Reaching Net-Zero Targets through Electrification and Distributed Manufacturing: Techno-economic Analysis Using Radio Frequency Electrothermal Heating for Endothermic Processes

Energy transition has been discussed in the literature for the past few decades where we have witnessed a shift from conversations around resource efficiency; end of pipe treatment solutions; and, more recently, using alternate sources of energy. In this paper, we present the techno-economic and environmental impact analysis of electrification-assisted distributed propylene production using the propane dehydrogenation (PDH) process. For high-temperature endothermic reaction systems, such as PDH, heating is typically carried out conventionally using fuel-fired furnaces, which results in significant greenhouse gas emissions. Electrification of reactors is one approach for decarbonizing emissions associated with heating reactors and reducing the infrastructure footprint of fuel-fired furnaces and their associated utilities. However, the heating technology for the reactor system cannot be viewed in isolation for a “net-zero” goal; it requires a complete systems analysis and quantification of benefits for the viability of the process. This work compares the environmental and techno-economic analysis of the centralized and electrified (radiofrequency field-assisted) manufacturing of propylene via the PDH process in a production facility. Based on the techno-economic analysis (TEA), the unit production cost of centralized manufacturing (CM) of propylene is much lower than that of electrified distributed manufacturing (DM) of propylene, which is expected since economies of scale play a role in the PDH process. However, the global warming potential (GWP) of DM using renewable electricity sources is lower than that of fuel-furnace-based CM by 57%. The paper includes various discussions on impact of available feedstock prices, integration of renewable electricity, technology selection, and modifications necessary for electrification. From a broader perspective, this work emphasizes the potential of a phased approach for derisking new technology (electrification) while focusing on the demonstration in areas where carbon resources are currently wasted for lack of opportune infrastructure, while continuing to develop technology with the promise of reducing the environmental footprint and providing intermediate solutions for process industries.