Carbon dioxide is the most known greenhouse gas and a major contributor to climate change. To reduce its impact, carbon capture, utilisation, and storage technologies (CCUS) offer a solution to turn CO2 into a valuable raw material.
The petrochemical industry, one of the most concerned by climate change, is on the cusp of a transformative breakthrough, and those who aren’t paying attention risk missing out on the next big shift in the sector.
By harnessing the power of cutting-edge technologies like in-situ Diffuse Reflectance Infrared Fourier Transform Spectroscopy (DRIFTS), scientists can significantly improve the conversion of carbon dioxide to methanol, which is low (often below 10–20% for conventional catalysts, depending on reaction conditions and catalyst quality) due to the high thermal stability of CO2 [1] [2]. In situ-DRIFTS offers the potential to take advantage of carbon capture technologies and address resource scarcity, setting the stage for a greener and more sustainable petrochemical industry.
CO2 Hydrogenation to methanol: a pivotal moment in petrochemicals
Methanol has long been a cornerstone of the petrochemical industry since more than 88 Million metric tonnes (MMT)/year are required to fulfil the global demand from industries spanning marine transportation, automotive, and pharmaceuticals.
However, its production relies mainly on fossil fuels, such as coal and oil [3], which are unsustainable sources, to support the industry’s growing demand. As a result, the catalytic hydrogenation of captured CO2 to methanol is revolutionary, transforming a harmful pollutant into a valuable chemical feedstock – addressing environmental concerns while enhancing economic viability. The global methanol market is projected to grow to $46.32 billion by 2032, partly driven by advancements in CO2 hydrogenation [4]. Companies like BASF and Celanese Corporation are at the forefront of this transformation, investing in large-scale projects that demonstrate the feasibility and scalability of using CO2 as a raw material for methanol production [5] [6].
Optimising the catalytic reaction pathway is key to enabling viable green methanol synthesis. Hence, a technology for characterising the catalyst and monitoring the formation of reaction intermediates in real time is critical. This is precisely the role of in-situ DRIFTS [7].
In-situ DRIFTS: unleashing the power of catalysts
Metal-metal oxide catalysts facilitate CO2 hydrogenation into methanol, but water formation inhibits their performance. Thus, researchers are increasingly developing new ways to improve the conversion yield of the reaction in Figure 1[1] [8]:
This is where in-situ DRIFTS becomes indispensable. Notably, when compared with XRD (X-Ray powder Diffraction) or XAS (X-Ray Absorption Spectroscopy), in situ DRIFTS has demonstrated better performance insights when monitoring the transient reaction intermediates at the catalyst surface, providing unprecedented insights into the CO2 hydrogenation mechanism.
Recent research highlights the critical role of intermediate species, such as formates and carbonates, in the hydrogenation process. For example, Cu-based catalysts doped with Zn or Zr have demonstrated significant promise, achieving 88%-98.2% methanol selectivity under optimised pressure, temperature, and molar ratio conditions [1, 7]
The insights gained through in-situ DRIFTS are accelerating the development of next-generation catalytic materials. These advances reduce the energy input required for CO2 hydrogenation, making the process sustainable and cost-effective. By improving catalytic performance, industries can achieve greater scalability, paving the way for the widespread adoption of CO2-to-methanol technologies.
A sustainable solution with an economic payoff
The production of methanol from CO2 offers benefits that extend beyond emissions reduction. Its versatility makes it a critical component in various industries. For instance, it is a key ingredient in biodiesel production, a promising alternative to conventional fossil fuels. Similarly, methanol’s role in fuel cells highlights its potential to support the transition to renewable energy sources.
The concept of green methanol, synthesised from sources such as captured CO2, is particularly transformative and is emerging as crucial in the global shift toward carbon neutrality. For example, the shipping industry, responsible for approximately 3% of global carbon emissions, is exploring green methanol as a low-carbon fuel alternative. Maersk, a global shipping leader, has already ordered vessels capable of operating on methanol, signalling a broader industry shift [9].
