Reduction In Total Annual Cost Research Articles

Enhancing exergy efficiency and environmental sustainability in pressure swing azeotropic distillation

This study explores the economic, energetic, exergy efficiency, and environmental benefits of energy integration in pressure-swing distillation, focusing on the separation of tetrahydrofuran/water and acetone/chloroform azeotropes. Heat integration and heat pump techniques are applied to reduce energy consumption. Three energy-efficient configurations are examined, comparing total annual cost (TAC), total energy consumption (TEC), CO2 emissions, and second-law efficiency. In the tetrahydrofuran/water system, heat integration and heat pump technologies outperform conventional processes, achieving up to 50.2% TAC reduction, 59.6% TEC reduction, 82.8% CO2 emission reduction, and thermodynamic efficiencies up to 23.5%. In the acetone/chloroform system, similar improvements are observed, with up to 70.9% TAC reduction, 87.2% CO2 emission reduction, and thermodynamic efficiencies up to 17.6%. These findings demonstrate the effectiveness of energy-saving strategies, endorsing process intensification for environmentally sustainable azeotropic mixture separations.

A vapor phase side stream intensified extractive distillation process for separation of azeotropic mixture 2, 2, 2-trifluoroethanol and water

2,2,2-Trifluoroethanol (TFE) is an important organic fluoride with various commercial applications. During the production of TFE through hydrolysis, an azeotrope of TFE and water can form, making it challenging to separate using conventional distillation. This study proposes a novel approach employing vapor phase side stream intensified extractive distillation separation (VSED) with glycerol serving as an entrainer to address this challenge. Additionally, a dividing wall column process (DWC) is established. The total annual cost (TAC), CO2 emissions and total energy cost (TEC) of the proposed separation processes are calculated and compared. The results indicate that VSED process can recover TFE with a purity of 0.9995 (mole fraction). VSED exhibits a TAC reduction of 34.2 % and a CO2 emissions reduction of 33.9 % compared to the CED process. In addition, a dual-composition control strategy is proposed for the VSED process. The results show that control strategy can effectively cope with the feed flow perturbation of ±20 % and the feed composition perturbation of ±5 %.

Design and control of a novel multi-product extractive dividing wall column process for recycling organics from wastewater

The wastewater from a pharmaceutical plant consists of a tetrahydrofuran/isopropanol/water azeotrope. This investigation utilizes dimethyl sulfoxide as an extractant and employs an extractive dividing wall column to separate the aforementioned azeotrope. The extractive dividing wall columns are constructed with single, double, and triple partition walls, and a multi-objective genetic algorithm is used to optimize the operational parameters of the separation process. Of these columns, the extractive dividing wall columns with triple partition walls show the most favorable economic, environmental, and energy utilization performance, and it has a lower risk of combustion and explosion. Compared to the conventional design, the use of triple-partition extractive dividing wall columns results in a 22.13 % and 10.54 % reduction in total annual cost and CO2 emissions, respectively, and an increase in thermodynamic efficiency of 2.66 %. Studying the dynamic characteristics of this process reveals its excellent dynamic controllability.

Efficient hybrid strategy for simultaneous design of refinery hydrogen networks and pressure swing adsorption unit

Refineries face increasing hydrogen demand due to the consumption of heavy and sour crude oil. This study presents a novel hybrid method to optimize hydrogen network configurations with a rigorous pressure swing adsorption (PSA) process model. This method utilizes Bayesian optimization to address the upper-level unknown constraints black-box optimization problem while employing deterministic algorithms to manage the lower-level nonlinear programming problem. Furthermore, infeasible regions are transformed into feasible ones by introducing a dummy stream, and the costs incurred during the transformation process are accurately calculated. The proposed method is validated using two literature cases. In Case 1, Bayesian optimization outperformed the Kriging model, resulting in a 7.84% reduction in total annual cost (TAC). In Case 2, a comparison of four search strategies revealed the developed two-phase strategy as the most effective one. This method offers a powerful and practical tool for optimizing real-world hydrogen networks with PSA processes.

