30-07-15

 sodium and potassium salts of the long chain

carboxylic acid.
 A soap molecule consists of a long
hydrocarbon chain (composed of carbons and
hydrogens) with a carboxylic acid on one end
which is ionic bonded to metal ion usually a
sodium or potassium.
 Large non-ionic hydrocarbon group and an
ionic group COO-Na+.
 Sodium stearate (Chemical formula:
C17H35COO-Na+)
 Sodium palmitate (Chemical formula:
C15H31COO-Na+)
 Sodium oleate (Chemical formula:
C17H33COO-Na+)
 The process of making soap by the hydrolysis
of fats and oils with alkalies is called
saponification.
 Soap is made by heating animal fats or
vegetable oil with concentrated sodium
hydroxide (NAOH).
 Fat or Oil + NaOH → Soap + Glycerol
Glyceryl tripalmitate Glycerol 3 sodium palmitate
(tripalmitin) (soap)
  A soap molecule has two ends with
different properties-
1. A long hydrocarbon part which is
hydrophobic (i.e. it dissolves in
hydrocarbon).
2. A short ionic part containing COO-
Na+ which is hydrophilic (i.e. it
dissolves in water).

micelle
 When a dirty cloth is put is put in water
containing soap than the hydrocarbon
ends of the soap molecule in the micelle
attach to the oil or grease particles
present on the surface of dirty cloth. In
this way the soap micelles entraps the
oily particles by using the hydrocarbon
ends. The ionic ends of the soap
molecules remain attached to the water
when the dirty cloth is agitated in soap
solution. The oily particles presents on
its surface gets dispersed in the water
due to which the cloth gets clean.
 ADVANTAGES DISADVANTAGES
 Soaps are eco-friendly  Soaps are not suitable
and bio degradable in the hard water.
 They have weak
cleansing properties
than detergents.
DETERGENTS
 Detergents are the sodium salts of long chain
benzene sulphuric acids.
 Detergents are primarily surfactants, which
could be produced easily from
petrochemicals.
 Surfactants lower the surface tension of
water, essentially making it 'wetter' so that it
is less likely to stick to itself and more likely to
interact with oil and grease.
 The ionic group in a detergent is
 Two basic examples of well-known detergents of the
sulphonate group or the sulphate group are:
 Detergent molecule having two parts at each end i.e., one large non-
polar hydrocarbon group that is water repelling (hydrophobic) and
one short ionic group usually containing the or group that is water
attracting (hydrophilic).

 Thus the cleansing action is exactly similar to that of soaps whereby

the formation of micelles followed by emulsification occurs.
However, synthetic detergents can lather well even in hard water.

 This is because they are soluble sodium or potassium salts of

sulphonic acid or alkyl hydrogen sulphate and similarly form soluble
calcium or magnesium salts on reacting with the calcium ions or
magnesium ions present in water.

 This is a major advantage of the cleansing property of detergents

over soap.
 Since detergents are the salts of strong acids they do
not decompose in acidic medium. Thus detergents
can effectively clean fabric even if the water is acidic.
 Synthetic detergents are more soluble in water than
soaps.
 They have a stronger cleansing action than soaps.
 As detergents are derived from petroleum they save
on natural vegetable oils, which are important as
essential cooking medium
 Many detergents are resistant to the action of
biological agents and thus are not biodegradable.
Their elimination from municipal wastewaters by the
usual treatments is a problem.
 They have a tendency to produce stable foams in
rivers that extend over several hundred meters of the
river water. This is due to the effects of surfactants
used in their preparation. Thus they pose a danger to
aquatic life.
 They tend to inhibit oxidation of organic substances
present in wastewaters because they form a sort of
envelope around them.
 SOAPS
 They are metal salts of
long chain higher fatty
acids.
 These are prepared from
vegetable oils and animal
fats.
 They cannot be used
effectively in hard water as
they produce scum i.e.,
insoluble precipitates of
Ca2+, Mg2+, Fe2+ etc.
 DETERGENTS
 These are sodium salts of
long chain hydrocarbons
like alkyl sulphates or
alkyl benzene sulphonates.
 They are prepared from
hydrocarbons of petroleum
or coal.
 These do not produce
insoluble precipitates in
hard water. They are
effective in soft, hard or
salt water.
•Insoap making palm oil, coconut oil, caster oil,neem oil, kernel oil, ground
nut oil, ricebran oil and animal fat especially tallow are used.