The European Commission also supports innovation in this field, as demonstrated by the “Zero-emission shipping” initiative. Part of “Mission Innovation 2.0”, this program stimulates private-public partnerships to obtain carbon-neutral marine fuels. Economic forecasts underscore the growing importance of methanol. Industry analysts predict a compound annual growth rate (CAGR) of 3.8% in global methanol production, increasing from 88 MMT in 2023 to 123.18 MMT by 2032. This growth is driven not only by increasing demand but also by advancements in catalytic technologies enabled by tools like in-situ DRIFTS.
Methanol synthesis: Industrial challenges and opportunities
Besides the need for improving catalysts, CO2-to-methanol technology faces additional challenges. One significant hurdle is the availability of renewable hydrogen. Green hydrogen production cost is still 3 times higher than blue hydrogen (relying on fossil fuel and carbon capture technologies). However, improvements to the electrolyser technologies can reduce costs by 80% compared to the current levels [10].
Another challenge lies in scaling up production facilities to meet global demand. While pilot projects demonstrate the feasibility of CO2-to-methanol conversion, achieving economies of scale requires significant investment in infrastructure. Governments and the private sector must collaborate to create favourable policy frameworks and financial incentives encouraging large-scale adoption.
These challenges also present opportunities. The transition to a circular carbon economy, where CO2 is captured, reused, and transformed into valuable products, aligns with global sustainability goals. Companies that invest in this transition early, stand to benefit from both economic and reputational advantages.
Why does optimising CO2 conversion to methanol matter for the petrochemical industry?
For industry professionals, the implications of these technological advances are massive. By leveraging in-situ DRIFTS, companies can significantly improve the efficiency of their methanol production processes, cut operational costs, and meet growing regulatory demands for lower carbon footprints. Here’s why companies should care:
- Increased efficiency: With real-time data on catalyst performance, companies can make continuous improvements, ensuring that each reaction is optimised for maximum yield and minimal waste.
- Lower carbon footprint: Using CO2 as a feedstock for methanol production directly reduces emissions, aligning with global sustainability targets. It’s estimated that large-scale adoption of CO2 hydrogenation could cut global CO2 emissions by up to 10%, depending on the technologies and scales involved.
- Profitability and growth: As the demand for renewable methanol rises, early adopters will be in a prime position to capitalise on this growing market, which is expected to hit $46.32 billion by 2032 [4].
The bottom line
The petrochemical industry is at a crossroads, facing increasing pressure to balance economic growth with environmental responsibility. Technologies like in-situ DRIFTS are unlocking new possibilities for CO2 hydrogenation, transforming carbon emissions into valuable products like methanol. This is not just an opportunity; forward-thinking companies must embrace these advancements.
The future of petrochemicals lies in sustainability and innovation. By turning CO2 from a liability into an asset, the industry can play a pivotal role in addressing climate change while driving economic growth. This is the next big shift in petrochemicals, and the time to act is now.
References
1) R-P Ye, J Ding, W Gong, M D Argyle, Q Zhong, Y Wang, C K Russell, Z Xu, A G Russell, Q Li, M Fan and Y-G Yao, Nat. Commun., 2019, 10, 5698.
2) Zhang, X., Zhao, H., Liu, S., et al., Front. Energy Res., 2020, 8, 621119. DOI: 10.3389/fenrg.2020.621119
3) M Fasihi and C Breyer, Energy Environ. Sci., 2024, 17, 3503–3522.
4) https://www.marketsandmarkets.com/Market-Reports/methanol-market-425.html
5) https://www.mordorintelligence.com/industry-reports/methanol-market
6) https://www.businesswire.com/news/home/20210624005496/en/Worldwide-Methanol-Industry-to-2026—Key-Market-Drivers-and-Success-Factors—ResearchAndMarkets.com
7) S M Fehr, K Nguyen and I Krossing, ChemCatChem, 2021, 14 (3) e202101500.
8) B C Dharmalingam, A Koushik V, M Mureddu, L Atzori, S Lai, A Pettinau, N S Kaisare, P Aghalayam, J J Varghese, 2022, Appl. Catal., B, 332, 122743.
9) https://www.maersk.com/news/articles/2023/06/26/maersk-orders-six-methanol-powered-vessels
10) IRENA (2021), Making the breakthrough: Green hydrogen policies and technology costs, International Renewable Energy Agency, Abu Dhabi.