DOI: https://doi.org/10.9767/jcerp.20705

Energy Optimization of Methanol Production using CO₂from Natural Gas Sweetening via Reactor Heat Recovery, Compressor Integration, and Cooling Water Reuse

Department of Chemical Engineering, Universitas Diponegoro, Jl. Prof. Sudarto, SH, Tembalang, Semarang, Indonesia

Received: 11 Apr 2026; Revised: 27 Apr 2026; Accepted: 28 Apr 2026; Available online: 10 May 2026; Published: 28 Dec 2026.
Editor(s): Istadi Istadi
Open Access Copyright (c) 2026 by Authors, Published by Universitas Diponegoro and BCREC Publishing Group
Creative Commons License This work is licensed under a Creative Commons Attribution-ShareAlike 4.0 International License.
Fulltext View|Download

Citation Format:
Cover Image
Abstract

Methanol production via CO₂ hydrogenation is an efficient alternative for supporting energy sustainability and reducing carbon emissions; however, conventional processes still face limitations in energy efficiency and resource utilization. This study aims to optimize the methanol production process through the integration of heat recovery, compressor energy utilization, and water recycling. Simulations were conducted using Aspen HYSYS by comparing baseline process conditions with modified process conditions under the same operating conditions. The results show that integrating heat from the reactor effluent and the cooling unit reduces external energy requirements, while the water recycling system successfully reduces fresh water usage by up to 100%. Additionally, heating energy requirements decreased by 27.21%, and compressor energy needs were fully met through internal energy recovery. From an economic perspective, significant operational cost savings were achieved, particularly in steam consumption, without compromising product quality, as methanol purity remained at 97.91%. Overall, the integration of mass and energy in this process has proven capable of improving efficiency, reducing costs, and supporting the sustainability of CO₂-based methanol production.

Keywords: Methanol production; CO₂ hydrogenation; Heat integration; Energy optimization; Water recycling
Funding: Diponegoro University

Article Metrics:

