Towards zero carbon emissions: Electrification and decarbonization of an ethylene Plant's utility system

The industrial sector faces significant challenges in decarbonization, within the petrochemical industry being a major contributor to global greenhouse gas (GHG) emissions. Ethylene, a key feedstock for polymers such as polyethylene (PE) and polyethylene terephthalate (PET), is primarily produced through steam cracking, a process heavily reliant on fossil fuels and responsible for substantial CO₂ emissions. This study introduces a systematic approach to retrofit steam utility system for an ethylene production plant, featuring the integration of hydrogen-fired boilers, electric superheaters, electric boilers and supplementary turbines linked to electrical generators. Powered entirely by renewable energy sources, this innovative electrification strategy is designed to enhance operational efficiency while optimizing both capital and operating costs. By adopting renewable energy options within the utility system, the proposed design significantly reduces the plant's carbon footprint, contributing to a more sustainable and environmentally responsible ethylene production process.