Production of α-olefins from biomass gasification: Process development and multi-objective optimization for techno-economic and environmental goals

Efficient utilization of biomass as a substitute for fossil fuels holds great promise for meeting future greener chemical demands in a sustainable manner. This study presents a process simulation and multi-objective optimization for an innovative process of biomass-based Fischer-Tropsch synthesis of value-added linear α-olefins. Optimal design and operation solutions with heat-exchange network integration taken into account are obtained that minimize total annual costs (TAC), generalized energy consumption (GEC), greenhouse gas emissions (GHG), and maximize product yields (η). Compared to the benchmark case, this optimization leads to a 9.93 % reduction in TAC, a 21.76 % reduction in GEC, a 19.23 % reduction in GHG, and increases η by 1.41 %. Additionally, a comprehensive factor analysis of the optimal design and operation parameters in the Pareto front helps to discover patterns related to energy consumption, environmental impact, or economy. This allows to maximize a specific key process performance metric while minimizing the loss in the other, thus enabling flexible process design and operation under diverse manufacturing environments.

A new hybrid reactive-extractive distillation configuration for ternary azeotropic separation with intensification opportunity

The concept of reactive-extractive distillation (RED) is not new and has gained significant attention as an innovative approach for separating azeotropic mixtures. Presently, there have been at least 18 studies on RED, exploring variations such as triple column RED (TCRED), double column RED (DCRED), and their intensified configurations like dividing-wall DCRED (DW-DCRED) or side-stream DCRED (SS-DCRED). However, a major drawback observed in all existing intensified RED studies is the inability to achieve energy savings, which contrasts with the outcomes of most conventional distillation system studies. To address this, we propose a new alternative configuration called extractive-reactive distillation (ED-RD) by rearranging the column sequence in DCRED. The ED-RD configuration achieves a substantial 7 % reduction in the total annual cost (TAC) compared to DCRED, primarily due to a reduced number of stages and the utilization of relatively cheaper low-pressure steam in the extractive distillation column (EDC). Furthermore, the intensified thermally coupled ED-RD (TC-ED-RD) configuration demonstrates superior performance, achieving an impressive 21 % reduction in TAC compared to the proposed ED-RD configuration, mainly driven by a significant decrease in total reboiler energy consumption. Overall, the TC-ED-RD configuration excels with a remarkable 28 % reduction in total reboiler energy consumption and a 27 % decrease in TAC compared to DCRED. This reflects the potential of incorporating process intensification techniques to the proposed configuration to achieve substantial energy and cost savings, in contrast to the limitations observed in the conventional RED systems.

Molecular mechanism-based extractant screening and process design for the separation of methanol/dimethyl carbonate azeotrope

The separation of methanol/dimethyl carbonate azeotrope is an important process in the industrial production of dimethyl carbonate. Extractive distillation is an effective separation method, which can ensure the full utilization of resources and achieve sustainable development. In this work, an extractant screening method based on density functional theory (DFT) was proposed. By comparing the interaction energy difference, the optimal extractant (dimethyl sulfoxide, DMSO) was obtained. The molecular mechanism of action between the extractant and the separated components was explained. The separation order of the components of the extraction distillation process was obtained by the magnitude of the interaction energy. The σ-profile curve and isovolatility curves method were used to verify the effectiveness of the proposed method. A new separation process with DMSO as an extractant was designed. With the lowest total annual cost (TAC) as the goal, sensitivity analysis and cyclic iteration method is used to optimize the parameters involved in the process to determine the best process parameters. Heat integration technology is introduced to further reduce energy consumption. TAC, energy utilization efficiency, and global warming potential (GWP) were used to evaluate the process. Compared with the reported optimal extractant methyl salicylate, the TAC of the simple process using DMSO as the extractant was reduced by 9.08%. The heat-integrated process with DMSO shows a TAC reduction of 17.17% compared to the simple process. And the energy utilization efficiency and GWP were increased by 40.90% and decreased by 31.88%, respectively. The results show that the extractant screened by DFT method is applied to the azeotrope separation, which makes the process have good economic benefits, low energy consumption, and less environmental impact.

