Sustainable Route of Ethylene Carbonate Production via CO₂ Carboxylation: Process Development, Process Integration, and Economic Analysis

CO₂ carboxylation with ethylene glycol (EG) to synthesize ethylene carbonate (EC) is an ecofriendly alternative to traditional methods that rely on toxic, fossil-based epoxides. In this study, the sustainable production of EC for large-scale feasibility and economic viability through experimental and simulation analyses were developed. Our experimental work (case A) using a CeO₂ nanorod catalyst achieved the highest EC production (0.072 mmol EC/g EG) reported in the literature without a dehydrating agent. For a comprehensive evaluation, we conducted a techno-economic comparative assessment against a study with the best EC yield using 2-cyanopyridine (case B). Process integration for both cases was implemented through a heat exchanger network system (HENS) design, achieving ∼60% in heat recovery, and further exergy analysis reported an efficiency of >90%. Although case B achieved near-perfect conversion efficiency with 2-cyanopyridine, its economic viability was less promising than case A. With current technology, neither case is feasible for commercialization at an annual EC production of 5 ktonne. The minimum selling price of EC must exceed AUD 10.20/kg for case A and AUD 26.50/kg for case B. Our results suggest that eliminating hazardous 2-cyanopyridine is possible, with further recommendations to fully realize the profitability of this production’s approach.