This work addresses the multiobjective design of complex reactive distillation columns through the use of feasible regions. A cost indicator reflecting energy usage and column size is introduced and used to build the Pareto surface describing the optimal combinations of cost and performance. The study includes the use of superheated and subcooled feed streams and searches for the optimal distribution of feeds and catalyst inside the column. The technique is first illustrated for a base case system with ideal vapor-liquid equilibrium and then for two variants with different volatilities for reactants and products. The best trade-off solutions for each system are identified, the operating conditions analyzed, and a selected number of cases investigated further using rigorous simulation in Aspen Plus. Important insights gained and a few heuristic rules about the distribution of the reaction and feed in the column are presented. Furthermore, a methodology that may potentially contribute to overcome limitations on catalyst volume by increasing the specific reaction turnover is presented.
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