*Article* **A Detailed Process and Techno-Economic Analysis of Methanol Synthesis from H2 and CO2 with Intermediate Condensation Steps**

**Bruno Lacerda de Oliveira Campos \*, Kelechi John, Philipp Beeskow, Karla Herrera Delgado \*, Stephan Pitter, Nicolaus Dahmen and Jörg Sauer**

> Institute of Catalysis Research and Technology (IKFT), Karlsruhe Institute of Technology (KIT), Hermann-von Helmholtz-Platz 1, D-76344 Eggenstein-Leopoldshafen, Germany

**\*** Correspondence: bruno.campos@kit.edu (B.L.d.O.C.); karla.herrera@kit.edu (K.H.D.)

**Abstract:** In order to increase the typically low equilibrium CO2 conversion to methanol using commercially proven technology, the addition of two intermediate condensation units between reaction steps is evaluated in this work. Detailed process simulations with heat integration and techno-economic analyses of methanol synthesis from green H2 and captured CO2 are presented here, comparing the proposed process with condensation steps with the conventional approach. In the new process, a CO2 single-pass conversion of 53.9% was achieved, which is significantly higher than the conversion of the conventional process (28.5%) and its equilibrium conversion (30.4%). Consequently, the total recycle stream flow was halved, which reduced reactant losses in the purge stream and the compression work of the recycle streams, lowering operating costs by 4.8% (61.2 M€·a<sup>−</sup>1). In spite of the additional number of heat exchangers and flash drums related to the intermediate condensation units, the fixed investment costs of the improved process decreased by 22.7% (94.5 M€). This was a consequence of the increased reaction rates and lower recycle flows, reducing the required size of the main equipment. Therefore, intermediate condensation steps are beneficial for methanol synthesis from H2/CO2, significantly boosting CO2 single-pass conversion, which consequently reduces both the investment and operating costs.

**Keywords:** methanol synthesis; CO2 utilization; power-to-X; intermediate condensation steps; product removal; techno-economic analysis; heat integration; plant simulation
