A convenient procedure for the synthesis of bis-quaternary ammonium salts from long-chain alkyldimethylamines and epichlorohydrin is studied. An improved preparation of bis-quaternary ammonium salts from N, N-dimethyloctylamine, N,N-dimethyldodecylamine or N,N-dimethyloleyl-amine, their amine hydrochlorides, and epichlorohydrin can be achieved by carrying out the reaction in an aqueous micellar medium. The amine hydrochlorides are used as functional surfactants to produce the self-micellization and solubilization of reactants. The formation of micelles is a necessary condition for a successful quaternization. Comparison of the quaternization performance in ethanol, ethanol/water mixtures, and aqueous micellar medium leads to the conclusion that this micellar-improved synthesis enables easier and cheaper access to bis-quaternary ammonium salts by avoiding the formation of the mono-quaternary ammonium salts as intermediates, and by using water as solvent under mild reaction conditions. Mechanistic aspects of the quaternization reaction in micellized medium are also suggested.Paper no. S1332 in JSD 6, 231-237 (July 2003).KEY WORDS: Aqueous micellar medium, bis-quaternary ammonium salt, epichlorohydrin, functional surfactant, quaternization reaction.Bis-quaternary ammonium salts have found broad utility ranging from industrial to personal-care applications (1-6).Since they have unique aggregation abilities and better surface-active properties than single-chain surfactants of equivalent chain length (7,8), their micelle-forming properties and surfactant effects are difficult, if not impossible, to reproduce by using classical cationic surfactants (9-11). The preparation of bis-quaternary ammonium compounds today is based on three different synthetic routes: (i) reaction of long-chain tertiary amines with dihalogenated substrates, such as organic dibromides or dichlorides; (ii) reaction of N,N,N´,N´-tetramethylpolyethylenediamines with alkyl halides; and (iii) reaction of long-chain tertiary amines with a haloalkylene oxide substrate, commonly epichlorohydrin. The dihalogenated route is preferred when the organic dihalides are commercially available, whereas the alkyl halide route is chosen to prepare bis-quaternary ammonium salts with a diethylene spacer (12). The haloalkylene oxide route is also attractive because haloalkylene oxides are more reactive than dihalogenated substrates (13,14). All of these procedures involve the use of alcohols, such as ethanol, propanol, and isopropanol, or alcohol/water mixtures, as reaction medium. Today, fast and selective quaternization reactions using inexpensive solvents are especially attractive for commercial-scale production. In this connection, our primary impulse to improve the preparation of bis-quaternary ammonium salts by the epichlorohydrin route arose from the unique features of the micellar systems for alteration of rates and/or paths of reaction (15-18). Our earliest results were in agreement with this expectation (19). Aqueous micellar systems were an excellent reacti...