Self-sustained carbon capture and utilization: Techno-economic insights for CO2 to C2H4 deployment at scale

Abstract

Ethylene (C 2 H 4 ), a crucial building block in the petrochemical industry, is traditionally produced through energy-intensive thermal cracking of hydrocarbons, emitting about 1.5–3 tons of CO 2 per ton of C 2 H 4 . The proposed tandem electrochemical architecture represents a transformative approach that utilizes external electricity and water to capture and convert CO 2 in industrial flue gas into C 2 H 4 . The self-sustained system integrates three electrochemical reactors: a hybrid electrolyte reactor for capturing CO 2 while generating electricity, an auxiliary reactor for producing fuels for the capture reactor, and a conversion reactor for transforming CO 2 into C 2 H 4 . A comprehensive techno-economic assessment (TEA) reveals that the system can achieve production costs that are competitive with current market prices while significantly reducing CO 2 emissions. The TEA further demonstrates the system’s scalability and its potential to drive industrial decarbonization and sustainable CO 2 utilization. Tandem electrochemical systems represent an innovative solution to produce chemicals through sustainable means while also ensuring the possibility of eventual carbon neutrality.