Term 252

Pathways to Net-Zero Carbon in Ethylene and Propylene Production

Project Type: Self-Initiated

Project Description

Ethylene and propylene are essential building blocks of the petrochemical industry; however, their conventional production through steam cracking is one of the most energy-intensive and carbon-intensive industrial processes. High operating temperatures exceeding 850 °C and reliance on fossil-fuel-fired furnaces result in significant CO2 emissions that challenge global and national decarbonization goals. This project proposes an integrated pathway toward net-zero carbon olefin production by combining an electrically heated cracking furnace powered by a hybrid energy supply (solar and grid electricity) with a post-combustion carbon capture and geological storage system. The proposed system aims to significantly reduce CO2 emissions while maintaining ethylene yield, process efficiency, and industrial scalability. The design focuses on achieving high furnace thermal efficiency, effective CO2 capture using absorption technology, and compatibility with existing petrochemical infrastructure. Process validation and performance assessment are conducted using Aspen HYSYS simulations, while system-level feasibility is evaluated through multidisciplinary integration of chemical, mechanical, and petroleum engineering principles. The proposed solution offers a practical and scalable alternative to conventional steam cracking, aligned with sustainability targets and Saudi Vision 2030 objectives.