BASF, SABIC and Linde start up first large-scale electrically heated steam cracker

BASF, SABIC and Linde have opened the world's first large-scale electrically heated steam cracker demonstration plant. After three years of development, design and construction work, the demonstration plant is now ready to start regular operations at BASF's integrated plant in Ludwigshafen, Germany. In March 2021, the three companies signed a joint agreement to develop and demonstrate electrically heated steam cracker solutions.

Steam crackers play a central role in the production of basic chemicals and require large amounts of energy to break down hydrocarbons into olefins and aromatics. Typically, the reaction is carried out at a temperature of about 850°C. Until now, high temperatures have been achieved using conventional fuels. The demonstration plant aims to demonstrate that it is possible to continuously produce olefins using electricity as a heat source. By using electricity from renewable sources, this new technology has the potential to reduce CO2 emissions in one of the most energy-intensive production processes in the chemical industry by at least 90% compared to technologies commonly used today.

The demonstration plant, which produces olefins such as ethylene, propylene and possibly higher olefins from a saturated hydrocarbon feedstock, is fully integrated into the existing steam cracker in Ludwigshafen. The goal of the upcoming operations is to collect data and experience on material behavior and processes under commercial operating conditions in order to ultimately develop this innovative technology to industrial market maturity. In two separate demonstration furnaces, two different heating concepts will be tested. One uses electric current for direct heating, the other uses radiant heat from a heating element for indirect heating. The two electric heating furnaces process a total of approximately 4 tons of hydrocarbon feedstock per hour and consume 6 MW of renewable energy.

To support the development of new furnace technologies, the German Federal Ministry for Economic Affairs and Climate Action has allocated €14.8 million to the project under its "Decarbonisation of Industry" funding programme. The program supports Germany's energy-intensive industries in their efforts to become carbon neutral.