Process Modeling and Techno-economic Analysis of an Integrated Large-Scale CO₂/CO Electroreduction Plant to Produce...

CO₂ feedstock obtained from point sources, such as chemical industries or fossil fuel-based power plants, typically contains gaseous contaminants such as SO _x , NO _x , H₂S, and COS, which can be detrimental to the catalysts used to electrochemically convert CO₂/CO into valuable fuels and chemicals. A significant suppression of C₂₊ products is observed even in the presence of 10 ppm of these impurities due to catalyst poisoning and a selectivity change. Hence, it is necessary to have an upstream cleaning process to maintain a high selectivity toward high value C₂₊ products and to reduce the operational costs associated with frequent catalyst regeneration or replacement. We present a comprehensive process model and technoeconomic analysis of an integrated large-scale two-step CO₂/CO electroreduction plant that produces C₂₊ products including ethylene, acetic acid, ethanol, and n-propanol, using blast furnace gas obtained from a steel manufacturing facility as feedstock. Detailed modeling and integration of the upstream cleaning units, CO₂/CO electrolyzers, and the downstream separation of gas/liquid products are performed using Aspen Plus. Our analysis shows that the large-scale two-step CO₂/CO electroreduction process is not profitable under the base case scenario and requires significant improvements in electrolyzer performance, reduction in capital costs, and favorable market conditions to improve the economics. The upstream cleaning units only contribute to ∼15% of the CAPEX and ∼8% OPEX of the entire plant, while the electrolyzers contribute to ∼63% of the total CAPEX and OPEX. A positive net present value ($54M), a payback time of 13 years, and an internal rate of return of 12.8% can be achieved when the electrolyzer capital cost is $10,000/m² (-50%) and electricity price is $20/MWh (-50%), with current densities of 750 mA/cm² (+50%) for both electrolyzers and cell voltages of 2.5 V (-17%) for CO₂R and 2.0 V (-20%) for COR electrolyzers, and when the product prices are 35% higher than the current market prices. Incorporating an energy-saving coelectrolysis process or integration into facilities that can directly utilize the products can accelerate the commercialization of the two-step CO₂/CO electroreduction process.