An integrated engineering methodology for green hydrogen, point-source carbon capture and synthetic fuel production: An engineering assessment framework for industrial decarbonisation

The transition towards net-zero emissions requires integrated engineering solutions capable of simultaneously addressing renewable energy utilisation, industrial decarbonisation and sustainable fuel production. Although significant progress has been achieved in green hydrogen production, carbon capture technologies and synthetic fuel synthesis, these technologies are frequently investigated independently, limiting their practical deployment within integrated industrial systems. This study presents an Integrated Engineering Methodology combining an Engineering Assessment Framework (EAF), Engineering Assessment Outcome (EAO) and Integrated Hydrogen–Carbon Platform (IHCP) for the systematic evaluation and integration of renewable hydrogen production, point-source carbon capture and synthetic fuel generation. A structured methodology comprising literature review, comparative technology assessment, systems integration and engineering evaluation is applied to compare hydrogen-production and carbon-capture pathways based on technical performance, technology readiness, scalability and deployment potential. A conceptual engineering design example demonstrates application of the proposed framework using a 100 MW renewable-energy facility integrated with PEM electrolysis, point-source carbon capture and methanol synthesis. The assessment indicates the potential to produce approximately 3500 tonnes of hydrogen annually, require approximately 25,700 tonnes of captured carbon dioxide annually, and generate approximately 15,900 tonnes of net methanol annually, providing a quantitative engineering demonstration of the integrated hydrogen–carbon system. The proposed methodology provides a structured engineering basis for technology selection, system integration and industrial implementation and is intended to support engineers, project developers and policy makers in accelerating industrial decarbonisation through scalable and modular hydrogen–carbon platforms.