Acetic acid production from renewable processes such as biomass hydrolysis and electrochemical reduction of CO₂ exhibits low concentrations, which make downstream separation challenging. We measured the vapor–liquid equilibria of the binary systems acetic acid + 2-methyltetrahydrofuran (2-MTHF), methyl-t-butyl ether (MTBE) + acetic acid, and the ternary liquid–liquid equilibria of the system 2-MTHF + AA + water, fitted the data to the UNIQUAC-HOC and NRTL models, designed a hybrid extraction-distillation process for acetic acid separation with 2-MTHF, and evaluated its economics and compared with that of three other commonly used solvents (i.e., ethyl acetate, MTBE, and methyl propyl ketone). The lowest and highest costs of separation were observed for MTBE and MPK, while 2-MTHF and EA showed similar performance. The cost of separation increased exponentially as the feed concentration decreased, and renewable processes should aim for at least 5 wt % acetic acid in the feed to allow economically feasible separation.

CO₂ feedstock obtained from point sources, such as chemical industries or fossil fuel-based power plants, typically contains gaseous contaminants such as SO_x, NO_x, H₂S, and COS, which can be detrimental to the catalysts used to electrochemically convert CO₂/CO into valuable fuels and chemicals. A significant suppression of C₂₊ products is observed even in the presence of 10 ppm of these impurities due to catalyst poisoning and a selectivity change. Hence, it is necessary to have an upstream cleaning process to maintain a high selectivity toward high value C₂₊ products and to reduce the operational costs associated with frequent catalyst regeneration or replacement. We present a comprehensive process model and technoeconomic analysis of an integrated large-scale two-step CO₂/CO electroreduction plant that produces C₂₊ products including ethylene, acetic acid, ethanol, and n-propanol, using blast furnace gas obtained from a steel manufacturing facility as feedstock. Detailed modeling and integration of the upstream cleaning units, CO₂/CO electrolyzers, and the downstream separation of gas/liquid products are performed using Aspen Plus. Our analysis shows that the large-scale two-step CO₂/CO electroreduction process is not profitable under the base case scenario and requires significant improvements in electrolyzer performance, reduction in capital costs, and favorable market conditions to improve the economics. The upstream cleaning units only contribute to ∼15% of the CAPEX and ∼8% OPEX of the entire plant, while the electrolyzers contribute to ∼63% of the total CAPEX and OPEX. A positive net present value ($54M), a payback time of 13 years, and an internal rate of return of 12.8% can be achieved when the electrolyzer capital cost is $10,000/m² (−50%) and electricity price is $20/MWh (−50%), with current densities of 750 mA/cm² (+50%) for both electrolyzers and cell voltages of 2.5 V (−17%) for CO₂R and 2.0 V (−20%) for COR electrolyzers, and when the product prices are 35% higher than the current market prices. Incorporating an energy-saving coelectrolysis process or integration into facilities that can directly utilize the products can accelerate the commercialization of the two-step CO₂/CO electroreduction process.

Experimentally determining interfacial tension (IFT) for compositions relevant to CO₂ transport is challenging. We address this using molecular dynamics (MD) simulations and perturbed-chain statistical associating fluid theory (PC-SAFT) equation of state with classical density functional theory. We compute phase equilibria and interfacial properties of pure CO₂ and CO₂–CH₄, CO₂–Ar, CO₂–N₂, and CO₂–H₂ mixtures at 220–273 K. Both approaches accurately estimate CO₂ phase equilibria and IFTs. For binary mixtures, phase equilibria computed using PC-SAFT agree well with experiments when k_ij ≠ 0. IFTs computed from PC-SAFT depend strongly on k_ij, while MD simulations systematically overpredict IFTs. The IFT decreases with increasing pressure, least pronouncedly for H₂-containing mixtures. Binary mixtures exhibit interfacial enrichment of the light boiling component, decreasing with increasing temperature and pressure. Semiempirical Parachor and Winterfeld–Scriven–Davis models capture IFT–pressure trends with mixture-dependent accuracy. These results improve predictions of metastable limits and provide key insights for fast-transient multiphase CO₂ flow modeling.

