After extracting the glycerine the soap is slowly introduced into a boiling solution of sodium carbonate or soda ash and boiled until the soda has replaced the lime. This is indicated by the disappearance of the small lumps of lime soap. Caustic soda is then added to saponify the fat not converted by the lime saponification. The soap is then salted out and allowed to settle out the calcium carbonate. This drops to the bottom of the kettle as a heavy sludge entangling about 10 per cent. of the soap. A portion of this soap may be recovered by agitating the sludge with heat and water, pumping the soap off the top and filtering the remaining sludge.
While the soap thus obtained is very good, the percentage of glycerine recovered is greatly increased and the cost of alkali as carbonate is less. The disadvantages are many. Large quantities of lime are required; it is difficult to recover the soap from the lime sludge; the operations are numerous prior to the soap making proper and rather complicated apparatus is required.
The fatty acids obtained by various methods of saponification may be further improved by distillation.
In order to carry out this distillation, two methods may be pursued, first, the continuous method, whereby the fatty acids are continually distilled for five to six days, and, second, the two phase method, whereby the distillation continues for 16 to 20 hours, after which the residue is drawn off, treated with acid, and its distillate added to a fresh charge of fatty acids. The latter method is by far the best, since the advantages derived by thus proceeding more than compensate the necessity of cleaning the still. Better colored fatty acids are obtained; less unsaponifiable matter is contained therein; there is no accumulation of impurities; the amount of neutral fat is lessened because the treatment of the tar with acid causes a cleavage of the neutral fat and the candle tar or pitch obtained is harder and better and thus more valuable.
The stills are usually built of copper, which are heated by both direct fire and superheated steam. Distillation under vacuum is advisable. To begin the distilling operation, the still is first filled with dry hot fatty acids to the proper level. Superheated steam is then admitted and the condenser is first heated to prevent the freezing of the fatty acids, passing over into same. When the temperature reaches 230 deg. C. the distillation begins. At the beginning, the fatty acids flow from the condenser, an intense green color, due to the formation of copper soaps produced by the action of the fatty acids on the copper still. This color may easily be removed by treating with dilute acid to decompose the copper soaps.