Hybrid reactive-extractive distillation (RED) has been
popular
for separating azeotropic mixtures, as it combines the chemical reaction
and physical azeotropic separation in a single unit operation. At
least 18 studies have been published between 2020 and 2023, all of
them relying on the hydration of ethylene oxide (EO) to form ethylene
glycol (EG), without considering the potential side reactions that
could impact the RED performance. This study shows one possible scenario
where the formation of higher-level glycols during side reactions
has led to significant increases in the total energy consumption and
the total annual cost (TAC) by about 839 and 154%, respectively. These
increases were due to the larger column size, low operating pressure,
and more expensive cooling refrigerant. Hence, the performance of
RED may not be as favorable as previously reported, and side reactions
can significantly reduce its effectiveness. Future RED studies must
consider the potential side reactions.
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