An autoclave or digestor consists of a strongly constructed, closed cylindrical tank, usually made of copper, and is so built as to resist internal pressure. The digestor is usually 3 to 5 feet in diameter and from 18 to 25 feet high. It may be set up horizontally or vertically and is covered with an asbestos jacket to retain the heat. Various inlets and outlets for the fats, steam, etc., as well as a pressure gauge and safety valve are also a necessary part of the equipment.
LIME SAPONIFICATION.
The saponification in an autoclave is usually carried out by introducing the fats into the autoclave with a percentage of lime, magnesia or zinc oxide, together with water. If the fats contain any great amount of impurities, it is first necessary to purify them either by a treatment with weak sulfuric acid, as described under the Twitchell process, or by boiling them up with brine and settling out the impurities from the hot fat.
To charge the autoclave a partial vacuum is created therein by condensation of steam just before running the purified oil in from an elevated tank. The required quantity of unslaked lime, 2 to 4 per cent. of the weight of the fat, is run in with the molten fat, together with 30 per cent. to 50 per cent. of water. While 8.7 per cent. lime is theoretically required, practice has shown that 2 per cent. to 4 per cent. is sufficient. The digestor, having been charged and adjusted, steam is turned on and a pressure of 8 to 10 atmospheres maintained thereon for a period of six to ten hours. Samples of the fat are taken at various intervals and the percentage of free fatty acids determined. When the saponification is completed the contents of the autoclave are removed, usually by blowing out the digestor into a wooden settling tank, or by first running off the glycerine water and then blowing out the lime, soap and fatty acids. The mass discharged from the digestor separates into two layers, the upper consisting of a mixture of lime soap or "rock" and fatty acids, and the lower layer contains the glycerine or "sweet" water. The glycerine water is first run off through a clearing tank or oil separator, if this has not been done directly from the autoclave, and the mass remaining washed once or twice more with water to remove any glycerine still retained by the lime soap. The calculated amount of sulfuric acid to decompose the lime "rock" is then added, and the mass agitated until the fatty acids contained therein are entirely set free. Another small wash is then given and the wash water added to the glycerine water already run off. The glycerine water is neutralized with lime, filtered and concentrated as in the Twitchell process.
Due to the difficulties of working the autoclave saponification with lime, decomposing the large amount of lime soap obtained and dealing with much gypsum formed thereby which collects as a sediment and necessitates cleaning the tanks, other substances are used to replace lime. Magnesia, about 2 per cent. of the weight of the fat, is used and gives better results than lime. One-half to 1 per cent. of zinc oxide of the weight of the fat is even better adapted and is now being extensively employed for this purpose. In using zinc oxide it is possible to recover the zinc salts and use them over again in the digestor, which makes the process as cheap to work as with lime, with far more satisfactory results.
ACID SAPONIFICATION.
While it is possible to saponify fats and oils in an autoclave with the addition of acid to the fat, unless a specially-constructed digestor is built, the action of the acid on the metal from which the autoclave is constructed prohibits its use. The acid saponification is therefore carried out by another method.
The method of procedure for acid saponification, therefore, is to first purify the fats with dilute acid as already described. The purified, hot or warm, dry fat is then run to a specially-built acidifier or a lead-lined tank and from 4 per cent. to 6 per cent. of concentrated sulfuric acid added to the fat, depending upon its character, the degree of saponification required, temperature and time of saponification. A temperature of 110 degrees C. is maintained and the mass mixed from four to six hours. The tank is then allowed to settle out the tar formed during the saponification, and the fatty acids run off to another tank and boiled up about three times with one-third the amount of water. The water thus obtained contains the glycerine, and after neutralization is concentrated.
AQUEOUS SAPONIFICATION.
While lime or a similar substance is ordinarily used to aid in splitting fats in an autoclave, the old water process is still used. This is a convenient, though slower and more dangerous method, of producing the hydrolysis of the glyceride, as well as the simplest in that fatty acids and glycerine in a water solution are obtained. The method consists in merely charging the autoclave with fats and adding about 30 per cent. to 40 per cent. of their weight of water, depending on the amount of free fatty acid and subjecting the charge to a pressure of 150 to 300 pounds, until the splitting has taken place. This is a much higher pressure than when lime is used and therefore a very strong autoclave is required. Since fatty acids and pure glycerine water are obtained no subsequent treatment of the finished charge is necessary except separating the glycerine water and giving the fatty acids a wash with water to remove all the glycerine from them.