Aspen plus simulation-assisted vacuum distillation process optimization via response surface methodology (RSM): High-purity recovery of extractant from complex mixed phenolic raffinate and its industrial feasibility
Year: 2025
Type: article
Abstract: To address challenges of multi-component azeotropy, thermal sensitivity of target components in phenol raffinate extractant recovery, and limitations of traditional distillation (semi-empirical models, 6–12-month development cycle, high cost), this study establishes an efficient recovery system via Aspen Plus simulation coupled with Response Surface Methodology (RSM) for multi-factor (operating pressure, feed parameters, reflux ratio) optimization. Adopting a "shortcut→rigorous" simulation strategy, optimal parameters of sieve tray distillation columns were determined: For the cyclohexane column (20 theoretical plates, feed at the 15th plate), the reflux ratio is 0.104, distillate ratio 0.253, and bottom heat duty 5.9134 kW; for the isopropyl ether column (same structure), the reflux ratio is 0.09, distillate ratio 0.26, and bottom heat duty 5.3829 kW (operating pressure 30 kPa, feed pressure 50 kPa, feed temperature 65 °C). These parameters achieve >99.5% extractant recovery while avoiding thermal decomposition of sensitive components, with sieve tray structure optimization enhancing gas-liquid mass transfer. Economic analysis shows a 27.3% lower annual operating cost for alkane-based vs. ether-based schemes. The integrated "simulation-optimization" approach shortens the development cycle to 1–2 months, providing a basis for industrial scale-up with significant engineering value.
Source: Results in Engineering
Authors: Chenglei Wang, Yuanjian Xie, Yihong Zeng, Zhengmin Gao, Pingxiong Cai
Institution: Beibu Gulf University
Language: English
Subfield: Control and Systems Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,940
Award: G4588128081
OpenAlex ID: W4416426083