Patented Dec.

18, 1945 2,391,019

y

UNITED STATES PATENT OFFICE

sAPONIFICATION PROCEss
Sabine Hirsch, Minneapolis, Minn, assignor to
Cargill, Incorporated, Wilmington, Del, a cor
poration of Delaware
No Drawing. Application December 20, 1943,
serial No. 514,971
Clains, (C. 252-369)
This invention relates to processes for pro fining. The separation of the unsaponifable was
duction of Saponified products such as soaps made by first saponifying the product and then
from synthetic fatty acids produced by oxidation extracting the unsaponifiable from the result
of relatively high molecular weight hydrocar ant soap. Then the fatty acids were recovered
bons which are solid or liquid at normal temper from the soap by treatment with mineral acid
ature and pressure, and more particularly to and after being freed from unsaponifiable Sub
processes for producing saponified products from stances were further refined, either by Steam or
synthetic fatty acids obtained in accordance with vacuum distillation and by bleaching. w
my co-pending application Ser, No. 455,937 filed It is an object of this invention to provide
August 24, 1942, and Ser. No. 500,005 filed August improved methods of saponifying synthetic fatty
25, 1943. acids for production of light-colored and odorless
In my co-pending applications which are in soaps, using as a starting material Synthetic
corporated herein by reference, there are de fatty acids of high molecular weight hydrocaro
scribed processes of oxidation of relatively high bons fwhich are solid or liquid at normal temper
molecular weight hydrocarbons, liquid or Solid atures and pressures, and to
provide such in at normal temperature and pressure, wherein proved soap products.
such a hydrocarbon or hydrocarbon mixture is It is a further object of this invention to pro
heated to 80-150° C., preferably to 110-30° C., vide Saponification products of great stability.
and oxidized by blowing through it air or Oxygen It is an object of the invention to provide meth
containing gas mixture in the presence of a cata 20 ods of saponification for synthetic fatty acids, so
lyst of the type of the "siccatives,' a Small pers that they may be saponified in the manner in
centage of a persalt in emulsion of an oleaginous which the fats of the fatty acids of the Cocoanut
substance and a small percentage of moisture group are saponified, viz. cold Saponification.
which is carried into the reaction mass by the It is also an object of the invention to pro
oxygen containing gas which is blown through. 25 vide materials and methods by which difficultly
Constant stirring is obtained by mechanical Saponifiable natural fats can be made to Saponify
equipment, and after about 12 hours of Oxida more readily and in an improved manner.
tion, the reaction product has reached a Sapon Other and further objects are those inherent
ification number of about 80-200, the color of in the invention herein described, illustrated and
the product is almost white, its consistency, odor 30 claimed.
and saponification qualities are suggestive of the In carrying out the invention there is utilized
fatty acids of the cocoanut group. The So ob synthetic fatty acids which are prepared in ac
tained reaction product contains about 80% fatty cordance with my coepending applications, here
acids and the remainder is unsaponifiable mate tofore referred to, which describe the production
rial. The unsaponifiable material can easily be of fatty acids from hydrocarbons which are
separated from the fatty acids before saponifl liquid or solid at normal temperatures. For pro
cation, and after washing and filtering from the ducing fatty acids there is utilized a relatively
suspended inorganic and organic unsaponifiable high molecular weight hydrocarbon such as fuel
substances, the fatty acids are suitable for Sapon oil, lubricating oil, paraffin, crude mineral Wax,
ification. The fatty acids, as well as the organic 40 crude mineral oil or fractions thereof. To the
unsaponifiable material, are almost white, have selected starting material there is added a cata
no objectionable odor and can be used without lyst of the class of “siccatives' customarily used
any refining for processes requiring Such nate as Oxidation or polymerization catalysts with
rials. The residue of the catalytic substances paints, varnishes, and the like, for example,
can be used again for oxidation. 45 metallic salts such as zinc, manganese, cobalt,
Synthetic fatty acids produced by oxidation lead or other heavy metal, stearates, oleates,
of high molecular weight hydrocarbons by meth palmitates, linoleates and other materials as
ods prior to the methods disclosed in my appli described in my co-pending applications. The
cations mentioned above, contained a much high siccative is used in a range from 0.05% to 3.0%
er percentage of unsaponifiable material and the 5 and may be added directly to the selected start
oxidation yielded dark-colored products having ing ingredient or may be added by way of an
objectionable odors and saponification numbers emulsion, as specified. To the selected starting
much lower than 180-200. The dark color and ingredient there is also added a perSalt having
especially the objectionable odor of the prior art as a cation an alkali such as potassium, sodium
products could be corrected only by costly re 55 or the like, or ammonium, an alkaline earth such
 2,891,019
as calcium, barium or strontium, or a multivalent natural fatty acids from cocoanut oil,
metal such as magnesium, manganese, cobalt; this prop erty being that of greater stability.
