The decarbonization of the chemical industry is essential
to mitigate
carbon dioxide (CO2) emissions. Ethylene (C2H4) is the highest production petrochemical globally.
When powered by renewable electricity, the electrochemical conversion
of CO2 to C2H4 offers a promising
route to low carbon C2H4 production. We perform
a detailed techno-economic assessment (TEA) of the CO2 reduction
reaction (CO2RR) process, converting CO2 from
an industrial point source to polymer-grade C2H4. We pair the CO2 electrolyzer with industrially mature
upstream and downstream separation technologies in an Aspen Plus model.
This comprehensive approach enables us to assess the valorization
of both gas and liquid byproduct streams at commercial specification
and assess the viability of these processes as a function of scale.
We demonstrate that a minimum plant size of ∼3,000 tonne C2H4/year is needed to achieve economies of scale
among the upstream and downstream processes. This minimum plant size
is ∼200-fold smaller than that of conventional C2H4 plants, coincides with that of typical utility-scale
solar installations (∼25 MW), and could enable a more distributed
model of chemical production going forward. We further highlight technical
and economic enablers that would increase the profitability of the
CO2RR to C2H4 technology.