Assessing the economic viability of green methanol production: The critical role of CO2 purity in green methanol production

The growing concern over climate change and rising carbon dioxide (CO2) emissions have spurred the development of strategies to upcycle greenhouse gases. One promising solution is the synthesis of green methanol via catalytic hydrogenation of captured CO2 using renewable hydrogen (H2). This provides a versatile chemical feedstock for fuels and industrial processes while reducing CO2 levels. Recent advancements in CO2 capture technologies achieve purities ranging from 83% to 98% (v/v), enabling a sustainable integration with green hydrogen for methanol production. While research has largely focused on CO2 purities above 96%, such models overlook the variability and lower purities typical of industrial carbon capture streams. Addressing this gap, this study examines the economic impacts of CO2 purity on methanol synthesis. Using Aspen Hysys V14, the hydrogenation process is simulated to assess the effects of varying CO2 purities on operational costs, yield, and profitability, providing a realistic evaluation under actual industrial conditions. The results reveal that even slight changes in CO2 purity markedly influence both costs and profitability, highlighting the importance of studying CO2 capture technologies for methanol production. This study quantifies the relationship between CO2 purity and operational cost, contributing critical insights for process operation. By emphasizing the role of CO2 purity in enhancing both sustainability and economic feasibility, it advances the understanding of green methanol production as a viable strategy for climate change mitigation.