Efficient heat integration within discretely heat integrated distillation columns using liquid injection

Abstract Electrification of distillation processes through discretely heat integrated distillation columns (D‐HIDiC) is an effective approach to enhance energy efficiency and lower carbon emissions. For separating systems with high temperature lift, multi‐stage compression and inter‐stage cooling are necessary to link the high‐pressure rectifier and low‐pressure stripper. Traditionally, heat recovery employs pumparound loops, but this study introduces liquid injection as a more efficient and innovative alternative. Simulation results using methanol/water separation indicate that liquid injection reduces both reboiler duty and compression power, achieving up to 50% primary energy savings compared with conventional distillation columns. Unlike continuous heat exchange in conventional HIDiC (C‐HIDiC), D‐HIDiC simplifies heat integration, avoiding complex hardware and energy penalties. Comparative analysis across multiple configurations, including SuperHIDiC, confirms the potential of D‐HIDiC with liquid injection to fully electrify distillation, eliminate steam utility, and significantly support sustainable industrial operations.