Separation of Ternary System 1,2-Ethanediol + 1,3-Propanediol + 1,4-Butanediol by Liquid-Only Transfer Dividing Wall Column

This study focuses on separating a mixture consisting of 1,2-ethanediol (1,2-ED), 1,3-propanediol (1,3-PD), and 1,4-butanediol (1,4-BD). Vapor–liquid equilibrium (VLE) data for 1,2-ED + 1,4-BD and 1,3-PD + 1,4-BD are determined at 101.3 kPa using a modified Rose equilibrium still. The consistency of the VLE data is checked with both Redlich–Kister and Fredenslund tests. The VLE data are fitted by the Wilson, NRTL, and UNIQUAC activity coefficient models. All three models can effectively correlate the VLE data. Then, the separation of the mixture is designed with the NRTL model and its correlated binary interaction parameters. A liquid-only transfer dividing wall column (LDWC) is investigated on the basis of a direct conventional distillation sequence (DCDS). For a fair comparison, both DCDS and LDWC are optimized to minimize total annual cost using sequential iterative optimization procedures. After optimization, LDWC exhibits a 16.87% reduction in total annual cost, while cooling and heating utility consumptions are reduced by 28.40% and 19.24% compared to DCDS.

Design and control of an energy-efficient intensified process for biobutanol purification from isopropanol-butanol-ethanol (IBE) fermentation broth

Biobutanol is one of the most preferable alternative fuels because of its superior fuel properties compared to other biofuels. In recent years, biobutanol production through isopropanol (IPA)-butanol-ethanol (IBE) fermentation has gotten more attention than acetone-butanol-ethanol (ABE) fermentation. However, the downstream separation process of this production is very energy intensive due to the several azeotropes. In this study, an energy-efficient process configuration including a reactive distillation column is proposed to break the azeotropes. In the proposed configuration, water present in the azeotropic mixture is consumed by a water-ethylene oxide (EO) reaction. Steady-state results show that the proposed configuration provides a 30% decrease in energy consumption and a 26.7% reduction in total annual cost (TAC) compared to the configurations in the literature, while ethylene glycol is obtained as a by-product besides the biobutanol of 99.5% purity. Additionally, two plantwide control structures are developed, and the dynamic controllability of the configuration is examined. Dynamic results illustrate that a robust control is provided with the proposed control structure 2 (CS2) when it is tested against disturbances in feed flowrate and feed composition.

An efficient multi-criteria decision making for assessing the optimization of reactive extractive distillation in terms of economy, environment and safety

In order to effectively separate complex azeotropic mixtures, it is crucial to consider economic, environmental, and safety factors during the process design and optimization. This study presents a systematic approach to separate a ternary azeotropic mixture of tetrahydrofuran, methanol, and water by employing multi-objective optimization and multi-criteria decision making. Two energy-efficient configurations, i.e., double-column reactive extractive distillation and reactive-extractive dividing wall column, are proposed by integrating reaction and extractive distillation in a single unit. The developed processes are then optimized using a multi-objective particle swarm optimization algorithm, considering the aforementioned factors. Finally, a multi-criteria decision making technique is applied to rank the Pareto frontier solutions obtained from the optimization process, using a combination of gray relational analysis and entropy weight method. Compared to the base case, the double-column reactive extractive distillation process exhibits a significant reduction in total annual cost (59.39 %) and CO2 emissions (61.75 %). Through comprehensive evaluation, the double-column reactive extractive distillation process is found to be the most effective separation solution among the proposed and existing processes. This systematic approach can be extended to other complex aqueous azeotropic systems for their design, optimization, and decision making.