We introduce OpenPyTEA , an open-source Python toolkit for conducting flexible and detailed techno-economic assessments (TEA) of chemical and energy systems. TEA is essential for evaluating economic feasibility in process design, yet commercial tools are “black-box” solutions with limited flexibility. Existing open-source options are usually process-specific, incomplete, or poorly documented, limiting reproducibility and cross-study comparisons. OpenPyTEA addresses these challenges by integrating equipment cost estimation, cash-flow analysis, and sensitivity and uncertainty methods into transparent and adaptable workflows. Its capabilities are demonstrated through a case study comparing hydrogen production via steam methane reforming, methane pyrolysis, and water electrolysis.

Computation of the excess entropy (Formula presented.) from the second-order density expansion of the entropy holds strictly for infinite systems in the limit of small densities. For the reliable and efficient computation of (Formula presented.) it is important to understand finite-size effects. Here, expressions to compute (Formula presented.) and Kirkwood–Buff (KB) integrals by integrating the Radial Distribution Function (RDF) in a finite volume are derived, from which (Formula presented.) and KB integrals in the thermodynamic limit are obtained. The scaling of these integrals with system size is studied. We show that the integrals of (Formula presented.) converge faster than KB integrals. We compute (Formula presented.) from Monte Carlo simulations using the Wang–Ramírez–Dobnikar–Frenkel pair interaction potential by thermodynamic integration and by integration of the RDF. We show that (Formula presented.) computed by integrating the RDF is identical to that of (Formula presented.) computed from thermodynamic integration at low densities, provided the RDF is extrapolated to the thermodynamic limit. At higher densities, differences up to (Formula presented.) are observed.

The development of advanced catalysts with innovative nanoarchitectures is critical for addressing energy and environmental challenges such as the electrochemical CO₂ reduction reaction (CO₂ RR). Herein, the synthesis of an innovative copper–sulfur planar structure, Cu–S–BDC, within a metal–organic framework (MOF) catalyst is presented, which demonstrates 100% selectivity toward formate as the sole carbon product. Structural analysis and surface characterizations reveal that Cu–S–BDC exhibits quasi-2D inorganic building units, with Cu bonded to two S-CH (Formula presented.) groups and one BDC linker, while carboxylate groups adopt a bridging coordination mode. This unique arrangement not only imparts remarkable structural stability but also enhances the electronic properties of the MOF, as evidenced by a narrow bandgap of 1.203 eV that facilitates efficient charge transfer and increased electrochemical current density in CO (Formula presented.) RR. Notably, it offers a Faradaic efficiency of 92% for formate at an overpotential as low as −0.4 V versus the reversible hydrogen electrode (RHE) in an aqueous electrolyte of 1 m KOH, as well as a current density of −25.8 mA cm² at −0.9 V versus RHE, averaged over 24 h of electrolysis. This study highlights a fresh perspective in the field of MOF electrocatalysts by demonstrating that engineering the metal coordination environment can significantly enhance the electronic properties and consequently improve the electrocatalytic performance of these materials.

Electrochemical CO₂ reduction (CO₂R) to chemicals and fuels has made tremendous progress since the introduction of gas diffusion electrodes (GDEs) to overcome mass-transfer limitations and enable industrial-scale current densities. The advancement in the field, however, has come with new challenges that are related to the stability and degradation of the GDE due to flooding issues, which currently hinder the scale-up. Here, we investigated the effect of six different binding materials (Nafion, polytetrafluoroethylene, Fumion, Pention, poly(vinyl alcohol), and polypyrrole) on the stability and performance of Ag-based GDEs for CO₂R to CO in alkaline media. All binders show a decrease in the Faraday efficiency (FE) of CO and increase in hydrogen evolution reaction over time. The most hydrophilic GDE based on polypyrrole can uphold a higher FE of CO for longer times, which is contrary to a common belief that low wettability is required for long-term stability. By using a range of tools (SEM-EDX, SEM-FIB, X-ray diffraction, and contact angle measurements) for the postelectrolysis characterization of the GDEs, we show that the performance loss is related to flooding, bi(carbonate) precipitation, and catalyst agglomeration. These results contribute to a better understanding of the stability issues in GDE-based CO₂ electrolyzers.

