Comparative Energy Analysis of Intensified Distillation Technologies for Sustainable Chemical Processing
DOI:
https://doi.org/10.61978/catalyx.v2i2.1329Keywords:
distillation, process intensification, energy efficiency, dividing wall column, heat integration, hybrid membrane systemsAbstract
Distillation remains one of the most widely applied yet energy-intensive separation processes in the chemical industry. This study evaluates the potential of intensified distillation technologies specifically Dividing Wall Columns (DWC), Heat-Integrated Distillation Columns (HIDiC), Mechanical Vapor Recompression (MVR), Reactive Distillation with Heat Integration (RD + HI), and Hybrid Membrane Systems to reduce energy consumption and improve sustainability. A comprehensive methodology was applied using standardized performance metrics, comparative data analysis, and literature-backed energy efficiency benchmarks. Key findings show that HIDiC systems achieve the highest energy savings, up to 70%, followed by MVR and RD + HI, while DWC systems offer practical energy reductions between 15–44% with additional environmental benefits. Hybrid systems also contribute to energy efficiency, particularly in applications targeting water recovery and zero-liquid discharge. The discussion addresses trade-offs between energy savings and capital investment, the influence of technology readiness levels, and decision-making frameworks for selecting appropriate technologies based on energy demands, control complexity, and product purity. The study concludes that process intensification technologies provide a viable route toward sustainable industrial distillation. Their adoption should be driven by long-term operational savings, environmental compliance, and integration potential with advanced control systems. This work offers a structured basis for evaluating and implementing intensified distillation technologies across industrial contexts.
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