<![CDATA[This study presents a comparative assessment of energy-saving configurations for high-purity multicomponent distillation, focusing on conventional column sequences, Dividing-Wall Columns (DWCs), side utility integration, and heat-pump-assisted systems. The objective is to evaluate each configuration’s potential for energy reduction, economic feasibility, and operational robustness. A ternary system was analyzed using shortcut design (Fenske–Underwood–Gilliland), rigorous MESH simulation, and thermodynamic targeting via Column Grand Composite Curve (CGCC). Optimization parameters included reflux ratio, stage count, feed location, and pressure. Simulations revealed that DWCs and heat-pump configurations achieved energy savings of 35–40% compared to the conventional setup. Side utility integration and feed stage/reflux optimization provided moderate reductions of 10–18%. Thermodynamic targeting identified a pinch temperature of 8°C, confirming potential for further heat integration through side reboilers and condensers. Sensitivity analysis indicated that DWCs and heat-pump systems maintained stable product purity and energy performance under ±5% feed variation. While DWCs and heat-pump systems involve higher capital costs, long-term operational savings justify investment. Control and integration complexity were addressed through discussion of adaptive strategies and predictive control methodologies. These findings suggest that intensified distillation configurations significantly enhance process efficiency and offer viable pathways toward sustainable chemical separation.]]>
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