(38h) Achieving Near Optimum Distillation Column Design Early on in the Design Process

Estimating the installed and operational costs of a distillation column is traditionally deferred until late in the design process due to the complexities involved in detailed cost calculation. As a result, early design decisions often rely on rules of thumb, such as selecting a reflux ratio between 1.2 and 1.4 times the minimum reflux ratio. We present a novel approach that integrates Excel with process simulators like Aspen Plus to perform detailed cost analysis across multiple column design alternatives. This method allows for an accurate estimation of both capital expenditure and annual operating costs—including heating and cooling utility expenses—enabling the selection of an optimal design with minimized yearly costs at an earlier stage in the project.
Furthermore, by incorporating our previous research on accurately determining the minimum reflux ratio without the constant relative volatility limitation, we provide a comprehensive, efficient pathway for column design. This approach accelerates the design process, offering engineers a more reliable and economically optimized solution before finalizing project specifications. The combined methodology thus supports more informed decision-making, enhancing the quality and cost-effectiveness of distillation column designs across a range of applications.