RSM optimization of the operating parameters for a butanol distillation column

Comprehensive optimization of distillation column operating parameters is very important in chemical production. Response surface methodology (RSM) was used in combination with process simulation for complex optimization of operating parameters on the butanol distillation column in solvent fermentation process. The single-parameter effect of theoretical number of plates, feed positions, flow rate, and reflux rate on the content of water and butanol in the overhead distillate were investigated using the chemical process simulation software PRO/II. Then, according to the results of single-parameter simulation, comprehensive optimization was done using the response surface optimization methodcentral composite design (CCD), with the minimization of water content in the overhead distillate as the objective. The best optimized mathematical model was established and the result was verified by industrial production process. It was that satisfactory results can be obtained when RSM is combined with process simulation. This can produce more optimal conditions than those obtained by single-factor optimization in multivariate optimization problems. The optimal operating conditions are as follows: number of theoretical plates = 47, feed positions at the 7th and 12th theoretical plates (from top to bottom), overhead distillate flow rate = 441 kg/h, and reflux rate = 1860 kg/h. The water and butanol contents in the overhead distillate under these conditions are 0.5093 and 0.001%, respectively. This process was a reference point for the optimization of operating parameters of a distillation system. Copyright (C) 2010 Curtin University of Technology and John Wiley & Sons, Ltd.