Electrification of distillation processes through discretely heat integrated distillation columns (D-HIDiC) is an effective approach to enhance energy efficiency and lower carbon emissions. For separating systems with high temperature lift, multi-stage compression and inter-stage cooling are necessary to link the high-pressure rectifier and low-pressure stripper. Traditionally, heat recovery employs pumparound loops, but this study introduces liquid injection as a more efficient and innovative alternative. Simulation results using methanol/water separation indicate that liquid injection reduces both reboiler duty and compression power, achieving up to 50% primary energy savings compared with conventional distillation columns. Unlike continuous heat exchange in conventional HIDiC (C-HIDiC), D-HIDiC simplifies heat integration, avoiding complex hardware and energy penalties. Comparative analysis across multiple configurations, including SuperHIDiC, confirms the potential of D-HIDiC with liquid injection to fully electrify distillation, eliminate steam utility, and significantly support sustainable industrial operations.

Distillation is widely used for separating liquid mixtures, but its high heating demand poses challenges for achieving net-zero emissions. This study presents an innovative approach to electrifying distillation for load adaptability and flexible operation, aligning with dynamic electricity markets driven by renewables. The approach integrates flash vapor circulation and thermal storage into the distillation to optimize power usage and capitalizes on economic opportunities from load-flexible operation in response to fluctuating electricity pricing. A methanol/water distillation case study, using two typical electricity pricing scenarios, demonstrates that the proposed approach is more economically efficient than mechanical vapor recompression distillation, especially in lowering operational costs when the latter operates under fixed electricity pricing. However, compressor capital costs significantly impact overall costs, with sensitivity analysis examining different cost models. This approach can be applied to general distillation, allowing integration with the power sector and demand response programs, while enhancing flexibility, decarbonization, and efficiency.

This study introduces a novel artificial neural network (ANN)-based control strategy for pressure-swing distillation (PSD) systems, integrating heat pump-assisted distillation (HPAD) and self-heat recuperation technology (SHRT) to transition from thermally-driven to electrically-driven processes. While previous research has validated the dynamics and controllability of conventional PSD (PSD-CONV), PSD-HPAD, and PSD-SHRT for separating a maximum-boiling acetone/chloroform azeotrope, this work specifically focuses on enhancing product purity control through composition-temperature cascade control (CC-TC). Although similar control strategies have been proposed, our approach uniquely predicts temperature set points using easily measurable process variables, effectively bypassing the inaccuracies of composition measurements. Simulation results demonstrate that this ANN-based strategy significantly improves dynamic performance and adaptability in controlling product purity without requiring a composition analyzer. By leveraging the strengths of traditional Proportional-Integral-Derivative (PID) control alongside data-driven methods, this research highlights a critical advancement in the control of electrified PSD applications, paving the way for more efficient and reliable distillation processes.

The transesterification of propylene carbonate (PC) or ethylene carbonate (EC) to dimethyl carbonate (DMC) by using catalytic reactive distillation (RD) is a promising approach for carbon dioxide utilization. However, there is still scarcity of comprehensive comparison between the two RD processes. Hence, using the UNIQUAC model and kinetics calibrated by literature and our experiments, we conduct an extensive comparison of the two RD processes. Based on the kinetic insights, laboratory RD processes for both reactions are modeled, analyzed, and experimentally validated. Consequently, two RD processes designed to produce 60 ktpy of DMC are optimized and compared. The interplay and control factors between reaction and separation are elucidated and clarified via investigating variations of the actual chemical equilibrium constant profile compared with theoretical values along the reactive section at various pressures, liquid holdups, etc. The results reveal that the optimized EC RD process achieves almost 50 % reductions in both total annual cost and carbon dioxide emission compared to the PC RD process. This work facilitates the carbon neutrality and provides an essential guide for quantitatively assessing the two routes.

Ethanol is used to produce various value-added chemicals and as automobile fuel. Acetic acid hydrogenation to ethanol is of practical significance to meet the increasing market. However, limited engineering research for reactor and crude separation process for the acetic acid hydrogenation to ethanol despite the increasingly mature catalyst system. Moreover, the traditional approach of industrial reactor design mainly relies on point data and inadequately quantifies the strong coupling between reaction rate and transfers within the reactor, which is prone to local and loose design and optimization. In this work, a coupled design approach that combines kinetics with transfers is proposed for designing and optimizing the multi-tubular fixed-bed reactor for the acetic acid hydrogenation to ethanol. To efficiently achieve the products crude separation, staged cooling/flash/absorption/desorption units featuring with N-methyl-2-pyrrolidone as an absorbent is proposed, numerically designed and optimized. Further heuristic heat integration is also investigated to conserve extra energy of the preliminary process, which features that a by-product steam generated from ethanol synthesis reactor is utilized to drive the reboiler of the desorption. It is demonstrated that the heat-integrated process presents significant economic and emission advantages compared with the preliminary process, specifically with 36.5 % and 10.9 % reductions in operating cost and total annual cost respectively, as well as 58.1 % reductions in CO₂ emissions. The cost of synthesizing ethanol with 100 ktpy production is as low as 14.25 $/t. This work could provide a feasible and promising reactor and crude separation process for acetic acid hydrogenation to ethanol, which features economic, high-efficient, energy-saving, and low-carbon.

In industrial processes there are instances where heat pump assisted distillation falls short of full electrification, necessitating an auxiliary reboiler. To solve this limiting issue, this short communication proposes a new method using flash vapour circulation (FVC) to recuperate the waste heat within the heat pump cycle. This method incorporates a flash drum after the throttling valve to generate flash vapour. Rather than employing an auxiliary cooler for condensing the mixed vapour-liquid in a conventional heat pump system, the produced flash vapour is circulated back to the compressor inlet to enhance the recycled heat in the reboiler. With proper energy match, this approach has the potential to realise full electrification of distillation. The distillation of methanol/water serves as an illustrative case study, showcasing the viability of FVC which allows additional 22% energy savings, as compared to mechanical vapour recompression. Yet, this strategy may not be advantageous if the waste heat is already maximally utilised in preheating both the compressor and column inlet feed. The separation of tetrahydrofuran/water is used as case study to demonstrate the limitations of this approach.

Distillation remains the leading and most frequently adopted technique for the separation and purification of condensable mixtures in numerous industries. However, the inherently poor thermal efficiency of distillation requires a large amount of thermal energy, making it the chief factor in total process energy usage and a significant emitter of carbon dioxide due to the combustion of fossil fuels. To address this issue, electrification has arisen as a popular approach to reduce carbon emissions in different processes by primarily replacing the energy source with electricity derived from renewable energy resources. This review is designed to thoroughly explore the electrification concept in decarbonizing distillation and present a detailed analysis and summary of the cutting-edge technologies used in various distillation operations. The focus is on creating electrified distillation processes and their associated utility systems, making use of a range of power-to-heat and intensification strategies, to achieve simultaneous carbon reduction and energy savings. With the increasing variety of operating environments that incorporate renewable power, this review additionally encompasses the control and operation aspects to ensure efficient management of electrified distillation processes. To further delve into the advantages of incorporating electrification into distillation, this work proposes future directions from the viewpoints of technological advancement, design optimization, operation, and real-time scheduling of electrified distillation processes. Furthermore, this review highlights the enormous potential of electrification in dramatically lowering carbon emissions and promoting sustainable practices in the distillation industry.