Production of propane and propene via carbon capture utilisation: comparison of its environmental and economic performance against conventional production methods

With an unabated global petrochemical growth, more sustainable production methods for production of materials and fuels are essential in a decarbonised future. Although Carbon Capture Utilisation (CCU) is generally considered a sustainable production route, it is imperative to compare its environmental and economic performance with that of current methods. This article reviews the environmental impact and economics surrounding conventional production of propane and propene via natural gas liquid fractionation and crude oil refining for propane. In addition, fluid catalytic cracking and steam cracking were explored for propene production. A CCU process has been modelled using Aspen Plus and analysed through Life-Cycle Assessment and Techno-Economic Analysis. Processes simulated include carbon capture using piperazine, dry methane reforming, direct syngas to propane and methanol to propene. The results obtained show a significant reduction in environmental impacts across multiple impact categories for both products when compared to conventional production. In addition, the price of propene from CCU was competitive with conventional. However, the price of propane was significantly higher. Sensitivity analysis of hydrogen production technology and electricity grid emission intensity identified them both as key determinants of economic and environmental performance.