricant includes reacting a low molecular weight initiator with ethylene oxide in the presence of a polymerization catalyst, the low molecular weight initiator having a nominal hydroxyl functionality at least 1, and the polymerization catalyst being a Lewis acid catalyst having the general formula M(R.sup.1)1(R.sup.2)1(R.sup.3)1(R.sup.4).sub.0 or 1, whereas M is boron, aluminum, indium, bismuth or erbium, R.sup.1, R.sup.2 and R.sup.3 each includes a same fluoroalkyl-substituted phenyl group, and optional R.sup.4 includes a functional group or functional polymer group. R.sup.1, R.sup.2, and R.sup.3 are the same fluoroalkyl-substituted phenyl group. The method further includes forming the alcohol ethoxylate surfactant or lubricant having a number average molecular weight of greater than the number average molecular weight of the low molecular weight initiator in the presence of the Lewis acid catalyst.

A process for transitioning a reactor from base-catalyzed polyol production to double metal cyanide (DMC)-catalyzed polyol production is described. The process includes discharging a base-catalyzed and un-neutralized product mixture from a reactor, and adding an acidified polyether polyol starter and DMC catalyst mixture to the reactor. A DMC-catalyzed polyol production reaction can then be conducted in the reactor without intermediate washing or rinsing of the reactor, and without catalyst deactivation from base or alkaline hold-up.