A novel hybrid process design for efficient recovery of hydrophilic ionic liquids from dilute aqueous solutions

AbstractIonic liquids (ILs) have received much attention in both academia and industries due to their superior performance in many applications. Efficient recovery/recycling of ILs from their dilute aqueous solutions is essential for the acceptance and implementation of many IL‐based technologies by industry. In this work, a practical and cost‐effective hybrid process design method that combines aqueous two‐phase extraction, membrane separation, and distillation operating at their highest efficiencies is proposed for the recovery of hydrophilic ILs from dilute aqueous solutions. The application of this hybrid process design method is illustrated through case studies of recovering two hydrophilic ILs, n‐butylpyridinium trifluoromethanesulfonate ([C4Py][TfO]) (CAS number: 390423‐43‐5) and 1‐butyl‐3‐methylimidazolium chloride ([C4mIm][Cl]) (CAS number: 79917‐90‐1), from their dilute aqueous solutions. For the recovery of 10 wt.% [C4Py][TfO] from aqueous solution, the hybrid process using (NH4)2SO4 as the salting‐out agent could reduce the total annual cost (TAC) and energy consumption by 57% and 91%, respectively, compared with the pure distillation processes. In the case of recovering 10 wt.% [C4mIm][Cl] from aqueous solution, the reduction in TAC and energy savings of the hybrid process with salting‐out agent (NH4)2SO3 could reach 49% and 87%, respectively, compared with the pure distillation process. Furthermore, uncertainty analysis through Monte Carlo simulations show that the proposed hybrid process design is more robust to uncertainties in energy prices and other material (e.g., equipment and solvent) costs.

Control of fully heat-integrated pressure-swing distillation with strict pressure manipulation: A case study of separating a maximum-boiling azeotrope with small pressure-induced shift

Pressure-swing distillation (PSD) is an alternative configuration used to separate pressure-sensitive azeotropes and avoid product contamination(s) in extractive or heterogeneous azeotropic distillation via the entrainer(s). Full heat integration between high- and low-pressure columns (HPC and LPC) can provide significant energy savings compared to the conventional case, while it also loses the control degree of freedom, trim condenser or reboiler heat load, via the integrated condenser/reboiler exchanger. Typically, the pressure of HPC is left uncontrolled, and additional pressure-compensated control strategies are implemented, which may create safety issues. To address this, the study proposes adding an auxiliary cooling-water-driven condenser to the fully heat-integrated PSD system, providing an extra manipulated variable to regulate the pressure of HPC. Compared to the conventional PSD system, the new modified process could achieve a 26.31% reduction in total annual cost. The research uses the maximum-boiling azeotropic mixture of acetone/chloroform as a case study which makes the distillation system characterized by high reflux ratios and a large recycle flow rate, leading to the unwelcome snowball effect. To achieve effective process control, robust control structures are proposed that rigorously regulate the pressure of the column by manipulating the heat removal in the trim condenser, attenuating or eliminating potential overpressure issues. Product purity and other evaluation indicators, such as product transient deviations, offsets, integral absolute error, and oscillation degrees, are also considered. Results show that the proposed control schemes can efficiently control the pressure of HPC, weaken the snowball effect, and maintain product purity. This study highlights the importance of pressure control for fully heat-integrated PSD systems, particularly for pressure-sensitive azeotropes with small pressure-induced shifts.