iron, zinc, copper or the like. As the anion of The fatty acids so produced and recovered have a
the persalt there may be used the permanga saponification number in the neighborhood of
nates, perborates, perchlorates, perchromates, 200-220, and after being washed can easily be
persulphates and similar persalt anions. The saponified by themselves or mixed with natural
persalt ingredient is carried in an emulsion com fatty acids, fats and oils. A small percentage of
posed of water, an oleaginous substance and a unsaponifiable material still remains in the fatty
small amount of SOdium or potassium soap, or acids, but it can be left with them, because this
soap produced from my synthetic fatty acids. In O unsaponifiable material is white in color, has
the emulsion there is carried the persalt which no odor but possesses good emulsifying and anti
is used in an amount ranging from 0.05% to 3.0%, Oxidant properties.
based upon the amount of hydrocarbon starting The fatty acids are now ready for soap manu
facturing. In carrying out the saponification,
material utilized. The heavy metal soap pre
15 there is utilized alkali hydroxide or carbonate so
viously mentioned, may likewise be dissolved in the
lutions, preferably sodium or potassium hydroxide
emulsion or may be dissolved directly in the
or carbonate solution having a concentration of
hydrocarbon Starting material as desired. 15-30%, at a temperature above 20° C., but below
The hydrocarbon starting material is heated to
100° C., preferably a temperature in the range of
a temperature of 80-150° C., preferably 100-130°
C., and to it there is added the siccative and the20 20-60" C. Saponification may also be
emulsion containing the persalt, these being pref carried
erably added in several proportions throughout out under conditions and temperatures of “cold
the course of the oxidation, and a gas containing Saponification,' customarily used for the sapon
ification of cocoanut oil. When saponification of
Oxygen such as air or air enriched with oxygen
the synthetic fatty acids or mixtures containing
or oxygen diluted with an inert gas is bubbled
through the reaction mixture. The oxygen con 25 such acids is carried out utilizing sodium or po
prising gas contains a minor percentage of nois tassium carbonate, good lathering, white soaps, free
ture. During the course of the oxidation the mix from odor are obtained. Saponification with the
corresponding hydroxides when carried out in
ture is stirred and after a period of 6-24 hours
the absence of "protective agents,' hereinafter de
a relatively large percentage of the hydrocarbon
80 Scribed, yield good lathering soaps having a
material is converted to fatty acids. Thus in a
color ranging from tan to brown and having the odor
typical run after 12 hours the reaction mass con
and appearance of rosin soap. Where color and odor
tains about 80% of Saponifiable natter of the are of relatively little importance, as where
fatty acid type. An average Saponification nun the Soap is used in lubricants etc., saponification
ber of about 200 is easily obtained after 2 hours 35 with the hydroxides and in the absence of said
of oxidation. protective agents may be utilized.
When the oxidation is interrupted, the unsapon By use of appropriate protective agents, fine,
ifiable portions of the mass may conveniently
white or cream-colored soaps, free from odor may
be separated by permitting the temperature of be obtained even when utilizing alkali hydroxide.
the reaction, mass to fall gradually, whereupon the 4) Thus, the Synthetic fatty acids may be saponified
reaction mass separates into three layers, viz. an With alkali hydroxide, for example sodium or po
upper layer of unsaponifiable material, a middle taSSium hydroxide, without discoloration of the
layer of fatty acids and a Small bottom layer of resultant Soap by adding about 1-5%, preferably
the residue from the siccative and persalt ingre 2%, of a water soluble oxidizing salt, preferably
dients. The separation is done at low tempera 43 a perborate, to the melted fatty acid or fatty
ture and Without chemicals, and as a result acid-containing mixture prior to saponification,
neither the Synthetic fatty acids nor the unsa or a somewhat greater percentage of such agent
ponifiable material undergoes a charage in stric may be used after Saponification as a color cor
ture or decomposition. Both materia is remain al
most white. The residue of the catalytic mate
rective and filler. In place
of alkali perborate,
rials forms a thin, brownish layer at the bot 50 for the Water soluble oxidizing salt there may be
tom of the reaction kettle and can be easily Sep utilized an equivalent amount of alkali bisulphite,
arated. alkali peroxide or other water soluble persalt,
The fatty acid layer may conveniently be sep cus tomarily used for soap-bleaching purposes. The
arated from the unsaponifiable layer and the perborates are desirable from the standpoint of
bottom layer by permitting the temperature of
55 effectiveness, cost, and freedom from any need
the reaction mass to fall until the top layer of for after treatment, and because they produce a
unsaponifiable material solidifles. The solidifica
tion temperature of the synthetic fatty acids is
stabilizing effect on the soap.
