Distillation processes account for over half of the energy usage in the chemical industry, so efforts to increase energy efficiency through distillation can substantially lower greenhouse gas emissions. To minimize energy usage in distillation and consequently carbon dioxide emissions, process integration (utilizing waste heat), low-grade waste heat upgrading by heat pumps, and optimizing product purification through distillation must all be maximized in order to achieve carbon emission reductions.
Though managing energy usage can be challenging, there are multiple methods available to you that can help minimize its usage. First is through efficient heating sources and insulation measures which reduce energy needs. Next comes optimizing operational aspects such as reducing reflux levels or operating at lower pressures to further lower energy needs. Thirdly comes membrane distillation to further cut back costs.
Distillation columns designed more efficiently can also significantly cut energy use. By employing novel mass transfer internals such as dividing wall towers and perforated trays, such as novel mass transfer internals such as perforated trays can offer significant energy savings. Furthermore, considering additional heat integration options such as boiling bottoms vapor in prefractionators or condensing overhead from distillation column can further cut consumption.
Though a higher reflux ratio would seem like it would provide improved separation, its increased traffic will require more energy to operate than running close to target levels. Furthermore, operating far below target requires even more power than doing so closer to target.
