How Johnson Matthey’s eMERALD™ flowsheet makes e-methanol viable at scale

As industries accelerate their decarbonisation journeys, e-methanol, produced from CO₂ and renewable hydrogen, is emerging as a strategic fuel and chemical feedstock for sectors like shipping, aviation and plastics. Yet the path to scalable production has been constrained by technology readiness, feedstock cost and process efficiency.

Johnson Matthey’s eMERALD™ flowsheet solves these challenges. By combining advanced catalyst science, efficient process design and systems integration, the eMERALD flowsheet delivers the technical and economic performance needed to make eMethanol viable at scale. Below is a closer look at the enabling technologies behind this breakthrough.

1. Catalyst innovation for long-term stability and activity

At the heart of the eMERALD flowsheet is JM’s silicon-promoted catalyst, eMERALD 201, which addresses the challenge of sintering under high-steam CO₂ hydrogenation conditions.

Silicon promotion stabilises zinc oxide crystallites, limiting deactivation, and providing enhanced hydrothermal resistance, ensuring steady productivity and minimal downtime

In commercial operation, this translates into higher plant availability and lower operating costs, critical for renewable methanol projects that rely on high-value feedstocks like green hydrogen.

2. Feedstock efficiency through high circulation loop design

The methanol synthesis reaction is equilibrium-limited. To overcome this, the eMERALD flowsheet uses a high circulation loop centred on a Tube-Cooled Converter (TCC).

• The high circulation ratio drives near-complete utilisation of hydrogen and CO₂
• Pressure drop is carefully managed to support high flow rates and maintain conversion
• The loop design supports flexible operation during renewable power fluctuations

This results in higher methanol yield and improved economics, including a reported 9% reduction in levelised production cost compared to conventional flowsheets.

3. Heat integration to reduce energy demand

Traditional methanol plants rely on fired reformers and complex front-end systems. The eMERALD flowsheet simplifies and improves thermal integration.

• Process heat from the methanol synthesis reaction is reused in feed gas preheating and distillation
• There is no need for a reverse water gas shift reactor, lowering capital and energy use
• Energy input requirements are reduced without compromising conversion

These design optimisations lead to a simpler, more compact plant with lower OPEX and improved environmental performance.

4. Global deployment and real-world impact

The eMERALD flowsheet is already being adopted in major projects worldwide.

• The Haru Oni pilot plant in Chile has been operational since 2022, converting wind power and biogenic CO₂ into methanol

HIF Global’s Paysandú facility in Uruguay will be South America’s largest e-methanol plant, with an ultimate planned capacity of 700,000 tonnes per year Additional deployments in Spain and Texas These projects demonstrate that eMethanol production at scale is not only possible, but actively underway.

5. Environmental performance and carbon avoidance

Life cycle assessments show that e-methanol can achieve up to 143 percent reduction in global warming potential on a cradle-to-gate basis compared to fossil-based methanol. These reductions depend on the carbon intensity of the electricity and feedstocks used.

The eMERALD flowsheet helps meet strict emissions targets while supporting long-term fuel security and global climate objectives.

Conclusion

Johnson Matthey’s eMERALD flowsheet delivers the core capabilities needed for commercial eMethanol production. With industry-leading catalyst stability, a proven high-circulation loop and integrated heat recovery, it offers a mature and bankable platform to meet the needs of net-zero energy systems.

For industries looking to decarbonise aviation, shipping and chemical production, the eMERALD flowsheet represents a clear and credible path forward.