A control perspective on hybrid membrane/distillation propane/propylene separation process

Abstract This study explores the design, dynamic behavior, and controllability of a hybrid membrane-distillation process for propane/propylene separation, offering a novel comparison with traditional single distillation columns. Our key innovation lies in integrating hollow fiber membrane technology with distillation to significantly improve process efficiency, reducing energy consumption and operational costs. Using rigorous economic and dynamic simulations, the hybrid process demonstrates superior performance, achieving a 12.6 % reduction in total annual cost (TAC) compared to the conventional distillation system. Advanced control methodologies, including Singular Value Decomposition (SVD) and condition number analysis, are applied to assess and optimize the controllability of the hybrid structure under disturbances such as fluctuations in feed composition and flow rates. The results highlight the hybrid process’s ability to maintain high product purity and faster dynamic response, offering a robust solution for large-scale propane/propylene separation in the petrochemical industry. This work provides crucial insights into improving both operational efficiency and control robustness in industrial separation processes.