presented by:
Muhammad Ayaz
Iftikhar Ahmed
Murad Ali
Sumaira Shah

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Process optimization of the Saponification reaction in CSTR by using statistical experimental design
Introduction
 A Design of Experiment (DOE) is a structured, organized method that is used to determine the relationship between the different factors (Xs) affecting a process and the output of that process (Y).
 When the results of these experiments are analyzed, they help to identify optimal conditions, the factors that most influence the results, and those that do not.
 The key to minimizing optimization costs is to conduct as few experiments as possible. DOE requires only a small set of experiments and thus helps to reduce costs.
Saponification
 Saponification is commonly used to refer to the reaction of a metallic alkali (base) with a fat or oil to form soap. Saponifiable substances are those that can be converted into soap.
 If NaOH (base) is used a hard soap is formed, whereas when potassium hydroxide (KOH) is used, a soft soap is formed. [3]
 The stiochemtric representation of saponification reaction between EtOAc and NaOH is given by eq. (1) NaOH + CH3COOC2H5→ CH3COONa + C2H5OH….(1)
Literature Review
 Per Johan Brandvik, 1998
 Suggested the use of statistical simulations as a cost-reducing alternative to traditional experimental design testing.
 Result of the work shows how statistical simulations can efficiently be used to illustrate the power of experimental design and response surface methods.
 Nihal Bursali ,2009
 Applied statistical experimental design for process improvement to the saponification reaction and studied the effect of various factors on the fractional conversion rate of NaOH (XA).
 The factors studied in this work were NaOH and EtOAc concentrations (mol/L), agitation rate (rpm) and temperature (0C)
 Optimum operating conditions at which maximum fractional conversion rate of NaOH (response) was obtained about 100% were found to be 0.01 mol L−1 NaOH and 0.1 mol L−1 EtOAc by applying response surface method (RSM).
Problem Statement
 It is observed that there are not so many studies on the process optimization of this process in CSTR.
 Previously published studies are generally related to kinetics of this reaction in a batch reactor.
 A systematic approach for determining optimum parameters for a reaction system is needed for:
 maximizing conversion
 reduction in experimental efforts
 enhancing product Quality
Objectives
 The objective of this study is to optimize the saponification process with respect to both operational efforts, consumed raw materials and obtained yield.
 Also to develop a correlation relating different variables and response (fractional conversion).
Methodology
 The Continuous stirred tank reactor (Armfield CEM Mk II, Hampshire, UK) is available in the CRE lab of the department.
 Experiments will be carried out for determining optimum parameters for saponification reaction in CSTR .
 3 basic principles of experimental design will be applied,
 Replication
 Randomization
 Blocking
 Expected Number of experiments= 32 to 243