Abstract
This study introduces a novel and eco-efficient CO2 hydrogenation process design. Following an extensive literature review, Formic Acid (FA) emerged as a viable bulk chemical. A market analysis was performed to estimate feedstock availability. The plant, located in Ravenna, Italy, can produce 50 kta of 85 %wt. FA. The conversion of CO2 and green H2 into FA was meticulously analyzed to identify the best operating conditions and separation technologies, including COPureTM. A key innovation of the sustainable process, simulated in Aspen Plus, is the implementation of Dividing Wall Column (DWC) configuration, which along with heat integration, results in 64% electricity savings, 20% less stream requirements and 51% reduction in CO2 emissions compared to conventional processes. A 2030 economic assessment estimates capital investment and production costs at 73.8 M€ and 41.8 M€/yr respectively, with a profit of 9.5 M€/yr. A sensitivity analysis showed that profitability is heavily impacted by natural gas and product prices. Future carbon taxation and energy or cost-saving initiatives could further increase profitability, making this process a compelling alternative to current methods.