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WHAT IS SOAP?????
1: Defination:- Soap is a sodium salt or Potassium salt of
long chain fatty acids that has cleansing action in water.
Chemical formula of soap..
O
3 Na+ -OC (CH2)14CH3
History of soap.
the first soap makers were Babylonians, Mesopotamians,
Egyptians, as well as the ancient Greeks and Romans.
Babylonians were the first one to master the art of soap making
.
many people made soap by mixing animal fats with
lye.But today soap is produce from fats and an alkali.
Types of soap..
1 Hard soap:- this is made by reacting fat with sodium
hydroxide.
Ex. Castile soap,marseille soap, etc.
2 soft soap:-soap that is liquid or easily soluble, usually
made by saponification with potassium instead of the
more typical sodium hydroxide.
Soap??
Soap is a sodium salt of long chain fatty acid.
It contains two part: 1 polar part :- the head part of the molecule is polar. polar
molecule are water-loving (or hydrophilic).
2 non polar :-nonpolarmoleculesdo not dissolve in water
as they cannot form hydrogen bonds.
Working of soap
Soapbreaks up the oil into smaller drops, which can mix
with the water. It works becausesoapis made up of
molecules with two very different ends. One end
ofsoapmolecules love water - they are hydrophilic. The
other end ofsoapmolecues hate water - they are
hydrophobic.
Micelles
When we mix soap into the water the soap molecules
arrange themselves into tiny clusters (called 'micelles').
The water-loving (hydrophilic) part of the soap molecules
points outwards, forming the outer surface of the micelle.
The oil-loving (hydrophobic) parts group together on the
inside, where they don't come into contact with the water
at all. Micelles can trap fats in the center.
Working..
Glycerol
Glycerol has three alcohol functional group (-OH).
Formation of triglyceride:
Glycerol has three OH groups, three fatty acids must
react with one glycerol molecule to make three ester
functional groups and form triesters of glycerol or
triglyceride.
Mechanism involved:
Saponification Process:
When triglycerides in fat/oil react with aqueous NaOH
or KOH, they are converted into soap and glycerol. This
is called alkaline hydrolysis of esters. Since this reaction
leads to the formation of soap, it is called
theSaponificationprocess.
Reaction:
Type of Reaction :
The saponification reaction is exothermic in nature,
because heat is liberated during the process.
Soap is precipitated as a solid from the suspension by
adding common salt to the suspension. This process is
calledSalting out of Soap.
Soap Manufacturing
Processes and Steps
Soap-making processes
The industrial production of soap involves continuous
processes, such as continuous addition of fat and
removal of product.
Smaller-scale production involves the traditionalbatch
processes.
The three variations are: (1) Fully boiled process
(2) Hot process or semi
boiled process
(3) Cold process
The cold process and hot process (semi boiled) are the
simplest ones.
Twitchell Process
Direct Saponification
using caustic
Twitchell Process
Heating of glycerides with sulphuric acid in open lead
lined tank
Reagents: Glyceride, 30% sulphuric acid
Catalyst: 0.5 to 1% mixture of oleic or other fatty acid
and naphthalene
Product: Glycerin, fatty acid
Time taken: 6-10 hours (batch process)
Glyceride
Acid waters
Fatty acid
Washed free
of acid with
water;
refined at
very low
pressure
Direct saponification
Traditional, one step batch process.
Reaction occurs as follows:
Continuous Saponification
Process
Raw Materials
1. Caustic soda
2. Imported tallow / Vegetable oil to derive distilled
fatty acids
Quantitative Requirements
a) Basis: 1 ton of anhydrous soap
Material
Quantity
Oil or Fat
1.1 tons
50% NaOH
0.3 ton
Sodium Silicate
6 kg
Steam
1.5 tons
Chemical reactions
a) Fat Splitting
(R COO)3 C3H5 + 3H20
3R COO H + C3H5(OH)3
triglyceride
fatty acid
glycerine
b) Saponification
R COO H + M OH
fatty acid
R COO M + H 2O
soap
Advantages of continuous
process over batch process
Flexibility in control of product distribution
Higher glycerin yields (>80%)
Less off colour production during short time hydrolysis
step
Requires less space and manpower
Glycerine recovery
Glycerol is an important by-product of soap manufacture.
The process of soap manufacture from fats and oils usually yield
glycerol to about 10% of the value of the soap formed and because
of its application in many uses, its recovery is very important for
better economy of soap manufacture.
Some of the major industrial applications of glycerol include
manufacture of alkyl resins and flexible polyurethane for plastic
industry.
It is also an important ingredient of cosmetics and adhesive
manufacture.
Sweet water from wash column and lye from the static separator
containing glycerol is processed for producing glycerine.
