Methanol Production via Power-to-Liquids: A Comparative Simulation of Two Pathways Using Green Hydrogen and Captured CO₂

Methanol is a versatile substance that can be used in combustion engines and fuel cells and as a feedstock for the production of various chemicals. However, the majority of methanol is currently produced from fossil fuels, which is not sustainable. The aim of this study was to analyze and evaluate the feasibility of methanol production from renewable sources as a bridge to a low-carbon economy and its potential as an alternative to fossil-derived chemicals. For this purpose, the process of methanol production from captured CO2 and water as an H2 source was simulated in Aspen Plus. For CO2 capture, the monoethanolamine (MEA) absorption process was assumed. The H2 required for methanol synthesis was obtained by alkaline water electrolysis using electricity from renewable sources. The captured CO2 and the produced H2 were then converted into methanol through the process of CO2 hydrogenation in two ways, direct and two-step synthesis. In the direct conversion, the hydrogenation of CO2 to methanol was carried out in a single step. In the two-step conversion, the CO2 was first partly converted to CO by the reverse water-gas shift (RWGS) reaction, and then the mixture of CO and CO2 was hydrogenated to methanol. The results show that direct synthesis has a higher methanol yield (0.331 kmol of methanol/kmol of H2) compared to two-step synthesis (0.326 kmol of methanol/kmol of H2). The direct synthesis produces 13.4 kmol of methanol/MW, while the two-step synthesis produces 11.2 kmol of methanol/MW. This difference amounts to 2.2 kmol of methanol/MW, which corresponds to a saving of 0.127 $/kmol of methanol. Besides the lesser energy requirements, the direct synthesis process also produces lower carbon emissions (22,728 kg/h) as compared to the two-step synthesis process (33,367 kg/h).