In this paper, a new integrated distillation-membrane separation process solution strategy based on genetic programming (GP) was established for azeotrope separation. Then, a price evaluation method based on the theory of unit membrane area was proposed. This method makes the membranes, which are still in the experimental stage, have no actual industrial cost, as a reference can also be used in this experimental study. For different characteristics and separation requirements of various azeotropic systems, the solution strategy can be matched with difference pervaporation membranes, and the optimal distillation-membrane separation integrated process can be solved quickly and accurately. Taking methanol-toluene as an example, the separation operation was optimized by using the algorithm. The effects of different feed flows and compositions on the modification of the chitosan membrane were discussed. These results provide a reliable basis for the prospects for development and modification direction of membrane materials which are still in the experimental research stage.

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A solution strategy of a distillation‐membrane separation process based on genetic programming algorithm (GP) is proposed. It can automatically match diverse membrane materials according to different azeotropic systems and generate various integrated processes. For the membrane, which is still in the experimental research stage, a theoretical prediction method of membrane cost is recommended. Taking the benzene‐cyclohexane system as an example, a GO‐AgNPs/PI membrane and polyurethane membrane were matched, respectively, and the optimal integrated processes can be obtained. The GP strategy provides a strong guidance for the comprehensive design and optimization of distillation‐membrane separation by using various new membranes.

The separation requirements of the ethanol‐tert‐butanol‐water system are difficult to meet due to the formation of azeotropes under normal pressure. After screening the four most important ionic liquids, i.e., [BMIM][BF4], [EMIM][Cl], [HMIM][Cl], and [EMIM][AC], ionic liquid [EMIM][AC] was selected as extractant, and quantum chemical calculations based on COSMO‐SAC theory were carried out to analyze the mechanism of the separation process. An ethanol‐tert‐butanol‐water extractive distillation process was designed, optimized with the goal of the lowest total annual economic cost, and the cost of carbon dioxide emissions was calculated. To further save energy, a heat pump distillation process was designed and compared with the conventional ionic liquid process. The annual total cost of the heat pump distillation process is reduced by 10.11 %, and carbon dioxide emission costs are reduced by 61.9 %. Comparison with the conventional extractive distillation process and its modified process revealed economic advantages for the ionic liquid extractive distillation process and its heat pump version.

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