Optimal design and multicriteria comparison of extractive distillation processes for separating of a quaternary low-boiling solvent mixture

This article mainly explores the eco-efficient separation of a complex quaternary azeotropic mixture of methanol, n-hexane, ethyl acetate and ethanol from a pharmaceutical enterprise via extractive distillation. To this end, aniline (AN) and ethylene glycol (EG) are selected as two alternative entrainers based on the relative volatility curve. Two conventional processes with AN and EG (AN-CED and EG-CED) are proposed and optimized with total annual costs (TAC) as a goal by simulated annealing algorithm. To improve energetic and economic performance, two optimal strengthening processes, that is, low-pressure side-stream extractive distillation process with AN (AN-SSED) and dividing-wall extractive distillation process with EG (EG-EDWC) are also developed for the first time. Finally, the four processes are compared in terms of economics, CO2 emissions and inherent safety. The results show that the AN-SSED process is recommended due to the best economic, environmental and inherent safety properties, as reflected by the lowest TAC, CO2 emission and process route index (PRI). It can reduce TAC by 9.38%, CO2 emission by 26.34% and PRI by 38.02% relative to the EG-EDWC process. Remarkably, the EG-EDWC process can reduce TAC by 11.12% than AN-CED process and 6.9% than the EG-CED process, but it is inferior to the two conventional processes in terms of CO2 emissions and inherent safety.