•Fatty acid present in tallow are mysteric acid, palmitic acid, stearic acid,
oleic acid, linoleic acid whereas the coconut oil contains lauric acid, mysteric
acid, palmitic acid, stearic acid.

•Different oils produce soaps of varying hardness, odour and lathering

properties.

• Normally 75-85% tallow and 15-25 % coconut oil is used in soap making.

•C12 and C14 soaps lather quickly but they produce an unstable, coarse
bubble foam while C16 and C18 lather slowly but lead to stable, fine bubble
foamed.

•For saponification caustic lye (50% caustic soda) is used.

•Some of the other ingredient in soap are talc as filler which also act as carrier
for perfume, fragrance. sodium silicate to give firmness to the soap, sodium
carbonate help dyes to impart color.
• Batch process.
• In a saponification vessel gradual addition to fats of just the right quantity of
soda lye to ensure complete saponification.
•The mixture is kept under vigorous agitation for approximately 2 hours.

•Dyes, perfumes and additives are generally added at this stage.

• Does not include the removal of impurities or separation of the glycerine .

•The process is simple, inexpensive and not highly mechanised.

•Low grade soap is produced.

•saponification mixture is heated to 70 - 90° C using a steam-heated coil to
accelerate and complete the saponification reaction.
•Dyes, perfumes, and additives are added at the end of the process to
prevent them from evaporating.

•better
incorporation of the additives and a wider choice of raw materials.
•Generally speaking, saponification is more complete.

•
•Thefull boiled process have various glycerine extraction, washing, and
adjustment operations which occur after saponification.

•Reaction
mixture kept agitated at (100°C), allowing a wider range of fatty
raw materials to be used.

•After saponification the mass is subjected to several washes using brine.

•Byrecycling the washing waters drawn off several times, glycerine

concentrations in the region of 15 to 20% can be obtained.

•The electrolyte (soda lye) concentration is then adjusted.

•after
maturation, an upper phase made up of neat soap* and a lower
phase made up of nigre form.
Neat Soap
comprising approximately 3/4 of the mixture, contains ± 30% water and has a
fatty acid content of approximately 63%.
Nigre
comprising approximately 1/4 of the mixture, contains ± 60% water and has a
fatty acid content of approximately 35%.

•Neat
soap, retained mainly for the manufacture of high-quality toilet soap, is
drawn off and moved to the drying and finishing line.

•Thebasic process may be modified somewhat to ensure that it meets the

producers' objectives.

•The use of a set of 3 to 6 tanks for enriching the washing water with glycerine,
or of the counter-current washing technique make it possible to improve
production rates.
The full cycle of operations takes nearly a week, and is broken down as
follows:
saponification
1 day
glycerine extraction
1.5 days
adjustment
1/2 day
separation of neat soap and nigre
1 .5 to. 2 days
•To maintain the correct level of activity throughout the production line, the
full boiled process requires a large number of tanks operating simultaneously.
•Large initial investment.

•Process is justified only when the marketing of large volumes of high-grade

soaps is anticipated.
•The process is highly flexible .

• wide range of soaps .

• constraints in terms of volume, investment, by-product upgrading and

technological and operational expertise.
 Blended oils and fats along with appropriate amount of
caustic lye and salt is continuously fed to the pressurized,
heated autoclave .
 Temperature 120 oC and pressure 200 kpa.
 The saponification proceeds very quickly requiring about
30 minutes or less.
 Reaction product are fed to cooling mixer where further
saponification is completed.
 The soap stream from the cooling mixer is sent to the
static separator where lye phase containing, glycerol,
caustic soda and salt are separated from the soap layer.
 The soap layer still contains glycerine which is washed in
a washing column with lye and salt solution to remove
impurities and allow further separation of glycerol.
 The soap solution is added at the bottom column while
the fresh caustic lye is added at the top for washing.
 Final separation of lye with soap is achieved in centrifuge.

 The soap from the crutcher is fed to feed tank.

 heat exchanger and then sprayed into the spray dryer for
drying.
 Removal of excess moisture from vapor and entrained
soap is achieved. Soap is separated by passing the vapor
in a cyclone.
 The dry soap is fed to noodles which is screw extruder.
The extruded soap is cut into small noodles.

 The soap from noddle silo is fed to noddles through

sigma mixer and roll mill. After milling it goes to pre
plodder, vacuum chamber and final plodder, bar cutter
and packing, wrapping and storage.