Continuous grease process

In a continuous grease manufacturing process wherein a saponifiable material is reacted with an aqueous solution of a metal base in a saponification zone at a saponification reaction temperature and superatmospheric pressure to produce a saponification reaction product comprising soap, the saponification reaction temperature in a range of about 200.degree. F. (93.3.degree. C.) to 25.degree. F. (13.9.degree. C.) below the soap melting temperature wherein said saponification reaction product is first (i) passed through a pressure reducing means to effect pressure reduction to flash vaporize substantially all the water present in said saponification reaction product;

• (ii) passed through a heat exchange means to heat the saponification reaction product to a dehydration temperature of at least 225.degree. F. (107.2.degree. C.) to the soap melting temperature;
• and then third (iii) passed to a dehydration zone to produce a dehydrated saponification reaction product, and wherein a first portion of said dehydrated saponification reaction product is recycled through a shear valve for conditioning the soap contained therein, and wherein lubricating oil is added to said recycled dehydrated saponification reaction product for producing a grease product, the improvement which comprises:
• recycling a second portion of the dehydrated saponification reaction product through the heat exchange means in a volumetric ratio of total throughput:recycle in the range of 2:1 to 20:1.