Abstract:

Producing ethylene from atmospheric CO₂ using renewable electricity offers a carbon-negative alternative to conventional steam cracking. This study examines the economic feasibility of integrating a KOH based direct air capture (DAC) plant with a membrane electrode assembly (MEA) CO₂electrolyzer and downstream separation for a plant designed to output 75 kt of ethylene annually. The resulting levelized cost of ethylene produced at this facility was estimated to be $9.64/kg or approximately ten times more than the price of ethylene currently being produced using petrochemical processes. Combined costs associated with operating the electricity generation systems and operating the DAC system account for greater than 70% of the total annual expenditure. Parametric studies were performed and results indicated that single pass CO₂conversion rate, electricity tariff and cost of capital have the greatest impact on the economics of this process. Under current economic conditions, a break-even carbon removal credit of about $700/t CO₂would need to be established for this project to be viable. Advances in DAC technology, improvements in design for electrolyzers and future carbon pricing policies may make the effective production cost of ethylene produced from CO₂by electrolysis competitive with that of ethylene produced from fossil sources by the late 2040's.

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Mr. Murat Kenez