That does sound strange. What fat did you start with? Was it an oil, and what type of oil was it -- olive, etc. It wasn't a saponifiable solid fat, was it? Anyway, even when salting the completed soap out, you get curds, not a dry powder. I assuming you used a strong solution of sodium hydroxide, with a little alcohol to help it mix before soap began to form, and helped it the rest of the way. You didn't just mix some NaOH pellets, alcohol and vegetable oil, right?