An Innovative Industrial Complex for Sustainable Hydrocarbon Production with Near-Zero Emissions

The Allam power cycle is a groundbreaking elevated-pressure power generation unit that utilizes oxygen and fossil fuels to generate low-cost electricity while capturing carbon dioxide (CO2) inherently. In this project, we utilize the CO2 generated from the Allam cycle as feedstock for a newly envisioned industrial complex dedicated to producing renewable hydrocarbons. The industrial complex (FAAR) comprises four subsystems: (i) a Fischer–Tropsch synthesis plant (FTSP), (ii) an alkaline water electrolysis plant (AWEP), (iii) an Allam power cycle plant (APCP), and (iv) a reverse water-gas shift plant (RWGSP). Through effective material, heat, and power integration, the FAAR complex, utilizing 57.1% renewable energy for its electricity needs, can poly-generate sustainable hydrocarbons (C1–C30), pure hydrogen, and oxygen with near-zero emissions from natural gas and water. Economic analysis indicates strong financial performance of the development, with an internal rate of return (IRR) of 18%, a discounted payback period of 8.7 years, and a profitability index of 2.39. The complex has been validated through rigorous modeling and simulation using Aspen Plus version 14, including sensitivity analysis.