Work

Evaluating operating trade-offs in CO2 hydrogenation to methanol: Conversion, energy efficiency, and techno-economic implications

Year: 2026

Type: article

Abstract: The direct hydrogenation of carbon dioxide (CO 2 ) to methanol presents a promising approach to mitigate atmospheric CO 2 levels while producing a valuable chemical feedstock. However, the technical and economic feasibility of renewable methanol is still under evaluation, making it essential to identify optimal operational conditions and develop predictive models to enhance its competitiveness. This study investigates the optimization of the methanol production process via CO 2 hydrogenation in a conventional catalytic reactor, combining simulation and statistical analysis to enhance both CO 2 conversion and energy conversion efficiency (ηPtF). Aspen Plus simulations were conducted under varying pressures, temperatures, and hydrogen-to-CO 2 feed ratios , and response surface methodology (RSM) was applied to identify optimal conditions. The results revealed that the maximum CO 2 conversion (91.1 %) occurs at 83 bar, 247°C, and a hydrogen-to-CO 2 ratio of 5:1, while the optimal ηPtF (58.4 %) is achieved at 50 bar, 210°C and a ratio of 3:1. A techno-economic assessment shows that the high-conversion scenario demands substantially higher hydrogen recycle and compression, increasing capital and operating costs. In contrast, the ηPtF-optimized condition offers lower energy demand and improved economic performance. CO 2 conversion and ηPtF reached values comparable to or exceeding those in state-of-the-art studies, while highlighting the trade-off between maximizing conversion and optimizing energy efficiency. This underscores the need for tailored operating conditions. The generated surrogate models accurately predict the process outcomes, offering valuable insights for future studies, and demonstrating the potential for different economic and energy outcomes depending on the optimization strategy.

Source: Journal of CO2 Utilization

DOI: 10.1016/j.jcou.2026.103359

Authors: Giovana Chinaglia Tonon Petrielli, Rubens Maciel Filho

Institution: Universidade Estadual de Campinas (UNICAMP)

Language: English

Topic: Catalysts for Methane Reforming

Subfield: Catalysis

Field: Chemical Engineering

Domain: Physical Sciences

SDGs: Affordable and clean energy, Climate action, Industry, innovation and infrastructure, Responsible consumption and production

Open Access status: gold

Estimated APC paid: $3,360