After saponification any of the usual and well
lower than the solidification temperature of un known soap builders and fillers may be crutched into
saponifiable matter and consequently the fatty the soap, if desired, as well as any perfume
acid layer may conveniently be drained or coloring matter for tinting the soap. As ex
away, preferably through a filter. emplary filler materials there may be mentioned
The separated fatty acids are aimost white in perborates, silicates, pyro- or triphosphates, po
coolr when they have cooled and solidified, their
tassium chloride, sodium chloride, potash, borax,
odor, consistency and saponification qualities are
suggestive of the fatty acids of the cocoanut 85 Sodium carbonate
group, and like cocoanut oil fatty acids they may etc. Thus, an additional
be saponified at low temperatures (viz. 'cold Sa amount of perborate may be crutched into the
ponification'). The characteristic of Cold sapon finished soap as a filler material, alone or to
ification of the fatty acids serves to differentiate gether with other filler materials. Such later
them from prior synthetic fatty acids made from additions of water soluble oxidizing agents serve
relatively high molecular weight aliphatic hydro 70 to rectify any discoloration which may have re
carbons. In one important property these fatty Sulted due to poor control or due to the use of
excessive temperatures or excessive alkali during
Saponification, and such materials, which act also
as fillers, enhance the detergent properties of the
acids made by my process are superior to the 75 resultant soap, The finished soap is worked up
 3
2,891,019
in the usual ways and may be dried in any ap leading to a water cooled condenser for the col
proved method, for example by spray or drum lection of volatile products driven off in the
drying, if desired. process. -
The synthetic fatty acids, utilized as starting An emulsion was separately prepared by melt
material in the present invention, may be mixed ing together 25 parts of synthetic fatty acids from
in any desired percentage with natural fats, oils or a previous run (or as prepared in accordance
fatty acids, and may likewise be used as a sub stitute with my co-pending applications), 15 parts of
for cocoanut oil to facilitate Saponification fatty acids from beef tallow, 0.3 part potassium
of difficultly saponifiable natural fats and oils stearate and 0.25 part potassium permanganate
and to improve their lathering effect. Thus, the 10 in 50 parts of hot water. These ingredients were
addition of a relatively small percentage of syn thoroughly stirred until a homogeneous mixture
thetic fatty acids to a difficultly saponifiable ma was obtained.
terial such as tallow renders the tallow very eas
To the melted and heated paraffin there were
ily Saponifiable and gives the resultant SOap im now added 3 parts zinc stearate and half of the
proved lathering properties. Where alkali hy 5 emulsion, prepared as indicated, and the mass
droxide is necessary for the saponification of the was stirred for a while until a homogeneous mix
natural fat or oil content of a mixture of Syn ture was obtained. Then the temperature was
thetic fatty acids and such natural fat or oil, dis raised to about 125° C., and air was blown
coloration of the Synthetic fatty acid Soap pro through in excess. The air carried about 2%
duced in the mixture may be prevented by adding 20 moisture. When the saponification number
to the reaction mixture a Small amount of Water of
soluble oxidizing Salt as a protective agent, all as the reaction mass had reached 100 (in about 5-6
heretofore described. Thus, a water Soluble per hours), the other half of the emulsion and an
salt may be added to the mixture of synthetic other 3 parts of zinc stearate were stirred into
fatty acids and natural fat or oil and thoroughly the reaction mass and the other conditions being
stirred until a homogeneous maSS is obtained and maintained until a saponification number of 180
then the saponification may be accomplished ei 200 was reached. This was obtained in about 12
ther by an appropriate amount of hydroxide or a hours.
