Sustainable Ethylene Production through Electrochemical CO2 Reduction Technology

Ethylene (C₂H₄) plays a critical role in the petrochemical industry, serving as a key intermediate for the production of various products like polyethylene, ethylene oxide, ethylene dichloride, and vinyl acetate. The conventional method of C₂H₄ production involves the conversion of ethane or naphtha into olefins through a steam cracking process. This process uses a significant amount of heat energy resulting in the release of a substantial amount of carbon dioxide (CO₂) emissions, estimated at approximately 1.56 metric tons of CO₂ equivalent per metric ton of C₂H₄. This issue highlights the importance of finding a balance between C₂H₄’s vital industrial function and the need to address its environmental impact by reducing CO₂ emissions.

Sustainable C₂H₄ production using electrochemical CO₂ reduction reaction (CO2RR) technology presents an eco-friendly approach to C₂H₄ production and reduces dependence on fossil fuels. Electrochemical conversion of CO₂ offers various advantages, including precise control of reaction rates and selectivities through voltage regulation, scalability due to modular electrolyzer designs, single-step process, not requiring external H₂ to drive reactions, and compatibility with intermittent renewable energy sources owing to the rapid response of electrochemical systems. This method enables the use of carbon-neutral electricity sources to electrochemically convert CO₂ into valuable fuels and chemicals, effectively closing the carbon loop and reducing CO₂ emissions.

CERT Systems is committed to transforming the way the world’s most important chemicals are made. The team has created a pilot-scale electrolysis system for converting CO₂ into C₂H₄ as finalists in the NRG COSIA Carbon XPRIZE competition. The pilot system, with a capacity of processing 100 kg of CO₂ per day, operated at a natural gas power plant at the Alberta Carbon Conversion Technology Centre. Flue gas was captured and then processed in CERT’s electrolyzer to produce ethylene and syngas. The pilot ran for nearly 2500 h during the competition. CERT will present the most recent advancements in achieving highly selective C₂H₄ production, lab-to-pilot scale-up, and the future development and scaling of the technology.