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• The efficiency factor that considers the catalyst layer structure was obtained. • A multi-scale and multi-objective model was proposed for catalytic distillation. • The parameters of column, and the structure of catalyst layer were optimized. This work aims to establishing a multi-scale and multi-objective optimization strategy for the catalytic distillation process. Firstly, the catalyst layer efficiency factor correlation that embraces the influence of the catalyst layer structure was obtained and then coupled with the process simulation to establish a multi-scale model for the catalytic distillation process. On this basis, genetic algorithm was employed to realize the multi-objective optimization. The hydrolysis process of methyl acetate in the reactive dividing wall column was investigated. The equipment parameters and operational conditions of the catalytic distillation column, and the structure parameters of the catalyst layer are optimized simultaneously. The results indicated that the minima of the total annual cost, the gas emission cost and the exergy loss decrease by 19.26%, 23.11% and 67.27%, respectively, by comparing with the counterparts obtained from the single-factor sensitivity analysis. Furthermore, the catalyst cost decreases by 30.88% per year. [ABSTRACT FROM AUTHOR]

• Vapor-liquid mass transfer layer performance was studied by the tracer method. • Mass transfer coefficients that consider four structure parameters were obtained. • The correlations of mass transfer coefficients exhibit good universality. • The correlations were used for the structure optimization of mass transfer layer. In order to implement the multi-scale model to optimize the structure of vapor-liquid mass transfer layer, vapor and liquid mass transfer coefficients that embrace the effects of structure parameters of mass transfer layer should be obtained in advance. In the study, the influences of four structure parameters on mass transfer performance were studied by the tracer method. Moreover, the corresponding mass transfer coefficients were correlated. By comparing with the experimental data of different types of structured catalytic packings, it has been found that the correlations exhibit good universality. Furthermore, the correlations were applied to the non-equilibrium model for the hydrolysis of methyl acetate (MA), so as to investigate the influences of four structure parameters on catalytic distillation process. The results indicated that wavy height and the area ratio of mass transfer layer to catalyst layer have more significant influences on the conversion of MA than inclined angle and base length. [ABSTRACT FROM AUTHOR]