Electrification of steam cracking as a pathway to reduce the impact of the petrochemical industry on climate change

In the Chemical Process Industry (CPI) only hydrogen production from steam methane reforming produces more greenhouse gas emissions than light olefins production. Various solutions have been proposed to reduce the CO2 emissions from olefins production. It is not clear which solution is best, particularly when you consider other sustainability factors. In this paper we report the results of our cradle-to-gate life cycle assessment (LCA) of three highly promising solutions: a so-called low-emission steam cracking furnace, the electrically driven RotoDynamic reactor (RDR), and a blue hydrogen-fired furnace. Life cycle inventory data is obtained from a first principles model for steam cracking, validated with industrial data, and combined with data obtained from process simulation. Our study shows that if the electrical supply is grey then the RDR-based cracking process has a 41% higher impact on climate change than the reference base case, a conventional plant with state-of-the-art furnaces. The low-emission furnace is only 7.2% higher. When using a mixed electrical grid, like Belgium's, the climate change impact for the RDR is 1.5% higher and the low emission furnace is 6.6% lower. With a grid that uses fully renewable power generation the RDR solution is an impressive 27% lower than the base case and the lowemission furnace 17% lower. We also analysed the impact of firing the furnaces with blue hydrogen from (a) a conventional steam-methane reformer and (b) an innovative gas-heated reformer: both (a) and (b) using carbon capture and storage (CCS). The climate change impact is reduced by 8% and 18% respectively compared to the base case. Since the blue hydrogen solution uses very little electricity, the climate change impact is insensitive to the method of electrical power generation.

Automated summary

In the Chemical Process Industry (CPI), hydrogen production from steam methane reforming is the only process that emits more greenhouse gases than light olefins production. Various solutions have been proposed to reduce CO2 emissions from olefins production, but it is unclear which solution is the best. In this study, we conducted a life cycle assessment (LCA) to compare three highly promising solutions: a low-emission steam cracking furnace, an electrically driven RotoDynamic reactor (RDR), and a blue hydrogen-fired furnace.