Simulation and Optimization of Dry Ice Production Process Using Amine-Based CO2 Capture and External Ammonia Refrigeration

Despite growing interest in carbon capture and utilization (CCU), the transformation of captured CO2 into dry ice remains poorly studied, particularly from a systems integration and energy optimization perspective. While previous works have examined individual components such as CO2 absorption, liquefaction, or refrigerant evaluation, no existing study has modeled the full dry ice production chain from capture to solidification within a unified simulation framework. This study presents the first complete simulation and optimization of a dry ice production process, incorporating CO2 absorption, solvent regeneration, dehydration, multistage compression, ammonia-based external liquefaction, and expansion-based solidification using Aspen HYSYS. The process features ammonia as a working refrigerant due to its favorable thermodynamic performance and zero global warming potential. Optimization of heat integration reduced total energy consumption by 66.67%, replacing conventional utilities with water-based heat exchangers. Furthermore, solvent recovery achieved rates of 75.65% for MDEA and 66.4% for piperazine, lowering operational costs and environmental burden. The process produced dry ice with 97.83% purity and 94.85% yield. A comparative analysis of refrigerants confirmed ammonia’s superiority over R-134a and propane. These results provide the first system-level roadmap for producing dry ice from captured CO2 in an energy-efficient, scalable, and environmentally responsible manner.