Methane pyrolysis is a promising route for low-emission hydrogen (H₂) production, with solid carbon as a potentially valuable byproduct. Despite this potential, the economic feasibility of Catalytic Methane Pyrolysis (CMP) with fluidized bed reactors (FBR) has been insufficiently studied. This study develops a conceptual CMP plant using two novel isothermal reactor models—based on continuous stirred-tank reactor (CSTR) and plug-flow reactor (PFR) assumptions—to represent the operational extremes of FBRs. Our reactor models incorporate reaction and catalyst deactivation kinetics from experiments with nickel-supported catalysts, and the framework enables process simulations that account for the catalyst rate required to sustain reactor activity. These models address the lack of proper reduced-order FBR models and the reliance on oversimplified assumptions in the literature. In the baseline scenario, the conceptual plant yields an LCOH ranging from $3.89 to $4.79 per kilogram, defining the expected cost bounds for an FBR-based CMP plant. At a H₂ selling price of $5.00 per kilogram, the process achieves favorable payback time and net present value. Monte Carlo and sensitivity analyses indicate that CMP remains cost-competitive under economic uncertainties. Increased carbon sales could make CMP more economical than steam methane reforming, while unsold byproducts may incur costly sequestration. Reactor heating assessment shows methane combustion with carbon capture minimizes both cost and emissions. Overall, this work demonstrates the economic potential of CMP for H₂ production and provides a practical modeling framework for process evaluation.

Cyclopentyl methyl ether (CPME) is a promising green solvent due to its eco-friendly properties; it is produced by adding methanol (MeOH) to cyclopentene. Separation of the resulting product mixture containing CPME and MeOH is critical, and it requires vapor-liquid equilibrium (VLE) data. In this work, isobaric VLE data were measured experimentally using an ebulliometer in a 60.0–101.3 kPa pressure range for a binary system of CPME + MeOH. VLE data were modeled using excess Gibbs (G (Formula presented.)) energy-based models such as Wilson, NRTL, and UNIQUAC. The formation of an azeotrope was analyzed. Flash point, surface tension, Gibbs adsorption, and thickness of surface layer were estimated using the Wilson model, which can help in determining molecule interaction and overall behavior of the system. Atmospheric and high-pressure distillation columns were designed using Aspen Plus to study the separation of CPME + MeOH, and an economic evaluation of the same was carried out.

Titanium dioxide (TiO₂) has been widely used as a photocatalyst in CO₂ reduction reaction (CO₂RR) due to its low cost, high stability, and strong absorption in the close-to-visible ultra-violet (UV) range. However, TiO₂ films suffer from poor selectivity in CO₂ reduction due to their unfavorable electronic properties. In this work, we address this challenge by fabricating ultra-thin (14 nm) defective TiO₂ films (TiO₂-DTF) to enhance the selectivity of CO₂RR towards formate. TiO₂ sol was prepared using a facile and reproducible sol-gel method and directly deposited onto the surface of the electrode, forming a uniform, ultra-thin TiO₂ layers with a high number of defects. The activity of the TiO₂-DTF catalyst was studied in both photochemical and photoelectrochemical CO₂RR, indicating that the applied potential increases both the yield and selectivity of CO₂RR to formate. The TiO₂-DTF photocathode exhibited remarkable formate production during CO₂ reduction, achieving exceptional Faradaic efficiencies of up to 45 %. To elucidate the mechanism of photoelectrochemical CO₂RR on TiO₂-DTF, an in-situ attenuated total reflection Fourier-transform infrared spectroscopy (in-situ ATR-FTIR) was used and experimental results were supported by density functional theory (DFT) calculations. This study demonstrates that ultra-thin highly defective TiO₂ film, prepared using the cost-effective and environmentally friendly sol-gel method, can be used as photoelectrocatalyst for CO₂ reduction.

