Modelling, techno-economic evaluation, and optimization of a solar-based methanol synthesis process using Process simulation

Abstract

The sustainable operation of methanol production is a primary lever for decarbonization in hard-to-abate sectors, with a significant reduction in greenhouse gas emissions. Although production costs remain high, e-methanol shows great potential in lowering the carbon footprint of the chemical and transportation sectors. This thesis evaluates the technical and economic performance of methanol production from captured carbon dioxide and hydrogen. The focus is on a key characteristic of the process, namely cutting electricity use through solar heat integration. A detailed process model in Aspen Plus is combined with an hourly dispatch of power consumption, alongside transparent capital and operating cost estimates.

A comprehensive techno-economic assessment using a levelized-cost framework finds an e-methanol cost of USD 1.59 per kg when integrating solar heat. Across the heat-supply options evaluated such as solar heat, power-to-heat, and power-to-heat with thermal storage, costs vary only modestly. The cost structure is dominated by hydrogen production. Electricity constitutes the largest share of operating expenses, almost entirely for hydrogen generation. The discussion identifies practical levers to reduce costs. Overall, the work provides technical and economic guidance to bring e-methanol closer to market-relevant prices and offers insights for decision-makers pursuing sustainable methanol production.