Ethylene production from shale gas using a dielectric barrier discharge plasma reactor: an integrative circular economy perspective

Abstract

Electrifying energy-intensive chemical manufacturing is a key strategy for achieving net-zero emissions. Plasma-assisted shale-gas-to-ethylene (STE) conversion offers a promising electrified alternative to steam cracking for decarbonizing olefin production. In this study, we present a detailed process model of commercial-scale plasma-assisted STE system and perform comprehensive techno-economic analysis and life-cycle assessment to evaluate economic and environmental feasibility prior to industrial deployment. Our findings indicate the economic viability of the proposed process, with a minimum selling price that is competitive within the current market prices. The environmental assessment reveals that the global warming potential of the proposed process is substantially lower than that of both conventional steam cracking and thermal STE conversion processes. The comparative analysis of on-site versus off-site feed strategies reveals critical trade-offs in capital intensity, energy demand, and upstream emissions. The results indicate the viability of plasma-enabled STE as a scalable and sustainable route for electrified, modular olefin manufacturing.