Rapeseed oil has a wide range of uses in industries like automotive, chemical, biodiesel, and culinary. However, during its production, the leaching process generates a significant amount of waste that contains cyclohexane, isopropanol, and water. Due to the presence of several azeotropes and ternary azeotropes in this wastewater, it's crucial to develop an effective and energy-efficient treatment method. Six design alternatives are proposed and evaluated, including triple column extractive distillation (TCED), extractive distillation reactive distillation (EDRD), double column reactive-extractive distillation (DCRED), TCED with heat integration (TCED-HX), EDRD with heat integration (EDRD-HX), and DCRED with heat integration (DCRED-HX). The optimal configurations of each design are determined using the Simulated Annealing Algorithm (SAA) optimization technique. By combining reactive and extractive distillations, these designs offer the advantage of simultaneous chemical reactions and separation, leading to improved separation efficiency. The application of ethylene oxide (EO) as a dehydrating agent in reactive distillation columns enables the efficient removal of water from the mixture, reducing the number of required columns for separation. This innovative approach results in significant reductions in both capital and operating costs, ultimately leading to substantial reductions in the total annual cost (TAC). Compared with conventional configuration (TCED), the DCRED-HX has the optimal results. It can save 64.51% energy consumption and TAC up to 63.56%. Moreover, a control structure was developed for DCRED-HX to ensure the maintenance of product quality and process safety. Two control structures were proposed, and among them, control structure 2 was identified as the most effective at maintaining product purity under ±10% feed and composition disturbances.

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