mixture of hydroxide and carbonate, without de The reaction product was almost white, and
velopment of color or Odor. had a consistency, Odor and Saponification qual
Discolored natural fats or fatty acids having 30 itles like those of fatty acids of the cocoanut
objectionable odor, when saponified together with grOup.
my synthetic fatty acids in the aforesaid ways, In order to separate the unsaponifiable from
lose their objectionable odor, and have much the Saponifiable material the temperature in the
improved color, sometimes white, depending upon reaction kettle was lowered to a point where the
the degree of discoloration of the original nat 5 fatty acids remain melted and the unsaponifiable
ural material. Solidifies. In this case it was somewhat below
In carrying out the saponification, whether by 42 C. Three layers were formed, viz. an upper
cold saponification procedure or by semi-boiling solidified layer contained the unsaponifiable or
procedure, the usual precautions customarily ob ganic substances; a middle layer contained the
served in the saponification of cocoanut oil are 40 melted fatty acids; and a thin layer in the bot
likewise observed in regard to the temperature of tom of the kettle, this thin layer being a brown
the melted fat, temperature of the alkali Solu ish mass of residues from the various catalysts.
tion, thorough crutching, filling the frames, cov The fatty acids were drawn off through a filter,
ering the frames etc. Washed with Water, or if desired by dilute mineral
In general, it may be stated that the synthetic acid and then with water, to separate water sol
fatty acid soaps have excellent detergent prop uble substances, and the fatty acids were then
erties, even when used in hard water or salt water, ready for saponification. Their color was almost
and extend the benefits of such properties to mix white, they were free from odor, and had a
tures wherein the synthetic fatty acid Soaps are Saponification number of 200. The fatty acids
present along with soaps prepared 50 contained about 6% unsaponifiable matter, but
from natural fats or fatty acids. this was unobjectionable, being snow white in
Having thus described in general the features color and having no smell whatsoever.
of the invention, reference is made to the exam These synthetic fatty acids were used in the
pies given hereinafter which illustrate Specific following examples for making various kinds of
and desirable modes of proceeding and the re 55 SOapS:
suitant products. These examples should not COLD PROCESS SOAPS
however be considered as imiting the invention. Eacample 2
In carrying out the invention the fatty acid is
One hundred (100) parts of synthetic fatty
first produced. This may be accomplished as set
forth in my cogending applications, the methods 60 acids were melted, and at a temperature not
of which are illustrated by Example I. It is to much higher than their melting point, a quantity
be understood, of course, that any of the pro of 20% sodium carbonate solution having a tem
perature of 25 C. and sufficient to neutralize the
cedures set forth in my aforementioned appli
cations which are incorporated here by reference, fatty acids, was gradually poured into the melt
may be utilized for the production of the Syn 65 ed fatty acids with constant and thorough stir.
ring. Combination soon took place. When the Soap
thetic fatty acid starting material. maSS became thicker and perfectly homoge Sneous,
Sadangole a a Solution of filler material having a tem
perature of 40° C. and a concentration of 25%
Six hundred (600) parts of paraffin having a
70 and containing 10% sodium silicate, 10% sodium
melting goint of 52-55° C. were melted and heat perborate and 10% potassium carbonate, based
ed to 120° C. in a covered reaction kettle having upon the weight of the anhydrous soap in the
an inlet tube at the bottom for blowing air mass, was crutched into the soap and the soap
through the reaction mass in finely dispersed maSS Was Worked up and then transferred to
bubbles, a mechanical stirrer and an outlet pipe 75 frames which were, covered in order to prevent
 4. s 2,391,019
rapid cooling off. If desired, perfumed material Qualities and was white and free from any odor
may be crutched into the soap at the same time other than that which is characteristic of good
the filler material is added. After cooling of and quality, pure soap.
drying by spray or drum drying to the desired Eacample 6
percentage moisture, there was obtained a very 6
good lathering, white soap, free from odor. The One hundred (100) parts of synthetic fatty
same soap may be prepared without fier mates acids containing 2% borax, in saturated solu
rial, if desired. Eacample 3 tion, and 50 parts olein were melted together and .
