Sustainable\nRoute of Ethylene Carbonate Production\nvia CO<sub>2</sub> Carboxylation: Process Development, Process Integration,\nand Economic Analysis

CO<sub>2</sub> carboxylation with ethylene glycol (EG)\nto synthesize\nethylene carbonate (EC) is an ecofriendly alternative to traditional\nmethods that rely on toxic, fossil-based epoxides. In this study,\nthe sustainable production of EC for large-scale feasibility and economic\nviability through experimental and simulation analyses were developed.\nOur experimental work (case A) using a CeO<sub>2</sub> nanorod catalyst\nachieved the highest EC production (0.072 mmol EC/g EG) reported in\nthe literature without a dehydrating agent. For a comprehensive evaluation,\nwe conducted a techno-economic comparative assessment against a study\nwith the best EC yield using 2-cyanopyridine (case B). Process integration\nfor both cases was implemented through a heat exchanger network system\n(HENS) design, achieving ∼60% in heat recovery, and further\nexergy analysis reported an efficiency of >90%. Although case B\nachieved\nnear-perfect conversion efficiency with 2-cyanopyridine, its economic\nviability was less promising than case A. With current technology,\nneither case is feasible for commercialization at an annual EC production\nof 5 ktonne. The minimum selling price of EC must exceed AUD 10.20/kg\nfor case A and AUD 26.50/kg for case B. Our results suggest that eliminating\nhazardous 2-cyanopyridine is possible, with further recommendations\nto fully realize the profitability of this production’s approach.