Steps involved
The first step is the pretreatment of lye for removal of traces of
soluble soap in the lye. Ferric chloride is added to the lye to
precipitate the soluble soap as ferric soap which is separated by
filtration.
The acidic filtrate after removal of soap is acidic and contains
excess ferric chloride. This is treated with caustic soda and
ferric chloride is separated as ferric hydroxide precipitate which
is separated by filtration.
The filtrate after removal of soap is sent to evaporation section.
In multiple effect evaporator,dilute glycerine is concentrated to
52% glycerine. Some salt is separated at this stage.
Contd..
The concentrated liquor after separation of salt is
centrifuged and the concentrated glycerin is sent to
another single effect evaporator to achieve a
concentration of about 84% glycerin.
This is called crude glycerin which is further refined in
special distillation column at 140 degC and 755 mmHg.
The distillation column contains three condensers in
series from which different fraction of glycerin are
recovered which is further treated with activated carbon
to achieve the finished product.
Environmental aspects
Surfactants and the hazardous wastes and effluents that are
discharged into the water bodies such as rivers, lakes etc from these
industries can be toxic to the aquatic life.
Also, some anti-bacterial soaps contain MIT (methylisothiazolinone),
which some studies have found to be allergenic, cytotoxic and linked
to nerve cell death. Other anti-bacterial chemicals commonly used
are triclosan and tricloban. These chemicals are registered with the
Environmental Protection Agency as pesticides and can destroy
fragile aquatic ecosystems
Soaps contain a variety of chemicals and fragrances which can harm
the environment. Some chemicals used in soap fragrances have been
proven to cause birth defects and liver damage in animals.
Contd..
Storage of fuels and chemicals has an added risk of
spillage which causes soil contamination, fire hazards as
well as water pollution.
Noise and odours are generated during the
manufacturing process giving rise to noise and air
pollution respectively.
Contd..
Inside the plant, all the process and operational areas are also bounded, and the
trade waste is piped to an interception tank before draining to the council's trade
waste system.
The contents of the interception tank are consistently monitored for alkalinity or
acidity, and are designed to maintain solids or light phase chemicals in right
amount. If in the case, a spill is observed in the plant itself, a part of the
interception tank can be isolated off and the consequences of the spill neutralized
before the waste is dumped.
At times, an off-spec product can be recycled and blended rather than dumped, and
even the wastewater can be reprocessed to minimize the discharges from the plant.
In some cases, the manufacturing method itself can be closely monitored to ensure
that any losses or wastes are kept to a minimum. Consistent measurement of key
characteristics, like - electrolytic levels and the moisture both assure that the end
product is being designed to specifications and the technique is functioning
properly as it was designed to.
Other remedies
Eco-friendly/biodegradable soaps can be used to avoid the
need of harmful chemicals in its manufacturing.
The non-addition of additives, like perfumes, color and
brightening agents decreases the toxicity of soaps.
Minimal packaging also helps in reducing the harm to
environment.
Non-petroleum surfactants or vegetable oil soaps can be used
to replace synthetic surfactants.
Sodium citrate and sodium bicarbonate can be used to replace
builders like phosphates and the use of dyes and fragrances
can be reduced or eliminated.
Economics
India is the largest soap manufacturer in the world.
In 1991-92, the capacity of the units manufacturing
soaps in the organized sector had reached 500,000 tons
and the production was about 480,000 tons.
In 1993-94, the production volume for toilet soaps was
1.49 million tons and the organized sector used up 0.42
million tons.
The Eighth Five Year Plan document projected the
capacity of soaps at 600,00 tons and production at
580,000 tons in 1996-97.
Factors affecting..
During the past 2.5 years, there has been a drastic change in the
economic policies.
The convertibility of rupee and exemption of income tax on profits
from exports are two measures which increased exports.
There are two factors affecting the export of soaps.
One is that the quality of indian soaps is of international standards
and their prices are competitive leading to higher export earnings.
Secondly, there has been an increase in the production of edible
oils which has increased the growth pattern as 50% of the cost of
soaps both toilet and laundry is due to presence of oils and fats.
Capacity
Production
1989-90
435
394
1990-91
435
435
1991-92
500
480
1996-97
600
580
Population million
Soap (kg)
China
1,151
0.8
India
860
1.4
W. Europe
348
NA
Indonesia
179
2.0
Philippines
55
3.4
Thailand
57
3.4
Japan
124
8.9
Taiwan
19
6.2
Korea
43.2
3.3
Malaysia
16
3.7
Australia
16
13.2
Av. SEA
349
2.3
Toilet soap
Laundry soap
1990
330
800
1992
380
890
1994
450
930
1996
515
1,075
1998
600
1,120
2000
690
1,180
2005
975
1,425