Electric cracking: RotoDynamic Reactor cuts 100% of CO₂ in steam cracking

Electric steam cracking enabled by RotoDynamic Reactor

Innovative RotoDynamic Reactor™ (RDR), a pioneering technology in electric cracking, electrifies previously fossil-heavy steam cracking process, reducing process CO2 emissions by 100%.

This translates into global CO₂ emission reduction potential of 300 million tons annually.

Moreover, the technology facilitates greater use of recycled and bio-based feedstocks, further lowering the lifecycle CO₂ footprint of plastics.

Conventional cracking

Olefins are traditionally produced by steam cracking ethane or naphtha at extremely high temperatures in large cracker furnaces. The reaction mixture is heated externally in tubular coils externally through tube walls using fossil fuels and significant amount of energy. This part of the process that is the main source of CO₂ emissions in olefin production.

Reduction of emissions

• 100% reduction in process CO₂ emissions from steam cracking
• Elimination of NOx and particulate emissions
• Improved energy efficiency
• Use bio-based and renewable feedstock enables further reduction in indirect CO₂ emissions

Savings in capital expenditure and operational expenditure

Lower operating expenses (OPEX)

• Easier maintenance
• Advanced controllability
• Less coke formation and less frequent decoking

Lower capital expenditures (CAPEX)

• Modular design, compact size and short construction time on site

A fundamental revolution in ethylene yield and operability

Because RDR creates higher temperatures with a shorter residence time, it is able to achieve 20% higher ethylene yields. For petrochemical producers, that translates into increased annual profits of over 200M $ per 1 million metric tonnes ethylene plant. Lower metal surface temperatures mean that RDR is less prone to coking than conventional furnaces, resulting in lower operational costs and increased uptime.

The 20% higher ethylene yield also means fewer CO₂ emissions per ethylene ton. Taking RDR into use also decreases capital expenditure when building a new ethylene plant.

Optimal temperature and residence time.
RotoDynamic Reactor has short residence at high temperature resulting in high yield with less energy and CO₂ emissions.

Electrification of steam cracking with RotoDynamic Reactor

RDR brings together space science, turbomachinery and chemical engineering. With aerodynamic action achieved through a rotating blade flow, RDR can replace conventional furnaces by directly imparting the rotor shaft’s mechanical energy to the hydrocarbon fluid needed to produce olefins.

RDR’s electric motor drives the rotors, gas is accelerated to very high velocities and then slowed down in the diffuser, creating a shockwave that converts kinetic energy into thermal energy.