Article Info
Section: Original Research Articles
Language : EN
Recent articles
Effect of Temperature and Pressure Variation on CO₂ Methanation Performance in a PFR Reactor Using Ni/Al₂O₃ Catalyst Process Optimization for Conversion Rate in NO Oxidation to NO2 over Co3O4 Catalyst Energy Optimization of Methanol Production using CO₂from Natural Gas Sweetening via Reactor Heat Recovery, Compressor Integration, and Cooling Water Reuse More recent articles
  1. International Energy Agency. (2020). Global gas demand in initial and revised forecasts, 2019–2025. Retrieved April 24, 2026, from https://www.iea.org/data-and-statistics/charts/global-gas-demand-in-initial-and-revised-forecasts-2019-2025
  2. Darani, N. S., Behbahani, R. M., Shahebrahimi, Y., Asadi, A., & Mohammadi, A. H. (2021). Simulation and optimization of the acid gas absorption process by an aqueous diethanolamine solution in a natural gas sweetening unit. ACS omega, 6(18), 12072-12080. https://doi.org/10.1021/acsomega.1c00744
  3. Mohajeri, M., Panahi, M., & Shahsavand, A. (2024). Optimal operation of a natural gas sweetening plant. Computers & Chemical Engineering, 184, 108631. https://doi.org/10.1016/j.compchemeng.2024.108631
  4. Solis-Jacome, A., Ramírez-Márquez, C., Morales-Cabrera, M. A., & Ponce-Ortega, J. M. (2024). Methanol production from residual streams of natural gas sweetening for achieving the sustainable development goals. Chemical Engineering and Processing - Process Intensification, 199, 109746. https://doi.org/10.1016/j.cep.2024.109746
  5. Lacerda de Oliveira Campos, B., John, K., Beeskow, P., Herrera Delgado, K., Pitter, S., Dahmen, N., & Sauer, J. (2022). A detailed process and techno-economic analysis of methanol synthesis from H2 and CO2 with intermediate condensation steps. Processes, 10(8), 1535. https://doi.org/10.3390/pr10081535
  6. Mordor Intelligence. (2026). Methanol market size, share, trends analysis & industry report (2031). Retrieved April 24, 2026, from https://www.mordorintelligence.com/industry-reports/methanol-market
  7. Borisut, P., & Nuchitprasittichai, A. (2019). Methanol Production via CO2 Hydrogenation: Sensitivity Analysis and Simulation—Based Optimization. Frontiers in Energy Research, 7. https://doi.org/10.3389/fenrg.2019.00081
  8. Kanuri, S., Roy, S., Chakraborty, C., Datta, S. P., Singh, S. A., & Dinda, S. (2022). An insight of CO2 hydrogenation to methanol synthesis: Thermodynamics, catalysts, operating parameters, and reaction mechanism. International Journal of Energy Research, 46(5), 5503-5522. https://doi.org/10.1002/er.7562
  9. Francis, A., Ramyashree, M. S., Priya, S. S., Kumar, S. H., Sudhakar, K., Fan, W. K., & Tahir, M. (2022). Carbon dioxide hydrogenation to methanol: Process simulation and optimization studies. International Journal of Hydrogen Energy, 47(86), 36418-36432. https://doi.org/10.1016/j.ijhydene.2022.08.215
  10. Machado, C. F. R., Medeiros, J. L., Araújo, O. F. Q., & Alves, R. M. B. (2014). A comparative analysis of methanol production routes: synthesis gas versus CO₂ hydrogenation. In Proceedings of the International Conference on Industrial Engineering and Operations Management
  11. Francis, A., MS, R., Priya, S. S., Kumar, S. H., Sudhakar, K., Fan, W. K., & Tahir, M. (2022). Carbon dioxide hydrogenation to methanol: Process simulation and optimization studies. International Journal of Hydrogen Energy, 47(86), 36418–36432. https://doi.org/10.1016/j.ijhydene.2022.08.215
  12. Abooali, D., Soleimani, R., & Rezaei-Yazdi, A. (2020). Modeling CO2 absorption in aqueous solutions of DEA, MDEA, and DEA+ MDEA based on intelligent methods. Separation Science and Technology, 55(4), 697-707. https://doi.org/10.1080/01496395.2019.1575415
  13. Yang, N., Kang, F., Liu, Z., Ge, X., & Zhou, Y. (2022). An integrated CCU-plant scheme and assessment for conversion of captured CO2 into methanol. International Journal of Low-Carbon Technologies, 17, 550–562. https://doi.org/10.1093/ijlct/ctac038
  14. Yaws, C. L. (2003). Yaws’ handbook of thermodynamic and physical properties of chemical compounds. Knovel
  15. Ren, M., Zhang, Y., Wang, X., & Qiu, H. (2022). Catalytic Hydrogenation of CO2 to methanol: a review. Catalysts, 12(4), 403. https://doi.org/10.3390/catal12040403
  16. Park, N., Park, M.-J., Ha, K.-S., Lee, Y.-J., & Jun, K.-W. (2014). Modeling and analysis of a methanol synthesis process using a mixed reforming reactor: Perspective on methanol production and CO₂ utilization. Fuel. https://doi.org/10.1016/j.fuel.2014.03.068
  17. Ahmetović, E., Kravanja, Z., & Grossmann, I. E. (2022). Combined water and heat integration in process industries. Frontiers in Chemical Engineering, 4, 1012754. https://doi.org/10.3389/fceng.2022.1012754
  18. Valverde, J., Ferro, V., & Giroir-Fendler, A. (2022). Application of the e-NRTL model to electrolytes in mixed solvents methanol-, ethanol- water, and PEG-water. Fluid Phase Equilibria, 560, 113516. https://doi.org/10.1016/j.fluid.2022.113516
  19. Lee, J.-Y., & Chen, P.-Y. (2023). Optimization of heat recovery networks for energy savings in industrial processes. Processes, 11(2), 1-9. 10.21608/eajast.2022.146577.1011
  20. Liu, C., Ma, H., Liu, S., Zhang, H., & Ma, D. (2024). Heat recovery technology and energy-saving effect analysis applied to cleanroom exhaust waste heat characteristics. Energy & Buildings, 306, 113935. https://doi.org/10.1016/j.enbuild.2024.113935
  21. Ribeiro, J. M., Dias, D. F. C., Nika, E., Delpech, B., Katsou, E., & Jouhara, H. (2025). Circularity assessment of industrial heat exchanger and water treatment systems integration. Thermal Science and Engineering Progress, 62, 103661. https://doi.org/10.1016/j.tsep.2025.103661
  22. Hall, S. (2017). Rules of thumb for chemical engineers. Elsevier Science. https://doi.org/10.1016/C2016-0-00182-1
  23. Trading Economics. (2026). Natural gas prices. Retrieved April 11, 2026, from https://tradingeconomics.com/commodity/natural-gas
  24. Intratec. (2026). Cooling water cost in the United States. Retrieved April 11, 2026, from https://www.intratec.us/solutions/industry-economics-worldwide/utility/cooling-water-cost-united-states
  25. World Population Review. (2026). Cost of electricity by country. Retrieved April 11, 2026, from https://worldpopulationreview.com/country-rankings/cost-of-electricity-by-country

Last update:

No citation recorded.

Last update:

No citation recorded.