Conceptual process design and process optimization of triple-column pressure-swing distillation for the separation of ternary mixtures embedding two azeotropes with different feed composition via thermodynamic insights and genetic algorithm

In this article, we take the tetrahydrofuran (THF)/ethanol (ETOH)/methanol (MeOH) as an example to investigate the process design of the triple-column pressure-swing distillation (TCPSD) for the separation of Serafimov’s class 2.0-2b mixtures with different feed composition. Two basic topology structures (TSI, TSII) and two separation sequences (SSI, SSII) are investigated, then, process optimization with total annual cost (TAC) as objective function is conducted via genetic algorithms. Heat integration (HI) is also applied to TCPSD. From a new perspective, the separation of THF/ETOH/MeOH can be regarded as the azeotropic distillation for THF/ETOH with MeOH as azeotropic agents based on thermodynamic features of Serafimov’s class 2.0-2b mixtures. The feasible topology structure and separation sequence of TCPSD for Serafimov’s class 2.0-2b mixtures depend on the feed composition and operating pressure. The feed composition is divided into three regions according to the concentration of methanol in azeotropic distillation column. The two critical points are azeotropic points at allowed minimum and maximum operating pressure. Especially, when feed composition is below azeotropic point at allowed minimum operating pressure, TSI is not feasible due to less MeOH as azeotropic agents. Furthermore, TCPSD combining pure azeotropic agents (ATPSD) can be developed based on this new insight. Then, two feed compositions are used to illustrate the detailed conceptual design of three topology structures as well as corresponding two separation sequences and their economic performance. The results show that when feed composition is 0.4ETOH/0.25THF/0.35MeOH, TSI and TSII are feasible, the best economical configurations without and with heat integration is TSII-SSII and TSII-SSII-HI. When feed composition is 0.4ETOH/0.4THF/0.2MeOH, TSII and ATPSD are feasible, the best economical configurations without and with heat integration is ATPSD-SSI and ATPSD-SSI-HI. Furthermore, ATPSD-SSI and ATPSD-SSI-HI have 18.28% and 19.38% TAC reduction than TSII-SSI and TSII-SSI-HI, respectively. In summary, feasible and the best economic topology structure and separation sequence of TCPSD for Serafimov’s class 2.0-2b mixtures depend on the feed composition and operating pressure. In addition, the proposed ATPSD shows good economic performance for Serafimov’s class 2.0-2b mixtures.

The quest for a better solvent for the direct hydration of cyclohexene: From molecular screening to process design

Cylcohexanol is an essential bulk chemical that can be produced via cyclohexene hydration, a liquid-liquid two-phase reaction that is limited by the low reaction rate and the equilibrium conversion. Adding an appropriate solvent is the most promising method to break through these limitations. However, in previous works the solvent was almost blindly selected without a global consideration. In this work, a rational multiscale method is proposed for the effective selection of an economical and sustainable solvent for the direct hydration of cyclohexene. At the molecular scale, liquid-liquid phase equilibrium was estimated using group contribution methods to rapidly screen the potential solvent candidates from a range of organics, based on the partition coefficient. At the reactor scale, the candidates were experimentally investigated to pick out the solvents that could significantly improve the conversion, without introducing side reactions or deactivating the catalyst. At the process scale, the total annual cost (TAC), CO2 emission, and other metrics were calculated to evaluate the eco-efficiency of all solvents. Using this multi-scale method, acetophenone was selected as an eco-efficient solvent from over 100 organics, resulting in the reduction of TAC by 8 % and CO2 emission by 17 % in the production process. Using acetophenone also led to the increase of cyclohexanol yield from 12.3 % to 27.6 % without the occurrence of side reactions and catalyst deactivation.

Selection of eco-efficient downstream separation configuration for isopropanol–butanol–ethanol purification process

Nowadays, renewable and cleaner biofuel requirements increase with the increase in economic, environmental, and social concerns. Biobutanol is a preferable alternative fuel due to its outstanding properties compared to other alcohol-based biofuels. Two alternative downstream process configurations are designed in this study to obtain high-purity alcohol products from isopropanol–butanol–ethanol (IBE) fermentation broth with the same feed flowrate and compositions. In process configuration 1, the excess amount of water in the fermentation broth is mainly taken away using a preconcentration column. In process configuration 2, an extractor-extractive distillation hybrid system is used to remove the excess amount of water from the system. The results show that the first configuration is superior with a 62% reduction in total annual cost (TAC). Besides economic superiority, process configuration 1 is also quantitatively better than process configuration 2 in terms of gas emissions and energy demand to purify butanol. As a result, process configuration 1 is found as an eco-efficient downstream separation sequence for IBE purification process.

