Design and Simulation of an Integrated Process for the Co-Production of Power, Hydrogen, and DME by Using an Electrolyzer’s System

The increasing global demand for clean energy and sustainable industrial processes necessitates innovative approaches to energy production and chemical synthesis. This study proposed and simulated an innovative integrated system for the co-production of power, hydrogen, and dimethyl ether (DME), combining the high-efficiency Allam– Fetvedt cycle with co-electrolysis and indirect DME synthesis. The Allam–Fetvedt cycle generated electricity while capturing CO2, which, along with water, was used in solid oxide electrolyzers (SOEs) to produce syngas via co-electrolysis. The resulting syngas was converted to methanol and subsequently to DME. Aspen HYSYS was used to model and simulate the process, and heat/mass integration strategies were implemented to reduce energy demand and optimize resource utilization. The proposed integrated process enabled an annual production of 980,021 metric tons of DME, 189,435 metric tons of hydrogen, and 7698.27 metric tons of methanol. The energy efficiency of the Allam–Fetvedt cycle reached 55%, and heat integration reduced the system’s net energy demand by 14.22%. Despite the high energy needs of the electrolyzer system (81.28% of net energy), the overall energy requirement remained competitive with conventional methods. Carbon emissions per kilogram of DME were reduced from 1.16 to 0.77 kg CO2 through heat integration and can be further minimized to 0.0308 kg CO2/kg DME (near zero) with renewable electrification. Results demonstrated that 96% of CO2 was recycled within the Allam–Fetvedt cycle, and the rest (the 4% of CO2) was captured and converted to syngas, achieving net-zero carbon emissions. This work presents a scalable and sustainable pathway for integrated clean energy and chemical production, advancing toward industrial net-zero targets.