Thermo-kinetic synergy in separating dimethyl carbonate/methanol/water mixtures using ionic liquids-based mixed solvents

[Display omitted] •Proposes a mixed solvent with a 6:4 ratio of methyl salicylate to [BMIM][NTf2].•Analyzes synergistic effects of thermodynamics and kinetics.•Compares transfer efficiency and TAC across four process configurations.•Direct extractive distillation outperforms indirect sequences.•Mixed solvent enhances transfer efficiency and reduces TAC versus pure solvents. The low selectivity of traditional organic solvents and the limited mass transfer efficiency caused by the high viscosity of ionic liquids (ILs) pose challenges in separating of dimethyl carbonate (DMC)/methanol/water mixtures. Therefore, a novel mixed solvent is proposed with a mass ratio of methyl salicylate to 1-butyl-3-methylimidazolium bis(trifluoromethylsulfonyl)imide of 6:4. The synergistic effects of thermodynamic, kinetic, and economic performance using the mixed solvent are investigated. Comparisons of overall efficiency and total annual cost (TAC) for four process configurations using direct and indirect extractive distillation sequences to produce industrial and battery-grade DMC products are conducted. The results indicate that direct extractive distillation outperforms the indirect sequence, reducing TAC by 6.1–14.3 % for producing industrial-grade DMC and 6.6–15.8 % for battery-grade DMC. Additionally, using mixed solvents in direct extractive distillation is more effective than using pure solvents, enhancing mass transfer coefficients by 2.8–20.9 % for industrial-grade DMC and 1.8–17.8 % for battery-grade DMC. This approach also reduces TAC by 3.2–3.6 % for industrial-grade DMC and 4.7–5.7 % for battery-grade DMC.