Electrochemical CO2 reduction
has promise
as a technology
that could help society reach carbon neutrality while producing valuable
fuels and chemicals. Herein, the electrochemical synthesis of methyl
formate, a product not observed in aqueous CO2 electrolysis,
has been analyzed by a rigorous technoeconomic model to evaluate its
commercial viability. Methyl formate synthesis has been demonstrated
with high faradaic efficiency through the electroreduction of CO2 in methanol. Four competing approaches were analyzed: (1)
electroreduction of captured CO2 in a dual CH3OH/H2O electrolyzer, (2) direct electroreduction of flue
gas CO2 in a dual CH3OH/H2O electrolyzer,
(3) electroreduction of captured CO2 in a CH3OH/CH3OH electrolyzer, and (4) electroreduction of captured
CO2 in a H2O/H2O electrolyzer with
a downstream CH3OH reactor. Sensitivity analyses, cost
contour plots, and comparison plots were generated. The dual methanol/water
electrolysis approach was the most cost competitive, with a levelized
cost of methyl formate below the present market price. The all-methanol
electrolysis route was more expensive due to increased methanol consumption
and greater distillation costs. Methyl formate production through
aqueous CO2 electrolysis to formic acid with a secondary
esterification reaction was by far the most expensive approach, primarily
due to the energy-intensive nature of distilling formic acid from
water.