Reactive distillation is a favorable alternative to conventional series of reactor-distillation processes for ether productions. However, the design of such columns is complicated due to the interaction between vapor-liquid equilibrium and reaction rates. There are conflicting reports on whether adding excessive separation stages degrade the column performance. A comparison is made of several designs of single and double feed reactive distillation columns for ETBE production to investigate the effects of separation and reaction stages on the overall performance. The explanations are presented using simulation results, whose mathematical models are written in the Aspen Plus environment. The results confirm that a conservative approach by adding extra separation and reaction stages can be applied to reactive distillation design. However, output multiplicity may be observed for longer column and should be considered in the early design phase.
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