Exploration of different water content on the performance of reactive-extractive distillation for separating the ternary azeotropic mixture

Reactive-extractive distillation (RED) has gained significant attention as an innovative approach for separating azeotropic mixtures. Although many studies have reported its positive benefits, no studies have explored the impact of varying water content on RED performance, a domain that has seen exhaustive exploration in conventional extractive distillation. In this study, we investigate how water content affects RED performance using the separation of ethyl acetate (EA), 1,4-dioxane (DIO), and water as a case study. We design diverse configurations tailored for feed compositions ranging from 0.35 to 0.8 water mole fractions using a double column reactive-extractive distillation (DCRED). These configurations are globally optimized and the performance is compared against the triple-column conventional extractive distillation (TCCED) based on economic, environmental, and thermodynamic efficiency considerations. The TAC and CO2 emission of TCCED schemes exhibit the linear decreases, reaching its lowest point at 50 mol.% water content. Beyond this threshold, both indicators increase significantly, even surpassing the reference case (20 mol.% water) at 80 mol.% water content. The thermodynamic efficiency of TCCED behaves inversely due to the intrinsic exergy destructions. Interestingly, the DCRED schemes show almost linear decreases in the trends of both economic and environmental indicators, and the notable deviations are then observed at 65 mol.% water content, accompanied with a slight decrease up to 80 mol.%. The thermodynamic efficiency of DCRED scheme gives an inverse trend, identical to those observed in TCRED. Overall, TCCED performs best at 50 mol.%, in which DCRED excels at 80 mol.% water content. This comprehensive study bridges a significant knowledge gap, offering insights into optimizing RED processes for varying water content, an unexplored topic despite widespread application of RED.