An optimization strategy for complex distillation configurations to escape local optima and analysis of its occurrence

Xing Chenghao; Wu Yanyang; Zhou Xiaolong; Wu Bin; Chen Kui; Ji Lijun

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An optimization strategy for complex distillation configurations to escape local optima and analysis of its occurrence

Updated：2026-05-14

- An optimization strategy for complex distillation configurations to escape local optima and analysis of its occurrence
- Chinese Journal of Chemical Engineering Vol. 90, Issue 2, Pages: 333-347(2026)
- Affiliations：
  
  School of Chemical Engineering, East China University of Science & Technology, Shanghai 200237, China
- Author bio：
  
  Corresponding authors. E-mail addresses: wyywitty@ecust.edu.cn (Y. Wu)
  Corresponding authors. E-mail addresses: xiaolong@ecust.edu.cn (X. Zhou).
- Funds：
- DOI：
  CLC：
- Received：31 July 2025，
  
  Revised：2025-09-26，
  
  Accepted：28 September 2025，
  
  Online First：31 October 2025，
  
  Published：2026-02
- Accepted：
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Xing Chenghao, Wu Yanyang, Zhou Xiaolong, et al. An optimization strategy for complex distillation configurations to escape local optima and analysis of its occurrence[J]. Chinese Journal of Chemical Engineering, 2026, 90(2): 333-347.
DOI：

Xing Chenghao, Wu Yanyang, Zhou Xiaolong, et al. An optimization strategy for complex distillation configurations to escape local optima and analysis of its occurrence[J]. Chinese Journal of Chemical Engineering, 2026, 90(2): 333-347. DOI：

摘要

Abstract

Common optimization methods for enhanced distillation include sequential iteration methods and metaheuristic algorithms

which typically face tedious computation

and are easily trapped into local minimum. Therefore

it is essential to develop a strategy that enables simultaneous evaluation of multiple solutions. In this paper

a global optimization framework integrating MATLAB and Aspen Plus for liquid-only extractive dividing wall column (LEDWC) and conventional extractive distillation (CED) systems is proposed to enhance both computational efficiency and search robustness. All possible combinations of key variables

including distillate and entrainer flow rates

feed stage

and total stage numbers

etc.—are considered systematically. They are arranged in full permutation within a sufficiently wide range. The permutation is then divided into multiple matrices by MATLAB. They are sequentially input into sensitivity analysis module in Aspen Plus through communication with MATLAB. Each group of integrated variables which satisfies the given constraints is used for the total annual cost (TAC) calculation. The mixture of ethanol (EtOH) and water

which can form a minimum boiling azeotrope (89.6% (mol) EtOH) at 100 kPa

is taken as a study system. Five different feed mixtures are taken for comprehensive analysis. The TAC profiles as a function of the total number of stages for the left column (N

) in the LEDWC clearly indicate that the proposed strategy successfully identified multiple local minima

demonstrating its capability to detect and escape suboptimal regions in highly nonlinear systems. The existence of local minima can be attributed to the coupling interaction between structural and process variables

as well as the influence of flow characteristics within the column. This work indicates that as N

increases

there is a competitive effect between the decrease in reflux ratio for the left column (RR

) and the increase in reboiler temperature

leading to fluctuations in energy consumption; while changes in the distillation flow rate for the left column cause nonlinear changes in RR

and the liquid flow rate between the l

eft and right columns

further promoting the emergence of multiple local minima during the TAC optimization process. Additionally

analysis of the flow characteristics within the column revealed that the back-mixing phenomenon commonly observed in CED is absent in LEDWC

suggesting that back-mixing may be an important factor contributing to the more frequent occurrence of local optima.

关键词

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