Modeling and Simulation of Reactive and Pressure Swing Distillation Columns for Ethyl Acetate Production using Aspen Plus and MATLAB
 |
International Journal of Recent Engineering Science (IJRES) |  |
| © 2025 by IJRES Journal | ||
| Volume-12 Issue-4 |
||
| Year of Publication : 2025 | ||
| Authors : Yiga F, Okwu K. C |
||
| DOI : 10.14445/23497157/IJRES-V12I4P108 |
How to Cite?
Yiga F, Okwu K. C, "Modeling and Simulation of Reactive and Pressure Swing Distillation Columns for Ethyl Acetate Production using Aspen Plus and MATLAB," International Journal of Recent Engineering Science, vol. 12, no. 4, pp. 86-96, 2025. Crossref, https://doi.org/10.14445/23497157/IJRES-V12I4P108
Abstract
This study develops mathematical models for the esterification of ethanol and acetic acid to produce and separate ethyl acetate from unreacted reactants in a Reactive Distillation Column (RDC). The models describe six discrete column envelopes: reflux drum, rectifying, reactive, feed, stripping, and column base. Four trays (stages 4–7) form the reactive zone, where ethyl acetate and water form alongside unreacted ethanol and acetic acid. The ethyl acetate–ethanol azeotrope forms at the top of the RDC and undergoes separation using Pressure Swing Distillation (PSD). In Aspen Plus, The High-Pressure Column (HPC) operates at 12 bar and 185°C, while the low-pressure column (LPC) runs at 0.5 bar and 45°C. Simulations yield 0.4123 mole ethanol and 0.5877 mole ethyl acetate (ASPEN PLUS) and 0.4356 mole ethanol and 0.5644 mole ethyl acetate (MATLAB) before PSD; values improve to 0.2589 mole ethanol and 0.7411 mole ethyl acetate after PSD. Comparison with literature data (0.2234 mole ethanol, 0.7766 mole ethyl acetate) reveals deviations of 13.74% for ethanol and −4.57% for ethyl acetate. A 10-stage column design improves separation, and optimal feed staging (ethanol at stage 7, acetic acid at stage 4) enhances purity. The results validate PSD’s effectiveness and offer a scalable, energy-efficient pathway for high-purity ethyl acetate production.
Keywords
Azeotrope, Ethyl acetate-ethanol, Reactive distillation column, Pressure swing distillation.
Reference
[1] Damandeep Singh, Raj Kumar Gupta, and Vineet Kumar, “Simulation Studies on Homogenously Catalyzed Finishing Reactive Distillation for Ethyl Acetate Production,” Chemical Engineering Communications, vol. 207, no. 1, pp. 1-14, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[2] N. Calvar, B. Gómez, and A. Domínguez, “Esterification of Acetic Acid with Ethanol: Reaction Kinetics and Operation in a Packed Bed Reactive Distillation Column,” Chemical Engineering and Processing: Process Intensification, vol. 46, no. 12, pp. 1317-1323, 2007.
[CrossRef] [Google Scholar] [Publisher Link]
[3] Chunli Li et al., “Process Intensification and Energy Saving of Reactive Distillation for Production of Ester Compounds,” Chinese Journal of Chemical Engineering, vol. 27, no. 6, pp. 1307-1323, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[4] J. Gmehling, U. Onken, and Wolfgang Arlt, Vapor-Liquid Equilibrium Data Collection, Dechema, pp. 1-600, 1997.
[Google Scholar] [Publisher Link]
[5] Yadollah Tavan, and Seyyed Hossein Hosseini, “Design and Simulation of a Reactive Distillation Process to Produce High-Purity Ethyl Acetate,” Chemical Engineering Research and Design, vol. 44, no. 4, pp. 577-585, 2013.