Mixed Ionic Liquids as Entrainers for Aromatic Extraction Processes: Energy, Economic, and Environmental Evaluations

Experimental measurements for the vapor–liquid equilibria (VLE) of benzene + 1-ethyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide ([EMIM][NTf2]), benzene + 1-ethyl-3-methylimidazolium ethylsulfate ([EMIM][EtSO4]), and benzene + mixed ionic liquids (ILs) (equimolar [EMIM][NTf2] + [EMIM][EtSO4] mixture) are performed. The non-random two liquid (NRTL) model binary interaction parameters are then obtained by fitting the new VLE data and the liquid–liquid equilibrium data previously reported. The interactions between chemical species are analyzed using quantum chemical calculations and the COSMO-SAC method, and it is found that the interactions between benzene and ILs are strongly attractive. Taking as a reference the industrial process that uses sulfolane as the entrainer, several novel industrial processes are proposed, which involve either pure ionic liquids [EMIM][NTf2] and [EMIM][EtSO4] or their mixtures as the extractant for separating aromatic hydrocarbons (benzene) and paraffins (n-hexane). The optimal operating parameters, such as the number of theoretical stages, the extractant-to-hydrocarbon feed ratio, the reflux ratio, and the feed stage, are determined for the different processes. Steady-state process simulations are performed to evaluate the total annual cost (TAC) and the environmental impact (carbon dioxide emissions). It is shown that significant savings in energy consumption (reduction of 19.6–48.7%), TAC (reduction of 6.3–27.1%), and CO2 emissions (reduction of 17.8–47.6%) can be achieved for the processes that use IL extractants, compared to the process based on sulfolane extractant. The proposed IL extractant and the corresponding process are promising alternatives to conventional solvents and processes for aromatic extraction.

Comparison of different extractive distillation processes for chloroform/n‐hexane separation: design and control

AbstractBackgroundWhen extracting total glycosides from Panax notoginseng, a waste liquid containing chloroform and n‐hexane will be produced. These waste liquids are not separated and recycled in time, which will not only waste resources but also cause environmental pollution. Chloroform and n‐hexane form an azeotrope which cannot be separated by ordinary distillation methods. This study proposes three extractive distillation processes to separate the chloroform/n‐hexane azeotrope: conventional extractive distillation (ED), side‐stream extractive distillation (SSED) and extractive dividing wall column (EDWC). The total annual cost (TAC) and carbon dioxide (CO2) emissions of the three options were compared, and the optimal process was selected. Furthermore, this research developed dynamic control of the optimal process.ResultsCompared with ED, from the perspective of economic indicators, the SSED process showed 18.9% reduction in TAC yet the EDWC process showed 33.2% reduction in TAC. In terms of CO2 emission indicators, the EDWC process also is more advantageous. Three control structures thus were developed for EDWC: applying ±5% or ±10% feed flow disturbance, and feed composition disturbance. The results show that CS3 with temperature composition cascade control structure can perfectly control all disturbances.ConclusionThis paper designs an economical, environmentally friendly and controllable chloroform/n‐hexane azeotropic separation process, which can provide a reference for the industrial application of chloroform/n‐hexane separation. © 2022 Society of Chemical Industry (SCI).

