Steam cracker of the future

A leading initiative by BASF.

BASF, Sabic, and Linde have initiated construction on the world’s first large-scale electrically heated steam cracker furnaces in Ludwigshafen. This groundbreaking technology, powered by renewable energy instead of natural gas, aims to slash CO2 emissions from one of the chemical industry’s most energy-intensive processes by up to 90% compared to conventional methods.  

To achieve net-zero CO2 emissions 2050 at BASF, a complete transition from fossil fuels to renewable electricity is needed. This transformation requires the development of innovative, low-CO2 processes, with a primary focus on basic chemicals, which account for the largest share of emissions in the chemical industry.  

Steam crackers are critical components of BASF’s production facilities in Ludwigshafen, Port Arthur (Texas), Antwerp (Belgium), and Nanjing (China). They play a vital role in splitting crude gasoline into olefins and aromatics, crucial for numerous chemical value chains. Traditional steam crackers rely on methane combustion to attain the high temperatures required for this process, reaching around 850 degrees Celsius.  

A revolutionary approach introduces electric resistance heating (eFurnace) and renewable energy sources, potentially eliminating up to 90% of process-related emissions. This pioneering solution promises to make a substantial contribution to reducing CO2 emissions within the chemical industry.  

The collaboration  

BASF and Linde began their collaboration in 2015, with the shared objective of electrifying steam crackers. Sabic joined the effort in 2019 during discussions at the Low Carbon Emissions Technology Initiatives workshop. This enthusiastic partnership brings together unique strengths, experiences, and expertise to develop an unprecedented solution and lead the chemical industry in climate protection.  

In 2021, BASF, Sabic, and Linde officially announced their collaboration to develop electric cracking furnaces.  

In September 2022, construction commenced on the world’s first large-scale electrically heated steam cracker furnaces demonstration plant. The feasibility of this innovative process and two heating concepts will be thoroughly tested. The project received funding from the German Federal Ministry for Economic Affairs and Climate Action, under the “Decarbonisation in Industry” program, supporting the transition to climate neutrality in energy-intensive industries. Financing also comes from the European Union.  

The site’s contribution to achieving net-zero CO2 emissions  

The inauguration of the construction site in Ludwigshafen, celebrated on 1 September 2022, marked the symbolic beginning of this groundbreaking project. The demonstration plant, integrated into an existing steam cracker at BASF’s Verbund site in Ludwigshafen, will test two heating concepts in parallel. The first directly applies electric current to the reactor’s tubes, while the second employs radiant heat from surrounding heating elements. The plant will process approximately 4 tons of hydrocarbons per hour, powered by 6 megawatts of renewable energy. It is scheduled to become operational in early 2024.  

BASF and SABIC share the investment in this project, with BASF overseeing the demonstration plant’s operation. Linde is the engineering, procurement, and construction partner and will market the developed technologies in the future.  

This electrification project marks a significant milestone in BASF’s journey towards achieving net-zero CO2 emissions 2050. It also receives support from the German Federal Ministry of Economics and Climate Protection, emphasizing the political backing for this approach. Furthermore, this collaboration showcases how global companies can successfully combine their technological expertise in various aspects, from development to operation, to provide sustainable solutions for the petrochemical industry. The demonstration plant’s development is a pivotal step towards offering sustainable solutions to this sector.  

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