Saponified as in Example 5. When worked up,
One hundred (100) parts of synthetic fatty sing a filler materia as in Example 2, a very
good lathering soap of white color was obtained.
acids were melted and 2% sodium perborate in
saturated aqueous solution was added and the The soap was free from objectionable odor.
mixture was stirred until 8, homogeneous. Irass One hundred Eacomple 7 of synthetic fatty
was obtained. A 20% solution of sodium hye 5 (100) parts
droxide having a temperature of 25 C. and acids containing 2% borax, by weight of the fatty
containing sufficient sodium hydroxide to neu acids, in saturated solution, were melted together
tralize the synthetic fatty acids, was then grad With 50 parts of soyabean oil and saponified as
ually poured into the melted fatty acid periodrate in Example 5 using the stearic fatty acids for final
mixture. Combination soon took place. The 20 neutralization of any excess alkali present. When
, soap Was Worked up as in Example 2, the added worked up, using a filler material as in Example
filler material being composed of 10% borax, 5% 2, an excellent White soap of good lathering quali
potassium carbonate and 10% sodiurn silicate, ties, free froEn odor Was obtained.
based upon the Weight of the anhydrolls soap Eacample 8
present in the soap mass. The filler material was 25
dissolved in a 25% solution (40° C.) and was One hundred (100) parts of synthetic fatty
crutched into the Soap mass. After being Worked acids containing 2% borax Were melted together
up and dried to the desired moisture content, with 50 parts of peanut oil, and at a temperature
there resulted a very good lathering, white soap, of 28-30° C., a quantity of 25% sodium hydrox
free from any odor. 30 ide solution, sufficient to neutralize the fatty
Eacomple 4 acids and to Saponify the peanut oil, was grad
One hundred (100) parts of synthetic fatty ually poured into the fat mass With constant and
thorough stirring. Reaction soon took place. The
acids were melted and into the melted fatty acids Soap was tested for alkali, free fatty acids and
there was gradually poured a 20% solution of 35
natural fat, and the necessary adjustments made,
sodium hydroxide, the amount of such solution as in Example 5, for completion of the reaction.
being sufficient to neutralize the fatty acids pres The soap Was Worked up, as in Example 5, and
ent. Reaction soon took place and the resultant there resulted a good quality, . White soap, hav
soap was worked up as in Example 2. Without ing excellent lathering properties. The soap was
filler materials being added, the soap was a light. 40
free from any odor other than that characteristic
tan and had the appearance and odor of rosin of good quality, high grade Soap.
soap. The lathering and detergent properties If desired, the sodium hydroxide used for neu
were excellent. If desired, filler material such as tralization of the Synthetic fatty acids and for
that described in Examples 2 and 3 may be add Saponification of the peanut oil, may be replaced
ed, in which case the color of the soap is white. by a mixture of Sodium hydroxide and sodium
Eacample 5 carbonate solutions, preferably 25%. The amount
of Sodium carbonate used is sufficient to neutral
One hundred (100) parts of Synthetic fatty ize the synthetic fatty acids present in the mix
acids, containing 2% borax, in a saturated Solu 50 tionture, and the amount of Sodium hydroxide solu
used is chosen sufficient to saponify the pea
tion, and 50 parts of beef tallow were melted and
mixed together, and at a temperature of about nut oil. The resultant soap is white, free from
odor and has good lathering qualities.
35° C., a 25%, 25 C., sodium carbonate solution, If an absolute white color is not of primary
sufficient to saponify the fatty acids was poured importance, the 2% borax added to the Syn
in, in order to saponify the synthetic fatty acids. 55 thetic fatty acids prior to the saponification re
Then a 25%, 25 C., sodium hydroxide solution, action, may be eliminated. If discoloration oc
sufficient to saponify the tallow, was stirred in. curs during saponification, this can be corrected
When the soap had become thicker and quite by adding to the filler material or by itself, a
homogeneous, it was tested for the presence of Small percentage of perborate or usual soap
free fatty acids and natural fat and alkali. 60 bleaching agentS.
When alkali is present, it may be neutralized by
adding the requisite amount of stearic acid, while SEMI-BoILED SOAPs.
if free fatty acids are present, these may be neu Eacample 9
tralized by adding the required amount of SO
dium carbonate. In the event free natural fat 65 Fifty (50) parts of synthetic fatty acids and
is present, this may be saponified by adding an 50 parts of beef tallow fatty acids were melted
appropriate quantity of sodium hydroxide. A together and at a temperature not much higher
filler material, composed of 10% borax, 10% so than their melting point were poured into a 20%
dium pyrophosphate, 5% potassium carbonate solution of sodium carbonate, 60-70° C., sufficient
and 5% sodium silicate in 25% solution, Was 70to neutralize the fatty acid mixture, with con
crutched into the soap and the resultant mass stant and thorough stirring. When all the car
transferred to frames and worked up as in Ex bonic acid gas was expelled and saponification
ample 2. If desired, perfume may be added at finished, the soap was worked up as in Example 2
the time the filler material is crutched into the and after drying there resulted a very good lather
soap. The resultant soap had excellent lathering 75 ing, White soap, free from any odor.
