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• The waste heat of extraction - extractive distillation is recovered by heat integration and organic Rankine cycles. • Compared with the heat-integrated process, organic Rankine cycle assisted process save 8.88% total annual cost. • The control scheme of organic Rankine cycle assisted extraction - extractive distillation process shows good robustness. The high-purity isopropanol butanol ethanol (IBE) mixture is a highly efficient gasoline additive that can be directly used without further separation. The product of isopropanol-butanol-ethanol fermentation contains a large amount of water, and a large amount of energy will be consumed in the purification process. In this paper, the separation IBE process is systematically studied from the aspects of process optimization, energy recovery and process control. The operation parameters of extraction combined with extractive distillation (E-ED) are optimized by a multi-objective genetic algorithm. Then, the pinch point technique is used to analyze the energy usage of the optimized process, and the maximum heat recovery heat integration scheme is obtained. Compared with the optimized process, the low pressure steam consumption of the heat integration process is reduced by 100%, the cooling water consumption is saved by 58.80%, and the TAC is reduced by 35.95%. In view of massive waste heat in the heat integration of the extraction combined with extractive distillation (E-ED-HI) process, a new configuration combining the E-ED-HI and organic Rankine cycle (E-ED-HI-ORC) is further proposed. The organic Rankine cycle using R600a can further reduce TAC by 8.88% based on the HI-E-ED process. Finally, the control scheme of E-ED process is proposed. The performance of the control scheme is examined with ±10% disturbance of the feed flow rate and composition change, and the results show that the process of extractive distillation and separation of IBE has good controllability. [ABSTRACT FROM AUTHOR]

[Display omitted] • Five control strategies are proposed for the reactive-extractive dividing wall column. • The basic control structure is established based on steady-state controllability indicators. • The three-point temperature control structure exhibits the best robustness. • The stoichiometric ratio and vapor split ratio are critical for mass control loops. The reactive-extractive dividing wall column (REDWC), which combines conventional reactive distillation, extractive distillation, and dividing wall column, is a highly integrated process with a compact physical space and strong interrelations between variables. It is challenging to design robust control strategies for the REDWC process. However, there are no investigations reported on the control of REDWC. In this study, through analyzing open-loop controllability indicators of the steady-state process, the basic control structure (CS1) is constructed. Subsequently, four proportional-integral control schemes are further established on the CS1: the proportional control structure (CS2), the internal composition control structure (CS3), the feedforward control structure (CS4), and the three-point temperature control structure (CS5) with feedforward loops. The dynamic performance tests are conducted with ± 10 % feed flow rate and ± 10 % feed composition disturbances. The qualitative research demonstrates that the CS5 offers the best dynamic performance in terms of settling time, steady-state deviations, and overshoots without the use of expensive composition controllers. With the integral absolute error (IAE) as an evaluation criterion, it is quantitatively demonstrated that the CS5 has the best robustness and should be the preferred control scheme. Another key finding shows that the vapor split ratio and the stoichiometric ratio of the reactants are two crucial degrees of freedom to guarantee product quality in the REDWC. The major contributions of this work are to provide a meaningful reference for the control of the REDWC and even more complicated distillation. [ABSTRACT FROM AUTHOR]

[Display omitted] • A new different pressure extractive distillation strategy is proposed. • The feasible ranges of entrainer/feed flow rate ratio and reflux ratio are determined. • The variables are optimized by an improved non-dominated sorting genetic algorithm. • The improved control scheme with feedforward loops performs the best robustness. Acetone and methanol are critical industrial feedstocks as well as organic solvents. Previous studies on the separation of the minimum-boiling azeotrope acetone-methanol by pressure-swing extractive distillation have shown superiority in terms of energy and cost savings. However, the pressure-varying configuration inevitably requires high-grade heat steam. To surpass the limitation, a novel different pressure extractive distillation strategy is proposed in this paper. The conceptual design of the different pressure extractive distillation configuration is carried out from thermodynamic insights, and the feasible ranges of entrainer/feed flow rate ratio and reflux ratio are determined. The design parameters are optimized by an improved non-dominated sorting genetic algorithm. Compared with the conventional extractive distillation process, the total annual cost (TAC) and CO 2 emissions of the proposed process are reduced by 22.17% and 48.14%, respectively. An alternative different pressure extractive distillation process with feed preheating is then obtained by changing feed thermal condition, which has a 24.08% reduction in TAC and a 48.33% reduction in CO 2 emissions in comparison with the conventional extractive distillation process. Compared with the existing heat-integrated pressure-swing extractive distillation process, the new process has a 2.90% and 22.36% reduction in TAC and CO 2 emissions, respectively. Subsequently, two control schemes are presented by calculating controllability indicators in the steady-state design stage. The results illustrate that the improved control scheme with multiple feedforward control loops performs the best robustness. [ABSTRACT FROM AUTHOR]