Optimization and Energy Efficiency in the Separation of Butadiene 1,3 from Pyrolysis Products: A Model-Based Approach

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.