 2,891,019 -- ra
5
Eacample 10 Soap in the mass. The soap mass was worked up
One hundred (100) parts of synthetic fatty as in the previous examples, and there resulted a
white soap, having good lathering qualities. The
acids and 50 parts of Soyabean oil were mixed soap was free from any objectionable odor.
together and at a temperature not much higher 5
than the melting point of the mixture, the fatty Eacample 14
acids were neutralized with a solution of potas The synthetic fatty acids may be used as a sub
sium carbonate (20%; 25 C.), the amount of stitute for cocoanut oil in the production of "stock
such solution being sufficient to neutralize the 10 Soap' or "kettle Soap' as follows:
synthetic fatty acids present in the mixture. The Twenty-five (25) parts of synthetic fatty acids
temperature of the mixture was then raised to and 100 parts of beef tallow were mixed together
40-60° C. and the soyabean oil was saponified and heated to a temperature not much higher
with potassium hydroxide (25%; 40 C.), the mix than their melting point. A quantity of 25%
ture being thoroughly stirred during the proc soda ash solution, sufficient to neutralize the
ess. When the mixture became homogeneous, 5 Synthetic fatty acids present in the mixture, was
a solution of filler material having a concentra then run into the fat mass with constant and
tion of 25% and containing 10% each of potas thorough stirring, and the temperature main
sium carbonate, potassium silicate and potas tained until the synthetic fatty acids were neu
sium chloride, based upon the Weight of the an tralized. The temperature was then raised to
hydrous soap present in the mixture, was then 20 about 80-100° C. and 25% sodium hydroxide solu
crutched into the soap and the Soap mass WaS tion, in an amount sufficient to saponify the
worked up in the usual manner. A Very good
tallow, was run into the reaction mass while
soft soap resulted. thoroughly stirring. When the Saponification
In place of soyabean oil there may be sub
stituted olive oil, olive oil foots, sesame oil, lin
was finished and the test showed no free fatty.
25 acid or natural fat, the soap was salted out and
seed oil or the like with excellent resultS. worked up as desired in any soap formula.
Eacample 11 Eacomple 15
One hundred (100) parts of synthetic fatty The soda ash of the preceding examples may be
acids and 20 parts of stearic acid were melted
together and at a temperature of about 30° C., a 30 replaced by Sodium hydroxide, and the mixture of
Synthetic fatty acids and tallow may be saponified
20% sodium carbonate solution, sufficient to neur in One Operation with SOdium hydroxide solution
tralize the fatty acids, was gradually poured into
the fatty acids with constant and thorough stir as follows:
ring. Reaction soon took place, and while con Twenty-five (25) parts synthetic fatty acids,

stantly stirring, the temperature Was raised to 35 emulsified with a Saturated sodium perborate
about 60-70° C., until all the carbonic acid gas solution, containing an amount of sodium per
borate equal to 2% of the weight of the synthetic
was expelled. The soap was filled and Worked
up as in Example 10, and there resulted a very fatty acids, Was mixed with 100 parts of beef
white soap, free from any odor. The soap had tallow and the mixture heated to a temperature

good lathering qualities. 40 of 60-100 C. 25% sodium hydroxide solution

was then run in while thoroughly stirring, the
Eacample 12 synthetic fatty quantity of such solution being sufficient to neu
one hundred (100) parts of tralize the synthetic fatty acids and saponify the
acids and 100 parts of tallow fatty acids were tallow present in the fat mass. The resultant
melted together and at a temperature not much 45 stock soap was then Salted out and was suitable
higher than their melting point were poured into for Working up in any desired soap formula.
a 25% sodium carbonate solution, Sufficient to For stock soap, the percentage of synthetic fatty
neutralize the fatty acids, which was heated to a acids used with the tallow may be widely varied.
