(513e) Electrification Pathways of Ethane Cracking Using Renewable Electricity

According to the U.S. Energy Information Administration (EIA), renewable electricity is projected to become the largest primary energy source globally by 2050, surpassing petroleum, natural gas, and coal. Solar and wind electricity are expected to lead as the largest individual electricity sources. This energy source shift, from fossil fuel combustion to the direct use of renewable electricity, will profoundly impact chemical manufacturing.

To facilitate the utilization of shale resources, our group has proposed and evaluated an innovative way for shale resource valorization, converting natural gas liquids (NGLs) in shale gas into high-value and easily transportable liquid fuels. In the proposed process, ethane cracking is the single most energy-intensive step, which activates NGLs into reactive molecules like olefins. Globally, ethane cracking accounts for ~8% of the sector’s total primary energy use.¹ Electrical heating of ethane cracking using renewable electricity could significantly lower annual CO₂ emissions.

In this talk, we will discuss different zero-carbon pathways for ethane cracking by integrating shale gas valorization with renewable electricity. Our previous research, featuring modeling and storage optimization, demonstrated that the energy storage requirement for around-the-clock operation of a typical size chemical plant could be economically challenging due to its large size.² To overcome this challenge, we will present a linear programming model for the energy storage system and propose novel storage options to reduce the storage size and the associated costs. Additionally, we will discuss ethane cracking reactor design that will allow for some load following of power supply along with modest energy storage for optimal economic operation of the plants.

Reference

1 Ren, T.; Patel, M.; Blok, K. Olefins from conventional and heavy feedstocks: Energy use in steam cracking and alternative processes. Energy 2006, 31, 425– 451

2 Du, S.; Chen, Z.; Agrawal, R. Assessing large energy storage requirements for chemical plants powered with solar and/or wind electricity, Chemical Engineering Journal, Volume 505, 2025, 158863.