This work addresses the economic comparison of a process based on reactive distillation (RD) with the conventional process for ETBE production. Nonlinear first-principles models for both processes were developed and implemented in gPROMS ModelBuilder, with the corresponding physical properties being calculated in Aspen Plus, connected through the CAPE-OPEN interface. The design of the RD column was performed using an optimisation-based strategy, which couples an evolutionary algorithm with a nonlinear solver. The RD-based process studied eliminated the need for the top ethanol fresh feed, thus eliminating the need for an ethanol recovery section. The payback period was found to be 3 years, if the RD column, condenser and reboiler are purchased and only 1.5 years if only the cost of purchasing a RD column is considered. The advantages of the RD-based process were found to be the higher yield of ETBE product, as well as lower costs of ethanol and steam. (C) 2017 Elsevier Ltd. All rights reserved.