(572c) Process Intensification of Ether Co-Production Systems

In our research, systems were designed to produce two distinct fuel ethers concurrently from a blend of methanol and ethanol. Two separate production systems were formulated: the first employs dedicated reaction-distillation columns to generate each ether post alcohol separation, while the second produces both ethers within a singular reaction-distillation column prior to separation. These systems were conceptualized across varying alcohol ratios and subsequently assessed based on the energy efficiency, economic viability, and carbon dioxide emission levels. In the methanol predominant case, a diminished relative volatility between the alcohols was observed within the alcohol separation column. This resulted in compromised separation efficiency and increased energy consumption within the dedicated production setup, rendering the simultaneous production approach more advantageous from both economic and environmental standpoints. Conversely, with a higher ethanol content, the internal flow rate in the simultaneous production reaction-distillation tower increased due to a low equilibrium constant. Consequently, the energy demands of the simultaneous production configuration surpassed those of its individual counterpart, making the latter more efficient. Furthermore, we engineered a heat integration framework utilizing external heat exchangers for the described systems, culminating in diminished energy expenditure, reduced costs, and curtailed carbon dioxide emissions. The thermally integrated system exhibited trends similar to those observed in the bare system when varying the alcohol ratios.