Abstract
•Reactive distillation has 19 % cost savings in contrast to conventional processes.•50 % less environmental impact can be achieved using reactive distillation.•Reactive distillation has 22 % less risk of accidents than the conventional process.•The feedback control and linear model predictive control have similar performance in controlling the reactive column.•Reactive distillation column has an energy saving of 50 % compared with the conventional process.
Biojet-fuel represents a promising avenue for decreasing CO2 emissions within the aviation industry. Among different biojet-fuel production processes, the Alcohol-to-Jet (ATJ) process stands out as highly promising. Despite its potential, the ATJ process currently faces economic challenges due to low yields and high energy usage. This study introduces a strategy for enhancing the economic feasibility of the ATJ process through process intensification, specifically by incorporating a novel reactive distillation column in the oligomerization stage. This innovative process was evaluated and compared with its conventional counterpart. The total annual cost, eco-indicator 99, and individual risk were chosen as critical parameters for assessing the improvements in cost, environmental impact, and safety brought about by the reactive column. Additionally, control studies were conducted using both Proportional-Integral (PI) and Model Predictive Control (MPC) controllers to determine the feasibility of operating the reactive distillation column. The results suggest that the reactive distillation process offers 20 % cost savings, reduces environmental impact by 50 %, and lowers risk by 22 % when compared to the conventional process. In terms of control strategies, the study found that the catalytic column can be successfully operated using both traditional feedback control and more advanced techniques, such as model predictive control.
[Display omitted]