Sophia Sardinha de Oliveira

Isobutane is a key feedstock for alkylate production. For separating an equimolar isobutane/n-butane mixture with 2 mol% ethane, two conventional designs are reported in the literature: a single water-cooled condenser (SC) and a dual condenser system with refrigeration (DC). This study proposes two vapor recompression retrofit configurations, SC-VR and SC-PHVR (with preheating), to improve energy efficiency and enable electrification. Economic and environmental performance were evaluated using total annualized cost (TAC) and CO₂ emissions. Compared with SC and DC schemes, SC-VR reduces CO₂ emissions by 49 and 52%, while SC-PHVR delivers higher reductions of 64 and 66%. A sensitivity analysis of electricity prices across 3-, 5-, and 10-year payback periods indicates the most favorable performance at 10 years. At 16.67 USD/GJ, SC-PHVR lowers TAC by 22 and 25%; in contrast, SC-VR provides marginal savings. At 24.03 USD/GJ, SC-VR is not economically competitive, whereas SC-PHVR continues to outperform the conventional cases, with TAC reductions of 8% and 4%. Both retrofit options significantly reduce emissions, with SC-PHVR offering the best economic performance. Finally, the proposed configurations enable the complete electrification of the de-isobutanizer system, eliminating reliance on fossil-based thermal utilities, which allows the use of renewable sources in line with the decarbonization efforts.