Comparative optimal design and effective control of different pressure extractive distillation for separating acetone - Methanol

Acetone and methanol are critical industrial feedstocks as well as organic solvents. Previous studies on the separation of the minimum-boiling azeotrope acetone-methanol by pressure-swing extractive distillation have shown superiority in terms of energy and cost savings. However, the pressure-varying configuration inevitably requires high-grade heat steam. To surpass the limitation, a novel different pressure extractive distillation strategy is proposed in this paper. The conceptual design of the different pressure extractive distillation configuration is carried out from thermodynamic insights, and the feasible ranges of entrainer/feed flow rate ratio and reflux ratio are determined. The design parameters are optimized by an improved non-dominated sorting genetic algorithm. Compared with the conventional extractive distillation process, the total annual cost (TAC) and CO2 emissions of the proposed process are reduced by 22.17% and 48.14%, respectively. An alternative different pressure extractive distillation process with feed preheating is then obtained by changing feed thermal condition, which has a 24.08% reduction in TAC and a 48.33% reduction in CO2 emissions in comparison with the conventional extractive distillation process. Compared with the existing heat-integrated pressure-swing extractive distillation process, the new process has a 2.90% and 22.36% reduction in TAC and CO2 emissions, respectively. Subsequently, two control schemes are presented by calculating controllability indicators in the steady-state design stage. The results illustrate that the improved control scheme with multiple feedforward control loops performs the best robustness.

Sustainable design and multi-objective optimization of eco-efficient extractive distillation with single and double entrainer(s) for separating the ternary azeotropic mixture tetrahydrofuran/ethanol/methanol

Sustainable process for the separation of ternary azeotropic mixture tetrahydrofuran/ethanol/methanol should be developed to recycle value-added organic components and protect environment. Thereby, in this work, we propose an approach to develop a sustainable process for the recovery of these valuable compounds from their ternary azeotropic mixture. The suitable entrainers of direct and indirect extractive distillation processes are firstly screened via the thermodynamic insights (e.g., volatility line). Next, the separation sequence for the developed extractive distillation processes is determined by combining the residue curve maps, volatility order, and Lever rule. Then, the multi-objective particle swarm optimization algorithm is employed to obtain the established processes with optimal operating parameters via the integration of Matlab and Aspen Plus. Eventually, four indexes include total annual cost, CO2 emissions, process route index, and thermodynamic efficiency, which are used to assess the economic, environmental, safety, and energy efficiency performances. Relative to the indirect process, the direct extractive distillation sequence, in particular, provides 15.61%, 9.75%, and 48.4% reduction in total annual cost, CO2 emission, and inherent safety, respectively, while it improves the energy efficiency by 29.7%.

Intensified hybrid reactive-extractive distillation process for the separation of water-containing ternary mixtures

• Process intensification for separating water-containing ternary azeotropic mixtures. • Combine reactive distillation and extractive distillation into one column. • Systematic VLE analysis helps to screen for feasible ternary systems. • Three ternary systems including: TBA/EtOH/water, THF/EtOH/water, and ACN/IPA/water. • Significant reduction in total annual cost is achieved in all applications. Separation of ternary mixture is a challenging task if multiple azeotropes exist among the components, and special distillation techniques should be adopted. For water-containing ternary mixtures with multiple azeotropes, a dehydrating agent, ethylene oxide (EO), can be used to consume water with the production of ethylene glycol (EG) as the product, which can be utilized as entrainer for separating the remaining two components. In this work, systematic thermodynamic analysis was conducted to screen for the feasible ternary systems. After conducting suggested analysis without needing of rigorous process simulation, tert -butyl alcohol (TBA)/ethanol (EtOH)/water, tetrahydrofuran (THF)/EtOH/water and acetonitrile (ACN)/isopropyl alcohol (IPA)/water mixtures were chosen to be suitable for this application. Within the scope of using dehydrating agent, a process configuration of triple column reactive-extractive distillation (TCRED) is developed for three different ternary systems. Subsequently, an intensified process configuration - double column reactive-extractive distillation (DCRED), which combines both functions of reactive distillation and extractive distillation in a single unit, is constructed to significantly reduce capital cost and energy consumption. With the application of further energy-saving schemes in the systems, total annual cost and total operating cost of the final proposed design flowsheets can be considerably saved compared to respective separation systems recently published in open literature.