Technoeconomic Perspective on the Electroreduction of CO₂ to Formic Acid: Scale-Up Strategies Toward Industrial...

The conventional industrial synthesis of formic acid is an energy-intensive process that contributes to the CO₂ footprint. As an alternative method, the electrochemical reduction of carbon dioxide (eCO₂RR) to formic acid has emerged as a viable means to reduce atmospheric CO₂ concentrations and advance the energy transition to a circular, carbon-neutral economy. Despite considerable progress in this field, the scale-up of electrolyzers from laboratory prototypes to commercial-scale production remains an important challenge. Thus, this technoeconomic analysis provides a detailed evaluation of the economic viability of upscaling the electrolyzer size to an industrial level, determining whether the eCO₂RR process can economically compete with the conventional industrial production of formic acid. The proposed technoeconomic assessment employs a bottom-up approach based on realistic cost models using the three most successful designs: dual flow (DF), direct formic acid production (DFAP), and zero-gap (ZG) electrolyzers. The results from this study underscore the necessity of implementing multiple-cell stacking to economically compete with established industrial processes. Among the three studied designs, DFAP and, to a certain extent, DF are promising. Although the scalability of the DFAP electrolyzer may initially appear inadequate, it holds potential for commercial application, particularly if technical improvements in the center compartment and solid-state electrolyte are materialized.