Life cycle assessment and technoeconomic analysis of naphtha cracking electrification using plasma for carbon neutrality

Plasma cracking of naphtha represents a promising electrification pathway for carbon-neutral ethylene production. It operates at high temperatures (3000–6000 K) in non-oxidative environments, achieving superior ethylene yields (50–60%) while eliminating direct greenhouse gas emissions. However, the energy-intensive nature of plasma reactors necessitates evaluating environmental and economic trade-offs. This study evaluates the performances of a modeled plasma naphtha cracking plant across varied operating conditions. When paired with renewable electricity, the emission intensity of produced ethylene decreased to 0.15 kg CO₂ eq. per kg C₂H₄, equivalent to 7.8–11.4% of conventional steam cracking levels. While the levelized cost of ethylene (1.75–2.00 $ per kg C₂H₄) at an electricity cost of 100 $ per MWh_el exceeded the conventional steam cracking by 18–35%, cost parity could be achieved at electricity costs of 40.3–47.9 $ per MWh_el under the optimized conditions that also minimized naphtha feedstock requirements. These findings highlight the dual advantages of plasma technology: eliminating direct emissions while enhancing ethylene yield. This research establishes plasma naphtha cracking as a viable decarbonization strategy for ethylene production, underscoring the need for affordable renewable electricity to unlock its full environmental and economic potential.