Electrochemical ammonia synthesis via the nitrogen reduction reaction (NRR) has been poised as one of the promising technologies for the sustainable production of green ammonia. In this work, we developed extensive process models of fully integrated electrochemical NH ₃ production plants at small scale (91 tonnes per day), including their techno-economic assessments, for (Li-)mediated, direct and indirect NRR pathways at ambient and elevated temperatures, which were compared with electrified and steam-methane reforming (SMR) Haber-Bosch processes. The levelized cost of ammonia (LCOA) of aqueous NRR at ambient conditions only becomes comparable with SMR Haber-Bosch at very optimistic electrolyzer performance parameters (FE > 80% at j ≥ 0.3 A cm ⁻²) and electricity prices (<$0.024 per kW h). Both high temperature NRR and Li-mediated NRR are not economically comparable within the tested variable ranges. High temperature NRR is very capital intensive due the requirement of a heat exchanger network, more auxiliary equipment and an additional water electrolyzer (considering the indirect route). For Li-mediated NRR, the high lithium plating potentials, ohmic losses and the requirement for H ₂, limits its commercial competitiveness with SMR Haber-Bosch. This incentivises the search for materials beyond lithium.

Experimentally determining thermophysical properties for various compositions commonly found in CO₂ transportation systems is extremely challenging. To overcome this challenge, we performed Monte Carlo (MC) and Molecular Dynamics (MD) simulations of CO₂ rich mixtures to compute thermophysical properties such as densities, thermal expansion coefficients, isothermal compressibilities, heat capacities, Joule-Thomson coefficients, speed of sound, and viscosities at temperatures of (235-313) K and pressures of (20-200) bar. We computed thermophysical properties of pure CO₂ and CO₂ rich mixtures with N₂, Ar, H₂, and CH₄ as impurities of (1-10) mol % and showed good agreement with available Equations of State (EoS). We showed that impurities decrease the values of thermal expansion coefficients, isothermal compressibilities, heat capacities, and Joule-Thomson coefficients in the gas phase, while these values increase in the liquid and supercritical phases. In contrast, impurities increase the value of speed of sound in the gas phase and decrease it in the liquid and supercritical phases. We present an extensive data set of thermophysical properties for CO₂ rich mixtures with various impurities, which will help to design the safe and efficient operation of CO₂ transportation systems.

The competitiveness of hydrogen as a sustainable energy carrier depends greatly on its transportation and storage costs. Liquefying hydrogen offers advantages such as enhanced purity, versatility, and higher density, yet current industrial liquefaction processes face efficiency and cost challenges. Although various large-scale and efficient liquefaction concepts exist in the literature, they often overlook the economic and technical viability of such plants. Here, we addresses this issue by establishing a framework for modeling a large-scale hydrogen liquefaction concept and conducting both technical and economic assessments, with a specific focus on 125 tonnes per day (TPD) high-pressure hydrogen Claude-cycle concept. The technical analysis involves preliminary designs of key process components, while the economic assessment utilizes Aspen Process Economic Analyzer. Our findings indicate that at an electricity price of €0.1/kWh, the Claude-cycle liquefier concept yields a specific liquefaction cost (SLC) of €1.55/kg_LH2. A sensitivity analysis was performed, which shows that electricity price has a significant influence on the economics. Further investigation on the compressors design shows that incorporating high-speed centrifugal compressors could reduce the SLC by 5.42% and potentially more. Scaling up to 250 and 500 TPD reveals further cost improvements, while cost projections indicate substantial declines as the technology matures. Ultimately, this paper presents novel cost-scaling and experience curves of hydrogen liquefaction technology, demonstrating the compelling economic viability of integrating large-scale hydrogen liquefaction into sustainable energy infrastructure.

Due to the intermittency of renewable energy sources, alkaline water electrolyzers are typically operated at partial load compared to the nominal design value. It is well-known that gas crossover is dominant at low current densities leading to higher anodic hydrogen content and higher cathodic oxygen content in the separator tanks. High anodic hydrogen content is tantamount to loss of product hydrogen which results in an explosive atmosphere in the gas phase if the volumetric hydrogen content in oxygen exceeds 4%. We have developed a transient model of a multi-cell stack which can describe the operation of the electrolyzer with mixed electrolyte flows (anolyte and catholyte), separated flows, or a combination thereof (dynamic switching). This is a major extension of the steady-state model developed by Haug et al. (International Journal of Hydrogen Energy, 2017, 42, 15,689–15707). In sharp contrast to the steady-state model by Haug et al., the transient model can calculate the gas crossover as the operating conditions (e.g. electrolyte flow cycles) dynamically change in time. Depending on the size of the stack and the separator tanks, the model estimates different rates for impurities to build up. The transient model is validated using independent experimental results by Haug et al. and Brauns et al. (Electrochimica Acta, 2022, 404, 139,715) The results show that the dynamic model can follow experimental results for fluctuating current densities for a period of several days. We found that the dynamic response and transition time to steady state depend significantly on the geometrical volume of the gas separators with respect to the single-cell stack. For a multi-cell stack, we find that the impurities build-up faster when increasing the number of cells in the stack. This model serves as a tool for sizing and process management of the electrolyzer system and the separator tanks especially with respect to explosion safety.

