The separation of butadiene 1,3 from pyrolysis products is a critical step in the petrochemical industry, as butadiene is a key raw material for producing synthetic rubber and other polymers. This study presents a detailed model-based analysis of the separation process, focusing on optimizing operational parameters to maximize butadiene recovery, enhance product purity, and reduce energy consumption. The simulation was conducted using Aspen Plus, evaluating critical variables such as the solvent-to-feed ratio, reflux ratio, number of column stages, and energy integration between distillation units. The simulation results indicated that an optimal solvent-to-feed ratio of 1.5:1 and a reflux ratio of 4.2:1 in the extractive distillation column provided the highest separation efficiency. Under these conditions, the recovery rate of butadiene 1,3 reached 98%, with a final product purity of 99.5%. Furthermore, this study revealed that increasing the number of theoretical stages in the distillation column improved the separation process without significantly increasing energy demand. Energy integration, specifically through heat recovery between the primary distillation and extractive distillation columns, led to a 12% reduction in total energy consumption. These findings demonstrate the importance of fine-tuning operational parameters to achieve high separation efficiency and product quality while minimizing energy use. This model-based analysis provides valuable insights into the design and optimization of industrial-scale butadiene separation processes, offering strategies to reduce operational costs and improve sustainability in production. The methodology and results can serve as a basis for further improvements in similar separation processes across the petrochemical industry.

In this study, a comparative study was conducted on the two reactor types (the plug-flow and continuous stirred tank reactor) employed for the traditional esterification process to investigate their potential applications to the esterification reaction with the ethanol-rich feed. Aspen Plus software was used to conduct a sensitivity analysis on the temperature profiles in the axial and radial directions, focusing in particular on the reactor and feed stream temperatures, operating parameters, and ethyl acetate yields for the reactors. The energy analysis for esterification processes with the different reactor types has also been evaluated. Compared with the continuous stirred tank reactor, the plug-flow reactor process with the ethanol-rich feed exhibited reduced hotspot temperatures. The simulation results show that the hotspot temperatures in the continuous stirred tank reactor can be within the operating temperature range of 90–100 °C. Regarding the comparison of these reactor types for the esterification process, the plug-flow reactor shows advantages in terms of efficient hotspot temperature with the operating temperature range of 70–75 °C. On the other hand, the yield of ethyl acetate product from the continuous stirred tank reactor is slightly higher than from the alternative esterification process with excess ethanol feed.

Methanol synthesis from CO₂ is a key strategy for carbon capture and utilization, offering a viable solution to mitigate climate change. The direct synthesis of methanol not only reduces greenhouse gases but also produces valuable chemicals for industrial applications. The aim of this study is to model and optimize the methanol synthesis process from CO₂, focusing on maximizing methanol yield while minimizing CO₂ content in the product stream. In this work, a detailed methanol synthesis process simulation was developed using the Soave–Redlich–Kwong equation of state in the Aspen Plus V11 commercial software environment. Pure CO₂ streams, which are produced from the post-combustion carbon capture process, and renewable hydrogen streams were used. The results are compared with open literature sources. In addition, a sensitivity analysis was employed to evaluate the effects of the pressure, temperature, and recirculation fraction on process efficiency. The results showed that the highest methanol yield of 76,838 kg/h was obtained at 80 bar, 276 °C, and a recirculation fraction of 0.9. The lowest CO₂ content in the final product (73 kg/h) occurred at 80 bar, 220 °C, and a recirculation fraction of 0.6. These findings demonstrate the trade-off between maximizing methanol output and reducing unreacted CO₂. In conclusion, optimal operating conditions for both the high yield and low CO₂ content were identified, providing a foundation for further process refinement. Future work will involve developing a more complex multi-reactor model and conducting economic assessments for large-scale industrial implementation.

A basis for modeling and simulation of the post-combustion CO₂ capture process was developed using hollow fiber membrane technology. The membrane cell was modeled using Aspen Custom Modeler (ACM) and exported to Aspen Plus as a membrane unit. The Aspen Plus methodology was effectively used to estimate the physico-chemical parameters of CO₂ absorption by kinetic and thermodynamic models. The membrane cell for the permeation of gas mixtures was programmed using ACM and successfully imported into the simulation media, as there was no model block included for the hollow fiber membrane unit in the standard package for a process flowsheet simulation. The transport mechanism in hollow fiber membranes was discussed, and both empirical and theoretical models are presented for the facilitated transport theory of gases in membrane cells. The goal of modeling membrane cells is to design and optimize membranes for carbon capture processes. The concept of modeling membrane processes is identified, and some of the most important aspects of the simulation of membrane systems are discussed. As a reference, a CO₂ flux of more than 700 NL m⁻²h⁻¹ through a membrane cell was obtained. Challenges adversely affecting the separation performance of hollow fiber-based gas separation membranes are explained in detail, and the significance of incorporating the effects of such challenges into membrane models is clarified. Parameters affecting the separation performance of hollow fiber-based gas separation membranes were studied, and the significance of integrating the effect of probable challenges into membrane models was clarified.

Natural gas streams extracted from production wells often contain undesirable components such as water vapor, gas condensate, and solid particulates. These impurities reduce fuel quality and damage downstream equipment through corrosion, fouling, and foaming. This study presents the development and field-scale evaluation of a high-performance gas–liquid separator designed for the deep decontamination of natural gas. The proposed separator incorporates 30 suspended baffles arranged in three rows and an anti-foaming mesh to enhance phase separation and prevent liquid re-entrainment. Field experiments were conducted at the Somontepa gas field in Uzbekistan. Compared to the baseline industrial unit, the upgraded separator reduced gas condensate from 16.58 g/m³ to 0.725 g/m³, water from 4.84 g/m³ to 0.10 g/m³, and solid impurities from 1.20 g/m³ to 0.0058 g/m³. The foam height was lowered from 96.4 mm to 10.2 mm, and the average bubble diameter was reduced by over 60%. The design maintained low pressure drops and demonstrated stable operation under varying flow rates. Fractional analysis confirmed the quality of a recovered condensate suitable for downstream utilization. The proposed configuration offers substantial improvements in gas purification performance and economic efficiency. These results support the application of this separator design for high-contaminant natural gas streams in industrial gas processing facilities.

The purpose of this work is to study the chemical technological processes for eterification processes, and the reactive distillation unit, which carries out the reaction and separation process in one device, was chosen as the object of research. А reаctive distillаtion system is exаmined to produce for the production of Ethyl Acetate (EtAc) viа eterificаtion of acetic acid (HAc) with ethаnol. Optimizаtion methods using sensitivity analysis аre аlso conducted. Cаlculаtion of vаpor liquid equilibrium of the mixture system is done using UNIFАC model. Heat integration from the distillate stream of the column to the acid feed stream and from bottom stream of the column to the ethanol stream with the purpose of saving reboiler duty of the reаctive distillаtion column, which enhаnces the energy sаvings (at least 5%) of this process. The feаsibility of the reаctive distillаtion (RD) for EtAc production process was evаluаted by rigorous simulаtion аnd optimizаtion using the Аspen Plus softwаre pаckаge. The effects of severаl designs аnd operаting vаriаbles were аlso investigаted for the proposed design.