Detailed techno-economic analysis of methanol synthesis from plasma assisted waste gasification derived syngas with captured CO₂ at pilot scale

Climate change, improper waste management, and the demand for renewable chemicals are the three pressing and interconnected global challenges this paper tackles by exploring an innovative process for sustainable methanol production. A pilot-scale thermal plasma gasification system (1.4–1.7 MW_e) is proposed that converts refuse-derived fuel (5.6–6.8 t/d) into syngas, using captured CO₂ as a gasification agent. Two CO₂ compositions (57 vol% CO₂ at 14.5 t/d and 96 vol% CO₂ at 10.0 t/d) were evaluated, along with a reference case using steam (4.2 t/d). The resulting syngas undergoes purification and hydrogen supplementation (0.2–1.7 t/d) to synthesize methanol (9.3–18.3 t/d). Techno-economic analysis demonstrates that this process is competitive even on a small scale, achieving methanol production costs as low as 500–620 €/t, comparable to the current market price. Sensitivity analysis highlights the importance of optimizing the input of hydrogen and electricity to maintain cost efficiency. Integrating the captured CO₂ from a waste-to-energy facility enhances the circular economy by using carbon that would otherwise be emitted. Additionally, the study examines the economic trade-offs of operating during lower electricity price periods, finding that a 70–85 % utilization rate is optimal (with fixed 10 % reserved for maintenance). As energy and hydrogen costs decline while CO₂ allowance prices increase, this technology is poised for even greater competitiveness. By merging waste valorization, CO₂ capture, and power-to-X principles, this work presents a scalable and economically viable pathway towards sustainable methanol production, bridging the gap between waste management and renewable chemical synthesis.