A technical evaluation on the production of sustainable formaldehyde was presented in this report, including process design, advanced simulation, economic analysis, and environmental analysis. Three process configurations to produce formaldehyde were developed: a base-case with no capture of carbon, a post-combustion capture (PCC) process, which utilized 14 wt.% MEA solution-based process, and a direct air capture (DAC) route which used NaOH. Sequestered CO₂ was used as a major feedstock for methanol production via an electrocatalytic reactor (ECR), after which was converted into formaldehyde via a FORMOX process. Large-scale simulations were carried out, demonstrating a yearly methanol production capacity of approximately 62 million kilograms, with a fixed formaldehyde-to-methanol conversion ratio of 1.4 kg per kg of methanol. Economic models were developed using Aspen Process Economic Analyser, indicating that the base-case option (without capture) would involve a capital expenditure... [more]