Process design, life cycle assessment, and eco-techno-economic analysis of different products based on carbon capture and utilization

Climate change is a matter of growing concern. The four largest industrial sectors – iron, steel, cement, and plastics – are responsible for 66% of the global industrial CO2 emissions.

With the continuous rise in population, and consequently plastic demand, it is projected that GHG emissions from plastics will increase more than two-fold from 2019 to 2060. One of the most globally popular plastics is polyethylene. The bulk of the emissions of polyethylene production can be attributed to olefin formation, ethylene. Attempts to reduce emissions from plastic production have been underway for a while, and suggested changes involve a variation in feedstock or in technology.

This PhD work focuses on the design and eco-techno-economic analysis of novel technologies for polyethylene production, based on CO2 capture and its utilization. First, three different routes are investigated, including two different CO2 conversion processes: CO2 hydrogenation and tri-reforming of methane and CO2. Using the simulation and lifecycle assessment results, a comprehensive profitability assessment and eco-techno-economic analysis of the proposed pathways are conducted for both low- and high-density polyethylene production, as well as the lifecycle greenhouse gas reduction credit that is required for each product.

The lifecycle assessment results show that the new pathway is an environmentally attractive option, in regions where low-carbon electricity is more prominent, however, the selling price is four to five times higher than that of conventional processes. As a result, the incorporation of chemical looping process for the effective conversion of CO2 to CO, and then syngas is considered.

This event is part of the CME Seminar Series Winter 2026.