Vapor-liquid equilibrium (VLE) data for the binary systems tetrahydrofuran (THF) + acetic acid (AA) and THF + trichloroethylene (TCE) were measured under isobaric conditions using an ebulliometer. The boiling temperatures for the systems (THF + AA/THF + TCE) are reported for 13/15 compositions and five/six different pressures ranging from 50.2/60.0 to 101.1/101.3 kPa, respectively. The THF + AA system shows simple phase behavior with no azeotrope formation. The THF + TCE system does not exhibit azeotrope formation but seems to have a pinch point close to the pure end of TCE. The nonrandom two-liquid (NRTL) and universal quasichemical (UNIQUAC) activity coefficient models were used to accurately fit the binary (PTx) data. Both models were able to fit the binary VLE data satisfactorily. However, the NRTL model was found to be slightly better than UNIQUAC model in fitting the VLE data for both systems. The results can be used for designing liquid-liquid extraction and distillation processes involving mixtures of THF, AA, and TCE.

Electrochemical reduction of carbon dioxide (CO₂) to useful products is an emerging power-to-X concept, which aims to produce chemicals and fuels with renewable electricity instead of fossil fuels. Depending on the catalyst, a range of chemicals can be produced from CO₂ electrolysis at industrial-scale current densities, high Faraday efficiencies, and relatively low cell voltages. One of the main challenges for up-scaling the process is related to (bi)carbonate formation (carbonation), which is a consequence of performing the reaction in alkaline media to suppress the competing hydrogen evolution reaction. The parasitic reactions of CO₂ with the alkaline electrolytes result in (bi)carbonate precipitation and flooding in gas diffusion electrodes, CO₂ crossover to the anode, low carbon utilization efficiencies, electrolyte carbonation, pH-drift in time, and additional cost for CO₂ and electrolyte recycling. We present a critical review of the causes, consequences, and possible solutions for the carbonation effect in CO₂ electrolyzers. The mechanism of (bi)carbonate crossover in different cell configurations, its effect on the overall process design, and the economics of CO₂ and electrolyte recovery are presented. The aim is to provide a better understanding of the (bi)carbonate problem and guide research directions to overcome the challenges related to low-temperature CO₂ electrolysis in alkaline media.

The removal of acid gas impurities from synthesis gas or natural gas can be achieved using several physical solvents. Examples of solvents applied on a commercial scale include methanol (Rectisol), poly(ethylene glycol) dimethyl ethers (Selexol), n-methyl-2-pyrrolidone (Purisol), and propylene carbonate (Fluor solvent). Continuous Fractional Component Monte Carlo (CFCMC) simulations in the osmotic ensemble were used to compute the Henry coefficients of the pure gases CO (Formula presented.), CH (Formula presented.), C (Formula presented.) H (Formula presented.), CO, H (Formula presented.), N (Formula presented.), N (Formula presented.) O, and H (Formula presented.) S in the aforementioned solvents. The predicted Henry coefficients are in good agreement with the experimental results. The Monte Carlo method correctly predicts the gas solubility trend in these physical solvents, which obeys the following order: H (Formula presented.) S > CO (Formula presented.) > C (Formula presented.) H (Formula presented.) > CH (Formula presented.) > CO > N (Formula presented.) > H (Formula presented.). The gas separation selectivities for the precombustion process and the natural gas sweetening process are calculated from the pure gas Henry coefficients. The CO (Formula presented.) /N (Formula presented.) O analogy is verified for the solubility in these solvents.