Detailed techno-economic analysis of methanol synthesis from plasma assisted waste gasification derived syngas with captured CO2 at pilot scale
Kateřina Sukdolová, Mika Järvinen, Shouzhuang Li, Farrukh Ilyas Abid, Judit Nyári, Ondřej Horký, Vineet Singh Sikarwar, Michael Pohořelý, Michal Jeremiáš
Abstract
Climate change, improper waste management, and the demand for renewable chemicals are the three pressing and interconnected global challenges this paper tackles by exploring an innovative process for sustainable methanol production. A pilot-scale thermal plasma gasification system (1.4–1.7 MW e ) is proposed that converts refuse-derived fuel (5.6–6.8 t/d) into syngas, using captured CO 2 as a gasification agent. Two CO 2 compositions (57 vol% CO 2 at 14.5 t/d and 96 vol% CO 2 at 10.0 t/d) were evaluated, along with a reference case using steam (4.2 t/d). The resulting syngas undergoes purification and hydrogen supplementation (0.2–1.7 t/d) to synthesize methanol (9.3–18.3 t/d). Techno-economic analysis demonstrates that this process is competitive even on a small scale, achieving methanol production costs as low as 500–620 €/t, comparable to the current market price. Sensitivity analysis highlights the importance of optimizing the input of hydrogen and electricity to maintain cost efficiency. Integrating the captured CO 2 from a waste-to-energy facility enhances the circular economy by using carbon that would otherwise be emitted. Additionally, the study examines the economic trade-offs of operating during lower electricity price periods, finding that a 70–85 % utilization rate is optimal (with fixed 10 % reserved for maintenance). As energy and hydrogen costs decline while CO 2 allowance prices increase, this technology is poised for even greater competitiveness. By merging waste valorization, CO 2 capture, and power-to-X principles, this work presents a scalable and economically viable pathway towards sustainable methanol production, bridging the gap between waste management and renewable chemical synthesis.