Semester

Summer

Date of Graduation

2025

Document Type

Dissertation

Degree Type

PhD

College

Statler College of Engineering and Mineral Resources

Department

Chemical and Biomedical Engineering

Committee Chair

Srinivas Palanki

Committee Member

John Hu

Committee Member

Debangsu Bhattacharyya

Committee Member

Fernando V. Lima

Committee Member

Yuhe Tian

Committee Member

Jignesh Solanki

Abstract

Methanol is a versatile chemical that can be used as a fuel, a solvent, a feedstock for other chemicals, and a hydrogen carrier. Methanol production from natural gas, which is mainly composed of methane, is a well-established process that involves steam reforming, methanol synthesis, and methanol purification. However, this process is energy-intensive and emits large amounts of carbon dioxide, which contributes to global warming and climate change. Therefore, there is a need for alternative methods of methanol production that are more efficient and environmentally friendly. The overall objective of this research is to develop simulation models of two novel methanol production processes and compare their performance with the conventional process of producing methanol via steam reforming. In the first method, a novel process is developed to produce industrial quantity of methanol in a centralized location by combining a chemical looping scheme with dry reforming of natural gas in a novel microwave reactor. A heat exchanger network is developed to substantially reduce the hot and cold utility usage. The effect of changing the operating cost of carbon dioxide feed, the capital cost of the microwave reactor, and the cost of electricity on the net present value is analyzed. Technoeconomic comparison with the conventional industrial process to produce methanol via steam reforming of methane indicates that the chemical looping generates a significant positive net present value along with a substantial reduction in carbon dioxide emissions. In the second method, a novel green methanol process is developed to produce smaller quantities of methanol in decentralized locations by integrating a novel building-based DAC process, functionalized solid sorbents, and low-energy SOEC technology, aiming to minimize operational and capital costs. The green methanol system emphasizes modularity, employing building-integrated DAC to eliminate air-handling infrastructure and coupling it with high-temperature electrolysis for efficient hydrogen production. A systemic analysis examines the interplay between natural gas markets, electricity pricing, and methanol production costs, establishing a comprehensive framework to quantify energy market volatility on process economics. By linking fuel price fluctuations to electrified process viability, this work highlights the need for adaptive designs in transitioning to low-carbon systems. This work advances process systems engineering by bridging gaps between conceptual innovation, energy economics, and industrial decarbonization. It establishes foundational methodologies for integrating emerging technologies into existing chemical infrastructures, emphasizing catalytic efficiency, reactor modularity, and renewable energy collaboration. The findings advocate for cross-sector collaboration, adaptive policy frameworks, and scalable process designs to align methanol production with global sustainability targets, offering a roadmap for transitioning from fossil-dependent systems to resilient, carbon-neutral value chains.

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