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A novel dynamic modeling and thermal optimization of magnesium stearate production using sustainable palm stearin: green chemistry approach for saponification in batch reactor.

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Title: A novel dynamic modeling and thermal optimization of magnesium stearate production using sustainable palm stearin: green chemistry approach for saponification in batch reactor.
Authors: Manimaran, Ravinkumar1 (AUTHOR), Mohd Ali, Jarinah1 (AUTHOR) jarinah@ukm.edu.my, Abd Rahman, Norliza1 (AUTHOR), Mohd Said, Mazlina2 (AUTHOR), Hussain, M.A.3 (AUTHOR)
Source: Journal of Industrial & Engineering Chemistry. Jul2026, Vol. 159, p403-415. 13p.
Subjects: Saponification, Batch reactors, Process optimization, Chemical kinetics, Sustainable chemistry, Temperature control, Fat, Chemical products manufacturing
Abstract: A comprehensive mathematical model has been developed to represent the saponification reaction for producing magnesium stearate using palm stearin as a sustainable and green alternative to conventional stearic acid. The model is based on the kinetic and energy models in a batch reactor, focusing on the direct reaction between magnesium hydroxide and sustainable palm stearin instead of conventional stearic acid. Unlike existing saponification studies that focus on the functionality of the final product, this paper predicts reactant and product concentrations, as well as reactor temperature, at various stages and temperatures for process optimization. The results indicated that higher temperatures accelerate the reaction rate but also promote the formation of byproducts, specifically magnesium hydroxystearate (magnesium-based soap). The highest yield of magnesium stearate, 68.2%, was achieved when the reaction temperature was maintained at 180°C. By the end of the third hour, palm stearin, the limiting reactant, was completely converted to product. Validation analysis revealed a modeling error of 1%. The reaction's heat release requires an external heat source, which can be efficiently managed using a jacketed reactor, allowing the temperature to be reached in just 0.4 s. In an upscale system, 10.0064 mg/L of magnesium stearate was produced. The time required to reach the set point temperature is 240 s, significantly longer compared to a small-scale system. This study demonstrates the viability of palm stearin in magnesium stearate production and highlights the critical role of temperature control in optimizing yields. [ABSTRACT FROM AUTHOR]
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Database: Engineering Source
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Abstract:A comprehensive mathematical model has been developed to represent the saponification reaction for producing magnesium stearate using palm stearin as a sustainable and green alternative to conventional stearic acid. The model is based on the kinetic and energy models in a batch reactor, focusing on the direct reaction between magnesium hydroxide and sustainable palm stearin instead of conventional stearic acid. Unlike existing saponification studies that focus on the functionality of the final product, this paper predicts reactant and product concentrations, as well as reactor temperature, at various stages and temperatures for process optimization. The results indicated that higher temperatures accelerate the reaction rate but also promote the formation of byproducts, specifically magnesium hydroxystearate (magnesium-based soap). The highest yield of magnesium stearate, 68.2%, was achieved when the reaction temperature was maintained at 180°C. By the end of the third hour, palm stearin, the limiting reactant, was completely converted to product. Validation analysis revealed a modeling error of 1%. The reaction's heat release requires an external heat source, which can be efficiently managed using a jacketed reactor, allowing the temperature to be reached in just 0.4 s. In an upscale system, 10.0064 mg/L of magnesium stearate was produced. The time required to reach the set point temperature is 240 s, significantly longer compared to a small-scale system. This study demonstrates the viability of palm stearin in magnesium stearate production and highlights the critical role of temperature control in optimizing yields. [ABSTRACT FROM AUTHOR]
ISSN:1226086X
DOI:10.1016/j.jiec.2025.12.032