Accelerating the net-zero economy with CO₂-hydrogenated formic acid production: Process development and pilot plant demonstration

A process capable of large-scale formic acid (FA) production via CO₂ hydrogenation is presented. This study provides the key strategies for use in developing a viable process for continuous operation. Based on the proposed strategies, a pilot-scale process with a capacity of 10 kg/day was constructed. The continuous operability of the process is demonstrated via pilot plant operation for >100 h, achieving a CO₂ conversion rate of 82% and producing FA with a high purity of >92 wt %. Techno-economic analysis and life cycle assessment results of the validated simulation model indicate that the proposed process significantly reduces the level of global warming impact by 42% while cutting the production cost by 37%, compared with the conventional process for producing FA. The contents of this study provide a comprehensive manual for developing a viable CO₂ utilization solution, showing economic profitability as well as environmental impact reduction.