temperature of about 60-70° C. Saponification, 50 MARINE SOAPS
filling and working up was as in the preceding Eacample 16
example. A very good lathering, white Soap, free One hundred fatty
from objectionable odor was obtained. (100) parts of synthetic
Eacample 13 acids were melted, and at a temperature not much
higher than their melting point there was poured
One hundred (100) parts of synthetic fatty 55 into the fatty acids a 20% solution containing
acids, containing 2% borax in Saturated Solution Sodium hydroxide and potassium carbonate in
were mixed with 50 parts of beef tallow and held the proportion of 2 to 1. The temperature of the
at a temperature of 35° C. A quantity of 25% hydroxide-carbonate solution was about 25° C.
sodium carbonate solution, sufficient to neutralize
the fatty acids, was heated to about 60-70° C. and
60 and
the
enough of the Solution was used to saponify
fatty acids present. The solution was poured
poured into the melted mixture of fatty acids and into the melted fatty acids with constant stirring,
tallow with constant and thorough stirring. and the temperature was raised until all the car
When the evolution of carbonic acid gas had bonic acid gas was expelled, that is to say, no
ceased, a quantity of 25% sodium hydroxide solu further gas bubbles appeared at the surface of
tion, sufficient to neutralize the tallow was heated 65 the mass. When saponification was finished, a
to 60-70° C. and was added to the soap mass with Solution of filler material (25% concentration;
constant and thorough stirring. When the Soap 40° C.) containing 10% sodium silicate, 5% po
mass had become thicker and homogeneous, it tassium carbonate and 10% sodium perborate,
was tested for alkali, free fatty acids and neutral based upon the amount of anhydrous soap present
fat, and final corrections made. After the final 70
in the mass, was crutched into the soap and the
corrections were made, the soap mass was worked mass was transferred to frames equipped so as
up by crutching in a solution of filler material not to be too rapidly cooled. After the soap was
having a concentration of 25% and composed of dried to the desired percentage of water, there
10% borax, 10% sodium silicate and 5% sodium resulted very good lathering soap, easily soluble in

carbonate, based upon the weight of anhydrous 75 salt water,

 6 2,891,019
Eacamplet? oxygen and a minor percentage of moisture so as
Eighty (80) parts of Synthetic fatty acids and to form an emulsion of the reaction mass during
20 parts rosin were mixed together and saponified the whole time of the process of oxidation, which
comprises reacting the synthetic fatty acids so
as in Example 16, utilizing for purposes of saponi
fication a solution (25% concentration; 40° C.) 5 produced with an alkali solution at a temperature
containing Sodium hydroxide and potassium car above 20 and not substantially exceeding 100° C.

bonate in the ratio of 3 to 1. The resultant soap and in the presence of a water soluble oxidizing
was worked up as in the preceding example and Salt.
5. A method of soap-making utilizing synthetic
was an excellent lathering soap when used in salt 0 fatty acids prepared by heating a high molecular
Water.
Washing tests utilizing the soap of either of Weight paraffinic hydrocarbon to a temperature
Examples 16 and 17 showed excellent cleansing of such that, if the hydrocarbon is normally solid it
soiled clothes when the soaps were used in salt will be liquefied, said temperature being not sub- .
Water. Stantially in excess of 150 C., and intimately mix
In general it may be stated that the soaps pro 5 ing with the heated liquid hydrocarbon catalytic
duced in accordance with the present invention amounts of a heavy metal soap and a persalt of

have excellent detergent properties, even when an alkaline reacting cation, the latter at least be
utilized in hard water, as indicated by washing ing carried by an emulsion of water, an oleaginous
tests. Thus, Washing tests utilizing soap solutions material and an emulsifying agent, simultaneous
of 0.2-0.3% in hard water, at a temperature of 20 ly dispersing throughout the reaction mass a gas
60-70' C. yielded fresh, clean-smelling products, comprising oxygen and containing a minor per
even though the Washing was carried out by hand centage of moisture, which comprises reacting
for Only a few minutes. Said Synthetic fatty acids with an alkali at a
As many apparently widely different embodi temperature above 20° C., but below 100° C.
ments of this invention may be made without de 25 6. The process of claim 1 further characterized
parting from the Spirit and scope thereof, it is to in that said alkali is a carbonate solution.
be understood that I do not limit myself to the 7. The process of claim 1 further characterized
Specific embodiments herein except as defined by in that the reaction with an alkali is effected in
the appended claims. the presence of a small percentage of soap
What claim is: 30 bleaching material.
