Technoeconomic analysis of fine chemical electrosynthesis: a case study using electrooxidation of 2-methylnaphthelene to vitamin K3†

Electroorganic synthesis has received significant attention due to its environmentally friendly nature, offering the potential to replace traditional hazardous chemical production routes. However, an in-depth technoeconomic analysis (TEA) of electrosynthesis technology is still necessary to objectively assess the economic viability of this technology as an alternative to the traditional chemical syntheses. In this study, we used the cerium-mediated electrosynthesis of 2-methyl-1,4-naphthoquinone (2-MNQ, also known as vitamin K₃) as a case study. The process development was conducted in both small-scale and large-scale electrochemical flow cells with 6.25 cm² and 208 cm² electrode sizes, respectively, to investigate the process scalability. Under the optimal conditions, a 66% yield was achieved for 2-MNQ with 90% faradaic efficiency at 50 mA cm⁻² current density. We performed a comprehensive TEA on the key factors influencing electroorganic synthesis, including current density, electrode cost and lifespan, membranes, and electricity price. Furthermore, considering ongoing technological advancements in electrodes, membranes, and renewable electricity generation, we analyzed the trend of future projected cost reductions for electrosynthesis processes.