Economic and environmental reasons have led to process intensifications in the process industries. Reactive
distillation is the most prominent example. However, often it is a challenge to satisfy the requirement for
sufficient catalyst volume for the reaction while providing the interfacial area needed for mass transfer. The
combination of a reactive distillation column with a pre-reactor is a valuable alternative. This paper presents
an approach to identify promising designs for such flowsheets and the optimum distribution of the reaction
extent between the pre-reactor and the reactive distillation column. The methodology uses a boundary value
method for the design of the column; chemical equilibrium is assumed. The column usually consists of a
reactive “core”, two rectifying sections, and one stripping section. The methodology will be demonstrated for
the production of ethyl-tert-butyl-ether (ETBE).