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Electrochemical conversion of CO2 (CO2R) into fuels and chemicals can bothreduce CO2 emissions and allow for clean manufacturing in the scenario ofsignificant expansion of renewable power generation. However, large-scaleprocess deployment is currently limited by unfavourable process economicsresulting from significant up- and down-stream costs for obtaining pure CO2,separation of reaction products and increased logistical effort. We havediscovered a method for economically viable recycling of waste CO2 thataddresses these challenges. Our approach is based on integration of a CO2R unitinto an existing manufacturing process: ethylene oxide (EO) production, whichemits CO2 as a by-product. The standard EO process separates waste CO2 from gasstream, hence the substrate for electroreduction is available at an EO plant atno additional cost. CO2 can be converted into an ethylene-rich stream andrecycled on-site back to the EO reactor, which uses ethylene as a raw material,and also the anode product (oxygen) can be simultaneously valorized for the EOproduction reaction. If powered by a renewable electricity source, the processwill significantly (ca. 80%) reduce the CO2 emissions of an EO manufacturingplant. A sensitivity analysis shows that the recycling approach can beeconomically viable in the short term and that its payback time could be as lowas 1-2 years in the regions with higher carbon taxes and/or with access tolow-cost electricity sources.

Economically viable CO2 electroreduction embedded within ethylene oxide manufacturing