1. A method of soap making utilizing synthetic 8. The process of claim 1 further characterized
fatty acids prepared by heating a high molecular in that the reaction with the alkali is effected in
Weight hydrocarbon to an elevated temperature the presence of a small percentage of perborate.
such that the hydrocarbon is liquefied, with cata 9. The process of claim 1 further character
lytic amounts of an oxidation catalyst, a persalt 35 ized in that said synthetic fatty acids are mixed
of an alkaline reacting cation and an emulsion with natural fatty acids prior to reacting with
While dispersing throughout the reaction mass a the alkali.
gaS comprising Oxygen and a minor percentage of 10. The process of claim 1 further character
moisture, which comprises reacting said synthetic ized in that said Synthetic fatty acids are mixed
40 With natural fatty acids and said mixture of
fatty acids with an alkali solution at a tempera

ture in the range of 20-100° C. fatty acids reacted with an alkali carbonate.
2. A method of soap making utilizing synthetic 11. The process of claim 1 further character
fatty acids prepared by heating a high molecular ized in that said synthetic fatty acids are mixed
Weight hydrocarbon to an elevated temperature with natural fatty acids and said mixture of
such that the hydrocarbon is liquefied, with cata 45 fatty acids reacted with an alkali in the presence
lytic amounts of an Oxidation catalyst, a metal of a Small percentage of soap-bleaching material.
persalt and an emulsion while dispersing through 12. The process of claim 1 further character
out the reaction mass a gas comprising oxygen ized in that said Synthetic fatty acids are mixed
and a minor percentage of moisture, which com 50 With a natural fat and with a small percentage
prises reacting said Synthetic fatty acids with an of soap-bleaching material, and said mixture re
alkali Solution at a temperature in the range of acted with an alkali,
20-100° C. and in the presence of a water soluble 13. The process of claim 1 further character
Oxidizing salt. ized in that said synthetic fatty acids are mixed
3. A method of soap making utilizing synthetic with a natural fat and with a small percentage
fatty acids prepared by heating a high molecular 55 of a water Soluble oxidizing salt and said mix
weight paraffinic hydrocarbon to an elevated tem ture reacted with an alkali.
perature and Such that the hydrocarbon is lique 14. The process of claim 1 further character
fied, with catalytic amounts of an oxidation cata ized in that said Synthetic fatty acids are mixed
lyst and a metal persalt in the presence of a water With a natural fat and said mixture reacted with
containing emulsion, while dispersing throughout 60 a solution containing sufficient alkali carbonate
the heated liquid hydrocarbon a gas comprising to neutralize said synthetic fatty
acids and con
Oxygen and a minor percentage of moisture so as taining sufficient alkali
hydroxide to saponify
to form an emulsion of the reaction mass during said natural fat.
the whole time of the process of Oxidation, which 15. The process of claim 1
further character
comprises reacting the Synthetic fatty acids so 65 ized in that said Synthetic fatty acids are mixed
produced with an alkali solution at a temperature with natural fat and a small percentage of a
above 20' and not substantially exceeding 100° C. water soluble perborate, said mixture being re
4. A method of soap making utilizing synthetic acted with an alkali.
fatty acids prepared by heating a high molecular 16. The process of claim 1 further character
Weight paraffinic hydrocarbon to an elevated tem ized in that said synthetic fatty acids are mixed
O
perature and Such that the hydrocarbon is lique with a natural fat, said mixture then being re
fled, with catalytic amounts of an oxidation cata acted with an aqueous solution containing suf
lyst and a metal persalt in the presence of a Water ficient alkali carbonate to neutralize the syn
containing emulsion, while dispersing throughout thetic fatty acids present in the mixture at a the
heated liquid hydrocarbon a gas comprising 75 temperature not greatly exceeding the melting
 2,891,019 7
point of said mixture, and then at an elevated perature not greatly exceeding the melting point
temperature further reacting the mixture with an of the mixture, reacting the mixture with a solu
aqueous solution containing sufficient alkali hy tion containing sufficient alkali carbonate to neu
droxide to saponify the natural tralize the synthetic fatty acids present in Said
fat present in said mixture. mixture and at an elevated temperature continu
17. The process of claim 1 further character ing said reaction with a solution containing suf
ized in that said Synthetic fatty acids are ficient alkali hydroxide to saponify said natural
mixed with a natural fat and with a small percentage oleaginous material.
of Water soluble oxidizing salt, then, at a tem SABINE HERSCH,