Preliminary economic ranking of reactive distillation processes using a navigation method

Evaluating the applicability of reactive distillation (RD) is an important stage in the conceptual design phase, when RD is considered as a promising process intensification option. However, performing that task may be both time consuming and difficult due to the complexity of the models and the detailed data required. To solve this problem, this study presents a quick approach to perform a preliminary economic ranking of RD using a navigation method. This method works like a global positioning system (GPS) in which pre-defined maps (i.e. the plot of reflux ratio vs number of stages) are used to charting the applicability of RD. Together with the pre-defined maps, the data of RD configurations (i.e. number of rectifying, reactive, stripping stages) are generated. By using the navigation method, this study checks the applicability of RD for quaternary reversible reaction systems (A + B = C + D) with different boiling point orders. The result of a preliminary economic assessment is given as RD cost ranking which can be used as a valuable pre-screening prior to performing any detailed economic analysis. Therefore a full assessment requiring a long time can be avoided. With a fair comparison in terms of relative volatilities, the system with mid-boiling reactants generates the lowest cost, whereas the system with mid-boiling products requires the most expensive RD setup.