Low Carbon Ethylene via Biomass Hydrogen Combustion
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Solution Overview
Problem
The petrochemical industry faces challenges in reducing the carbon intensity of ethylene production, as conventional steam cracking processes emit significant CO2 due to high energy requirements and reliance on hydrocarbon fuels, limiting the achievable carbon intensity of ethylene products to above 0.6 kg CO2e/kg C2H4 despite efforts to optimize energy input and capture emissions.
Innovation Solution
The method involves producing ethylene using a steam cracking process where the heating duty is provided by low, neutral, or negative carbon intensity hydrogen, generated through biomass power plant energy, which includes reforming or electrolysis processes, and utilizing carbon capture units to reduce emissions, aiming to achieve a carbon intensity of less than 0.6 kg CO2e/kg C2H4.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional steam cracking process uses hydrocarbon fuel combustion for heating duty, then sufficient heating energy is provided, but carbon intensity of ethylene product remains high (above 0.6 kg CO2e/kg C2H4)
Solution Approach 1:
The patent changes the chemical composition parameter of the fuel from hydrocarbon to hydrogen, fundamentally altering the combustion reaction from CO2-producing to CO2-free (or CO2-captured). This parameter change in fuel type enables decoupling of heating duty from carbon emissions, allowing sufficient thermal energy provision while eliminating the source of high carbon intensity in the ethylene product
Solution Approach 2:
The patent converts the previously harmful CO2 emissions from hydrocarbon combustion into a benefit by using hydrogen combustion, which produces water instead of CO2. Additionally, the patent captures any remaining CO2 from the process and converts it into a sellable product or sequesters it, transforming the harmful emission into a valuable resource or neutral element, thereby achieving negative or zero carbon intensity
2Object-generated harmful factors
If hydrogen content in steam cracking furnace fuel gas is increased, then carbon intensity is reduced, but fuel cost and hydrogen production requirements increase
Solution Approach 1:
The patent implements self-service by using the ethylene off-gas stream, which is already produced during the steam cracking process, as the feedstock for hydrogen production via reforming. This creates an internal circular economy where a byproduct of the main process becomes the原料 for the fuel needed in the same process, eliminating the need for external hydrogen imports and reducing overall quantity requirements
Solution Approach 2:
The patent merges multiple functions into an integrated system where the steam cracking furnace, hydrogen production unit, and CO2 capture system work together as a unified process. The off-gas from cracking feeds the reformer, the reformer produces hydrogen for the furnace, and the CO2 capture system handles emissions from both processes, creating a synergistic system that reduces total hydrogen quantity needs through internal recycling
3Object-generated harmful factors
If CO2 emissions are captured from steam cracking furnaces, then carbon intensity is reduced, but equipment complexity and operational costs increase
Solution Approach 1:
The patent designs the CO2 capture system to serve multiple functions: capturing CO2 from both the steam cracking furnace and the hydrogen production reformer, converting CO2 into a sellable product (such as food-grade CO2 or chemical feedstock), and potentially sequestering excess CO2. This multi-functionality justifies the equipment complexity by providing additional revenue streams and environmental benefits beyond simple emission reduction
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively reduces the carbon intensity of ethylene production to below 0.6 kg CO2e/kg C2H4, potentially reaching zero carbon intensity by utilizing biomass-derived energy and capturing biogenic CO2, thereby minimizing greenhouse gas emissions associated with ethylene production.
Implementation Method 1
converting a hydrocarbon feedstock to an unsaturated hydrocarbon stream through a steam cracking process
Implementation Method 2
wherein the hydrogen is produced using a hydrogen production process; The hydrogen production process may comprise converting a hydrocarbon feedstock to hydrogen through a reforming process
Implementation Method 3
The hydrogen production process may comprise converting a hydrocarbon feedstock to hydrogen through a reforming process, or may comprise the electrolysis of water
Implementation Method 4
combusting hydrogen to provide at least some of the heating duty to the steam cracking process
Data Source
AI summary
A method for producing an olefin product, including the steps of converting a hydrocarbon feedstock to an unsaturated hydrocarbon stream through a steam cracking process in an olefins production plant; combusting hydrogen to provide at least some of the heating duty to the steam cracking process, wherein the hydrogen has a carbon intensity less than about 1.0 kg CO2e/kg H2, wherein the hydrogen is produced using a hydrogen production process; providing at least some of the required energy for the hydrogen production process from a biomass power plant; and processing the unsaturated hydrocarbon stream to recover the olefin product. The olefin product may comprise ethylene having a well-to-gate carbon intensity less than about 0.6 kg CO2e/kg C2H4, or may comprise propylene having a well-to-gate carbon intensity less than about 0.6 kg CO2e/kg C3H6.