Decarbonizing ethylene production via renewable energy electrification: A techno-economic and environmental assessment

The transition to sustainable production in the chemical industry is essential for achieving global decarbonization targets. This study explores the electrification of an ethylene plant by replacing its conventional natural gas (NG) boilers with electric boilers powered by renewable energy sources. Unlike previous works that focus on single-technology substitution, this paper provides a comprehensive, system-level assessment of ethylene plant electrification by comparing integrated scenarios of concentrated solar power (CSP), photovoltaic (PV) solar energy, and wind power. The optimal configuration is evaluated based on economic feasibility, environmental impact, and land requirements, offering a methodology that can be adopted for other energy-intensive petrochemical processes. The analysis reveals that while wind energy presents the lowest cost among the available renewable sources, its significant land footprint poses a major challenge, particularly when direct power supply to electric boilers is required. Conversely, CSP, despite being the most expensive option, offers the advantage of simultaneously generating steam and power, enhancing system efficiency. PV-based electrification, positioned between wind and CSP in terms of cost and land use, presents a balanced alternative. The study also investigates the prospects of supplementing on-site renewable generation with imported clean electricity to overcome land constraints and improve operational resilience. The findings provide valuable insights into the trade-offs between cost, sustainability, and spatial constraints in electrifying ethylene production, and they outline potential pathways toward a low-carbon, robust and scalable future for the petrochemical sector. • The paper studies electrification of ethylene plant using CSP, PV, and wind power. • Cost, land use, and CO 2 savings are compared across renewable technologies. • The impacts of energy demand on cost and land footprint requirements are assessed. • The trade-offs of importing vs. producing renewable energy are analyzed.