Process optimization and techno-economic assessment of commercial scale synthesis of fatty alcohols from biomass-based syngas

Synthesis gas is widely employed in industrial sectors for ammonia and hydrocarbons generation through Haber-Bosch and Fischer-Tropsch processes, respectively. Yet, its utilization in commercial-scale production of fatty alcohols is in the developmental stage and requires extensive research for efficient and economic plant setup. Therefore, the present study contributes to developing experimental and modeling approach for generation of higher alcohols from syngas using catalytic conversion. In this route, neat syngas (H₂: CO ratio 2 and 1) derived from biomass gasification was catalytically converted into alcohols in a lab-scale fixed bed reactor; with hydrocarbons, carbon dioxide and water as the by-products. Aspen Plus process simulator was used for design and process optimization of a commercial-scale alcohol synthesis plant from syngas, incorporating reaction stoichiometry from lab-scale experiments. After separation and purification stages, the alcohols attained appropriate purity for commercial use. The study generated 14.7 tonnes fatty alcohols per day with 99.5 %. purity, with ethanol being the major product. As per the price index of year 2024, the economic analysis estimated 814$ for production, while 918 $ as a selling price per ton of alcohol. This cash flow gives an annual gross income of 1.07 M$ which can produce a reasonable profit of margin after synthesizing the aviation fuel. The work demonstrates technical and economic feasibility of the alcohol generation, promoting possible utilization of syngas in the downstream applications.