Traditionally, propylene production involves steam cracking of petroleum (naphtha) at temperatures of 800–900°C, followed by separation of propylene from the resulting gas mixture. Recently, there is a growing preference for utilizing propane, derived from natural gas liquids (NGL), as the feedstock in a propane cracker to generate propylene. The heated feed mixture enters a fired tubular reactor where it reaches final cracking temperatures. Immediately following cracking, the product gases are rapidly cooled in a quench tower to prevent undesired side reactions. Subsequently, the gas mixture is compressed and directed to a fractionation section, where propylene is separated from unreacted propane and by-products.
A detailed techno-economic analysis (TEA) of renewable-powered steam cracking systems for propylene production is conducted. The objectives are to (1) evaluate the economic feasibility of integrating renewable electricity, particularly solar energy, into steam cracking operations, and (2) compare economic outcomes against conventional fuel-powered steam cracking technologies. Initially, a validated steady-state simulation, developed in Aspen Plus, establishes baseline process performance metrics for the electrified steam cracking system. Subsequently, comprehensive economic models quantify capital expenditures (CAPEX), operational expenditures (OPEX), net present value (NPV), and the levelized cost of ethylene (LCOE) under both renewable-powered and fossil fuel-based electrification scenarios.
A sensitivity analysis further demonstrates how variations in electricity pricing, renewable energy incentives, and technological efficiency improvements affect overall economic performance. Results indicate clear scenarios under which renewable-powered steam cracking achieves cost competitiveness relative to conventional fossil-fueled processes.