Driving Green: A Comprehensive Sustainability Analysis of Natural Gas-to-Methanol and Methanol-to-Gasoline Supply Chains

This study presents an integrated Life Cycle Sustainability Assessment (LCSA) of the Natural gas-to-methanol (NGTM) and methanol-to-gasoline (MTG) pathways using Aspen HYSYS process modeling, Environmental Life Cycle Assessment (LCA), Social Life Cycle Assessment (SLCA), and Life Cycle Costing (LCC). The results reveal significant variability in sustainability performance across process units. The DME and MTG Reactors Section generates the highest direct greenhouse gas (GHG) emissions at 0.86 million tons CO2-eq, representing 54.9% of total global warming potential, while the Compression Section consumes 2717.5 TJ/year of energy, making it the dominant source of electricity-related indirect emissions. Distillation and Purification withdraws 31,100 Mm3/year of water—approximately 99% of total demand—yet delivers 86.6% of the overall economic surplus despite high operating costs. Social impacts concentrate in the Methanol Reactor Looping and DME and MTG Reactors Sections, with human health burdens of 305.79 and 804.22 DALYs, respectively, due to catalyst handling and high-pressure operations. Sensitivity results show that methanol purity rises from 0.9993 to 0.9994 with increasing methane content, while gasoline output decreases from 3780 to 3520 kg/h as natural gas flow increases. The findings provide process-level evidence to support sustainable development of natural gas-based fuel conversion industries, aligning with Qatar National Vision 2030 objectives for industrial diversification and lower-carbon energy systems.