Current Status of Electrochemical CO₂ Reduction to Commercial Products and Techno-Economic Assessment of Syngas Production

Electrochemical CO₂ conversion is emerging as a game-changing technology, transforming harmful emissions from the atmosphere or industrial sources, such as natural gas processing plants and petroleum refineries, into high-value chemicals through eco-friendly processes. This study explores the state of the art of this technology, focusing on the production of C₂⁺ hydrocarbons such as ethanol, ethylene, and propanol, as well as the generation of carbon monoxide, synthesis gas (syngas), and methanol. Experimental data were gathered for each case, and the progress of different alternatives was assessed based on key performance indicators: Faradaic efficiency, system stability, partial current density, electrode surface area, and catalyst composition. The findings indicate that the most mature technology is the production of carbon monoxide or syngas, followed by ethylene through a C-C coupling mechanism with a proper catalyst. With continued innovation, the electrocatalytic benchmarks for other CO₂ reduction products are within reach, paving the way for renewable energy integration into transportation and chemical industries, all while cutting greenhouse gas emissions. Furthermore, a comparative review of existing techno-economic analyses was conducted for each product to evaluate its feasibility for large-scale implementation. Building on these insights, a comprehensive techno-economic assessment (TEA) was performed for the most promising alternative, syngas production, taking into account the entire process, from reaction to downstream separation and purification, to ensure commercial viability. In conclusion, electrochemical CO₂ reduction is on the brink of revolutionizing renewable energy infrastructure. With continued advancements, it holds the potential to reshape the chemical industry and contribute significantly to global sustainability goals.