Optimum process configuration for ETBE production based on TAC minimization

A new process configuration consisting of hybrid pervaporation (PV) (with series-parallel arrangement and recycle streams)-distillation column (DC) or reactive distillation (RD) with a hybrid feed splitting-heat integrated distillation column (HIDiC)-heat integration method was proposed to produce ETBE. To evaluate the performance of the proposed method, 92 different processes for producing ETBE by RD columns, pressure swing distillation, PV, liquid-liquid extraction column or their combinations were optimized and compared to the new configuration. The PV modules were placed in four sections: before the column, next to distillate, next to bottom product and next to side stream. All process parameters in DC or RD, PV and heat integration were considered optimization variables, and all variables were simultaneously optimized by a hybrid GA-PSO algorithm. The proposed configuration reduced TAC by at least 30% and a maximum of 62% compared with other process configurations. This can be attributed to the use of PV instead of distillation columns, series-parallel arrangement instead of series and parallel arrangements in the PV process to reduce energy consumption and membrane area and also the use of heat integration between internal DC flows and PV streams to eliminate the need for hot utility.

Automated summary

The proposed new process configuration for producing ETBE combines hybrid pervaporation with distillation or reactive distillation, along with heat integration to significantly reduce total cost by 30% to 62% compared to other process configurations.