Studies on the process variables of the condensation reaction of cardanol and formaldehyde by response surface methodology

Different types of cardanol-based novolac-type phenolic resins are produced under a wide range of operating conditions for the application in the resin producing industries. Different operating conditions employed for the production of such resins result in different extent of conversion. In order to understand the system behavior, mathematical relationship between the process variables and the extent of conversion was established by employing the ‘Response surface methodology’. Geometrical representation of the mathematical models in three-dimensional surface plots served as a good aid in understanding the behaviour of reaction under different operating conditions. The maximum extent of conversion of the condensation reaction of cardanol and formaldehyde was found to be 93.0 percent at optimum sets of condition of reaction temperature, time, catalyst concentration and pH of the reaction mixture. All the predicted values for optimum process conditions were in good agreement with experimental data.