ROSIN SAPONIFICATION.
As has been stated, rosin may be saponified by the use of alkaline carbonates. On account of the possibility of the soap frothing over, the kettle in which the operation takes place should be set flush with the floor, which ought to be constructed of cement. The kettle itself is an open one with round bottom, equipped with an open steam coil and skimmer pipe, and the open portion is protected by a semi-circular rail. A powerful grid, having a 3-inch mesh, covers one-half of the kettle, the sharp edges protruding upwards.
The staves from the rosin casks are removed at the edge of the kettle, the rosin placed on the grid and beaten through with a hammer to break it up into small pieces.
To saponify a ton of rosin there are required 200 lbs. soda ash, 1,600 lbs. water and 100 lbs. salt. Half the water is run into the kettle, boiled, and then the soda ash and half the salt added. The rosin is now added through the grid and the mixture thoroughly boiled. As carbon dioxide is evolved by the reaction the boiling is continued for one hour to remove any excess of this gas. A portion of the salt is gradually added to grain the soap well and to keep the mass in such condition as to favor the evolution of gas. The remainder of the water is added to close the soap and boiling continued for one or two hours longer. At this point the kettle must be carefully watched or it will boil over through the further escape of carbon dioxide being hindered. The mass, being in a frothy condition, will rapidly settle by controlling the flow of steam. The remaining salt is then scattered in and the soap allowed to settle for two hours or longer. The lyes are then drained off the top. If the rosin soap is required for toilet soaps, it is grained a second time. The soap is now boiled with the water caused by the condensation of the steam, which changes it to a half grained soap suitable for pumping. A soap thus made contains free soda ash 0.15% or less, free rosin about 15%. The mass is then pumped to the kettle containing the soap to which it is to be added at the proper stage. The time consumed in thus saponifying rosin is about five hours.