[CrossRef] [Google Scholar] [Publisher Link]
[6] Miguel A. Santaella, Alvaro Orjuela, and Paulo C. Narváez, “Comparison of Different Reactive Distillation Schemes for Ethyl Acetate Production using Sustainability Indicators,” Chemical Engineering and Processing: Process Intensification, vol. 96, pp. 1-13, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[7] K.K.C.W. Kandanapitiya, and M.Y. Gunasekera, “Modelling of Reactive Distillation for Acetic Acid Esterification,” Engineer: Journal of the Institution of Engineers, Sri Lanka, vol. 48, no. 4, pp. 17-23, 2015.
[CrossRef] [Google Scholar] [Publisher Link]
[8] Jing Yang et al., “Simulation of Pressure-swing Distillation for Separation of Ethyl Acetate-Ethanol-Water,” IOP Conference Series: Materials Science and Engineering: 1st International Conference on Frontiers of Materials Synthesis and Processing, Changsha, China, vol. 274, pp. 1-8, 2017.
[CrossRef] [Google Scholar] [Publisher Link]
[9] Liu Shuhan et al., “Design and Control of Ethyl Acetate–Ethanol Separation via Pressure Swing Distillation,” Theoretical Foundations of Chemical Engineering, vol. 57, pp. 917-932, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[10] Sohail Rasool Lone, and Syed Akhlaq Ahmad, “Modeling and Simulation of Ethyl Acetate Reactive Distillation Column using Aspen Plus,” International Journal of Scientific & Engineering Research, vol. 3, no. 8, pp. 1-5, 2012.
[Google Scholar]
[11] Adnan Aldemir, Dilan Ersingün, and İsmail Bayram, “Dynamic Simulation of a Reactive Distillation Column for Ethyl Acetate Production: Optimization of Operating Conditions Using Response Surface Methodology,” Yuzuncu Yil University Journal of the Institute of Natural and Applied Sciences, vol. 27, no. 2, pp. 365-379, 2022.
[CrossRef] [Google Scholar] [Publisher Link]
[12] Xiuhui Huang et al., “Thermodynamic Analysis and Process Simulation of an Industrial Acetic Acid Dehydration System via Heterogeneous Azeotropic Distillation,” Industrial & Engineering Chemistry Research, vol. 52, no. 8, pp. 2944-2957, 2013.
[CrossRef] [Google Scholar] [Publisher Link]
[13] Statista, Number of Power Conditioners for Stationary on-grid Energy Storage Systems Shipped in Japan in Fiscal Year 2022, by Type. [Online]. Available: https://www.statista.com/statistics/1298183/ethyl-acetate-market-size-worldwide/
[14] Natalie J. Czarnecki, Scott A. Owens, and R. Bruce Eldridge, “Extractive Dividing Wall Column for Separating Azeotropic Systems: A Review,” Industrial & Engineering Chemistry Research, vol. 62, no. 14, pp. 5750-5770, 2023.
[CrossRef] [Google Scholar] [Publisher Link]
[15] Matthias Wierschem, and Andrzej Górak, Reactive Distillation, Reference Module in Chemistry, Molecular Sciences and Chemical Engineering, Elsevier, 2018.
[CrossRef] [Google Scholar] [Publisher Link]
[16] Shoutao Ma et al., “Energy-Saving Thermally Coupled Ternary Extractive Distillation Process using Ionic Liquids as Entrainer for Separating Ethyl Acetate-Ethanol-Water Ternary Mixture,” Separation and Purification Technology, vol. 226, pp. 337-349, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[17] Andras Jozsef Toth, “Comprehensive Evaluation and Comparison of Advanced Separation Methods on the Separation of Ethyl Acetate Ethanol-Water Highly Non-Ideal Mixture,” Separation and Purification Technology, vol. 224, pp. 490-508, 2019.
[CrossRef] [Google Scholar] [Publisher Link]
[18] Dong L. Zhang et al., “Separation of Ethyl Acetate−Ethanol Azeotropic Mixture Using Hydrophilic Ionic Liquids,” Industrial & Engineering Chemistry Research, vol. 47, no. 6, pp. 1995-2001, 2008.
[CrossRef] [Google Scholar] [Publisher Link]