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System-level thermal integration and electrification of carbon capture and methanol synthesis
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DOI：10.1016/j.jcou.2026.103442.png)
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Abstract
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The catalytic hydrogenation of captured CO2 to methanol is a critical pathway for renewable energy storage and sustainable chemical production. Existing integrated systems, however, typically depend on external fossil-based steam for solvent regeneration and lack sufficient system-level energy modification. This study develops a fully electrified, steam-free process coupling second-generation PZ/AMP-based CO2 capture with methanol synthesis. A high-temperature heat pump and mechanical vapor recompression (MVR) upgrade waste heat from the synthesis loop and distillation column to drive CO2 desorption, eliminating all external thermal utilities. The system is evaluated through comprehensive energy, exergy, and techno-economic analyses. The heat recovery process reduces the specific utility energy demand from 3.66 to 1.11 GJ/ton methanol (69.7% reduction) and total utility cooling duty by 35.5%. Exergy analysis shows a 15.3% decrease in total exergy destruction and an improvement in exergy efficiency from 80.2% to 82.0%. Under optimized conditions (210 degrees C, 75 bar, purge ratio 0.01), the process achieves a hydrogen-to-methanol energy efficiency of 77.0% and a total energy efficiency of 43.9%, approximately 7.7 %age points higher than previously reported MEA-based systems. Sensitivity analysis confirms thermal self-sufficiency across purge ratios of 0-0.04. Despite a 23.5% increase in capital investment, the hydrogen-excluded levelized cost of methanol decreases from 90.62 to 84.91 USD/t (6.3% reduction) owing to eliminated steam expenditure. Break-even analysis identifies an economically favorable window under moderately priced electricity and relatively expensive steam. These results provide a scalable, electrified framework for power-to-methanol technologies.
Keywords:
Carbon capture
Methanol synthesis
Heat integration
Process electrification
Techno-economic Analysis
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