Comparative Technoeconomic Analysis of Pathways for Electrochemical Reduction of CO 2 with Methanol to Produce Methyl Formate
Electrochemical CO 2 reduction has promise as a technology that could help society reach carbon neutrality while producing valuable fuels and chemicals. Herein, the electrochemical synthesis of methyl formate, a product not observed in aqueous CO 2 electrolysis, has been analyzed by a rigorous technoeconomic model to evaluate its commercial viability. Methyl formate synthesis has been demonstrated with high faradaic efficiency through the electroreduction of CO 2 in methanol. Four competing approaches were analyzed: (1) Electroreduction of captured CO 2 in a dual CH 3 OH/H 2 O electrolyzer, (2) Direct electroreduction of flue gas CO 2 in a dual CH 3 OH/H 2 O electrolyzer, (3) Electroreduction of captured CO 2 in a CH 3 OH/CH 3 OH electrolyzer, and (4) Electroreduction of captured CO 2 in a H 2 O/H 2 O electrolyzer with a downstream CH 3 OH reactor. Sensitivity analyses, cost contour plots, and comparison plots were generated. The dual methanol/water electrolysis approach was the most cost-competitive, with a levelized cost of methyl formate below the present market price. Here, the all-methanol electrolysis route was more expensive due to increased methanol consumption and greater distillation costs. Methyl formate production through aqueous CO 2 electrolysis to formic acid with a secondary esterification reaction was by far the most expensive approach, primarily due to the energy-intensive nature of distilling formic acid from water.