A systematic matrix-based method for synthesis and optimization of Reaction/Distillation processes including Reactive Distillation

In order to reach product purity specifications, reactor outlet streams are often purified using distillation columns, and the unreacted feed is recycled to the reactor. This makes Reaction-Separation processes very important in chemical industries. In the current study, a new version of the Reaction/Distillation Matrix algorithm previously presented by the authors is presented. The current version of the algorithm is capable of generating Reactive Distillation configurations as attractive process alternatives and also recycle streams to prevent the loss of unreacted feed components. Besides, major modifications have been carried out to the algorithm to make it more efficient and user-friendly. Production of cumene and dimethyl ether were studied as case studies to evaluate the performance of the developed algorithm. The conventional sequences generated using the Reaction/Distillation Matrix algorithm were simulated by Aspen Plus and then optimized using the Genetic Algorithm. It is observed that cost of reactive distillation configuration was approximately 62 % and 10 % lower than for the conventional process in the cumene production and dimethyl ether production case studies, respectively.(c) 2022 Institution of Chemical Engineers. Published by Elsevier Ltd. All rights reserved.