ExxonMobil Develops Hydrogen Burners to Cut Emissions in Olefins Production
ExxonMobil Develops Hydrogen Burners to Cut Emissions in Olefins Production

ExxonMobil Develops Hydrogen Burners to Cut Emissions in Olefins Production

  • 29-Jan-2025 8:30 PM
  • Journalist: William Faulkner

Decarbonizing the chemical industry is a significant challenge due to the extreme temperatures required for olefins production. Olefins, which serve as the fundamental components in plastics and other essential materials, are produced in steam cracking furnaces that operate at temperatures exceeding 2000°F. These furnaces typically rely on hydrocarbons, particularly natural gas, as their primary fuel source, leading to substantial CO2 emissions. However, a major breakthrough could be achieved by transitioning to hydrogen, a fuel that produces no CO2 when combusted.

ExxonMobil is at the forefront of this effort, having designed and installed advanced pyrolysis burners capable of running on up to 100% hydrogen fuel at its olefins plant in Baytown, Texas. A total of 44 hydrogen-ready burners were implemented in one of the facility’s steam cracking furnaces. In December, the company initiated commercial testing, operating the burners at 98% hydrogen—the highest concentration currently available for commercial demonstration at the site. The results showed that the production of ethylene and other olefins remained identical to those produced using conventional methods, confirming the feasibility of this low-carbon approach.

Dan Holton, senior vice president of ExxonMobil Low Carbon Solutions, emphasized the significance of this development. “We’re leading the way on hydrogen because with global demand for plastics continuing to grow, finding ways to reduce emissions from olefins production is crucial,” he stated.

Looking ahead, ExxonMobil plans to expand the use of these 100% hydrogen-capable burners across additional steam cracking furnaces at the Baytown Olefins Plant over the next several years. This move aligns with the company’s broader strategy to integrate hydrogen into its operations and reduce carbon emissions. A key component of this strategy is the construction of a large-scale hydrogen production facility at Baytown, expected to generate up to 1 billion cubic feet per day of hydrogen. This hydrogen will be produced with extremely low carbon intensity, as ExxonMobil intends to capture and store more than 98% of the CO2 emissions associated with its production.

The shift to hydrogen has the potential to significantly lower emissions. During initial testing, ExxonMobil demonstrated a 90% reduction in direct CO2 emissions from the furnace using the newly installed burners. If implemented at scale, this technology could drive substantial emissions reductions across the petrochemical industry.

The successful demonstration of these burners marks the culmination of over four years of research and development by ExxonMobil’s team of scientists, engineers, and specialists. As the company continues to refine its hydrogen-based solutions, its advancements could play a critical role in reducing emissions while ensuring the efficiency and scalability of olefins production. By embracing hydrogen, ExxonMobil is positioning itself as a leader in the transition toward a lower-carbon future in the chemical sector.

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