22-02-2011, 12:08 PM
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