Electrocatalytic CO
2 reduction reaction (CO
2RR) to ethylene (C
2H
4) has emerged as a promising approach for converting CO
2 into valuable chemicals while utilizing renewable electricity. To facilitate the commercialization of this technology, a process-level techno-economic assessment
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Electrocatalytic CO
2 reduction reaction (CO
2RR) to ethylene (C
2H
4) has emerged as a promising approach for converting CO
2 into valuable chemicals while utilizing renewable electricity. To facilitate the commercialization of this technology, a process-level techno-economic assessment (TEA) is constructed for a plant producing 100 tons/day of C
2H
4 from coal-power flue gas CO
2 using a membrane electrode assembly (MEA) electrolyzer and downstream gas separations. The model integrates (i) flue gas CO
2 capture by chemical absorption, (ii) CO
2RR to C
2H
4 with H
2 as the only co-product, and (iii) cathode off-gas separation by pressure swing adsorption (PSA) plus anode off-gas CO
2 recovery and recycle. A Cu
10–Sn catalyst measured in an H-cell is projected to MEA operation by scaling current density by 10×, yielding a “Case Study in This Article” scenario of
j = 246 mA·cm
−2 and
FE(C
2H
4) = 48.74%. Under this scenario, the total cost is 592.61 thousand USD/day (5926 USD/ton), dominated by electricity (39.8%). Scenario analysis shows that the total cost can decrease to 76,755.0 USD/day (767.6 USD/ton) under a future-outlook case with improved electrolyzer performance and low-cost power, enabling a net profit of 19,945.0 USD/day at an ethylene selling price of 967 USD/ton. Sensitivity analysis identifies
FE(C
2H
4), full-cell voltage, and electricity price as the most influential variables. The results translate laboratory catalyst metrics into industrial cost drivers and clarify quantitative performance targets for commercialization.
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