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. 2025 Jul 31;15(1):27911.
doi: 10.1038/s41598-025-10516-x.

Optimization of separation and purification processes in diethyl ether production for improved efficiency and sustainability

Amin Hedayati Moghaddam  1 , Morteza Esfandyari  2
Affiliations

Optimization of separation and purification processes in diethyl ether production for improved efficiency and sustainability

Amin Hedayati Moghaddam et al. Sci Rep. .

Abstract

This study focuses on optimizing the separation and purification processes in diethyl ether (DEE) production to enhance energy efficiency, reduce waste, and improve product quality. Utilizing process simulation with Aspen-Hysys-V14, statistical modeling, and optimization techniques, this study investigates operational parameters across key units, including two drums and two distillation columns. Design of experiment was performed using response surface methodology (RSM) and central composite design (CCD). Key results indicate that under optimized conditions, a DEE purity of 96.43% was achieved with total energy consumption of 2,150,566 kJ/h, corresponding to an energy requirement of 1,499,754.87 kJ/kmol of DEE. Scenario-based optimization minimized DEE loss in fuel and vent streams while balancing energy demands. Non-linear relationships between parameters, such as temperature and pressure, were modeled with high predictive accuracy. These findings contribute to the development of sustainable and cost-effective DEE production processes and offer transferable insights for similar chemical manufacturing systems.

Keywords: Diethyl ether; Energy efficiency; Process optimization; Sustainability.

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Conflict of interest statement

Declarations. Competing interests: The authors declare no competing interests.

Figures

Fig. 1
Fig. 1
Process flow diagram (PFD) of separation and purification section in DEE production process.
Fig. 2
Fig. 2
Effects of temperature and pressure on DEE flowrate and cooler energy consumption in drum1.
Fig. 3
Fig. 3
Composition of the top stream in distillation column1 under varying operational conditions.
Fig. 4
Fig. 4
Energy consumption in heater and reboiler of distillation column 1 as a function of key operational parameters.
Fig. 5
Fig. 5
Effects of temperature and pressure on DEE flowrate and cooler energy consumption in drum2.
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