Neat soap may or may not be blended with other products before flaking or powdering. Neat soap is sometimes filtered to remove gel particles and run into a reactor (crutcher) for mixing with builders. After thorough mixing, the finished formulation is run through various mechanical operations to produce flakes and powders. Because all of the evaporated moisture goes to the atmosphere, there is no wastewater effluent.
Some operations will include a scrap soap reboil to recover reclaimed soap. The soap reboil is salted out for soap recovery and the salt water is recycled. After frequent recycling, the salt water becomes so contaminated that it must be discharged to the sewer. Occasional washdown of the crutcher may be needed. The tower is usually cleaned down dry. There is also some gland water that flows over the pump shaft, picking up any minor leaks. This will contribute a very small, but finite, effluent loading.
There are a number of possible effluents shown on the flow diagram for process F (Fig. 6). However, a survey of the industry showed that most operating plants either recycled any wastewater to extinction or used dry clean-up processes. Occasionally, water will be used for clean-up.
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