Hummingbird ethanol to ethylene technology is an innovative process that converts ethanol into ethylene using catalytic conversion. Ethylene is an important raw material used to manufacture a variety of everyday plastic products. This technology provides a more sustainable way to produce ethylene than traditional methods.
How does it work?
The hummingbird process uses a specially developed solid catalyst that helps convert ethanol into ethylene. Ethanol vapor and water vapor are fed into a fixed-bed reactor filled with the solid catalyst. The reaction occurs at high temperatures, typically between 500-550°C. The catalyst enables the chemical conversion of the ethanol into ethylene gas. The ethylene is then purified and separated from the product stream.
Some key aspects of the process:
- Ethanol feedstock: The ethanol used can come from bio-based sources like sugarcane or corn, making it a renewable resource.
- Conversion rate: The catalyst can achieve conversion rates of ethanol to ethylene of over 70%.
- High selectivity: The reaction has good selectivity for ethylene production over other products.
- Less energy: The process requires less energy than conventional steam cracking of petroleum hydrocarbons.
What are the benefits?
Some potential benefits of hummingbird ethanol to ethylene technology include:
- Sustainable feedstock – Using renewable ethanol from biomass instead of non-renewable petroleum.
- Lower greenhouse gas emissions – Life cycle GHG emissions estimated to be 20-50% less than conventional methods.
- Less expensive – Potential for lower operating costs compared to steam cracking.
- High yields – Ethanol is an efficient feedstock, providing high ethylene yields.
- Bolster ethanol demand – Creates a larger market for ethanol producers.
- Flexible siting – Small-scale plants can be sited closer to ethanol supplies.
What companies are developing this technology?
Some of the key companies working on commercializing ethanol to ethylene technology include:
- LanzaTech – This company has developed a proprietary catalyst and process design leveraging extensive R&D.
- Braskem – A Brazilian petrochemical company partnering with LanzaTech on deploying the technology.
- LyondellBasell – A major chemicals producer that has licensing rights to LanzaTech’s process.
- Indian Oil Corp – Collaborating with LanzaTech on a demonstration plant in India.
- Neste – Finnish oil refiner that has partnered with LyondellBasell on bio-based plastics production including ethanol-based ethylene.
These companies see good commercial potential in this technology and are investing in scaling it up.
What is the current status of development?
While the process has been proven at pilot-scale, it is still in the early stages of commercial deployment. Some developments so far have included:
- 2018 – Successful pilot plant testing by LanzaTech and partners of a 10 ton per day unit in China.
- 2020 – LanzaTech and Indian Oil Corp announce plans for a demonstration facility in India producing 40,000 tons per year.
- 2022 – Groundbreaking on construction of first commercial facility in Georgia by LanzaTech, Braskem and LyondellBasell producing 220,000 tons per year.
The first full-scale commercial facilities are expected to come online within the next few years. Wider adoption will depend on the economics and performance compared to alternatives like steam cracking. But prospects look promising for this technology to make an impact in more sustainable ethylene production.
What are the challenges facing adoption?
Some potential challenges that need to be addressed for wider adoption of this technology include:
- High upfront capital costs – Building commercial-scale plants requires major investment in specialized equipment.
- Uncertain ethanol supplies – Questions remain around securing sufficient low-cost ethanol feedstock.
- Market dynamics – Petrochemical producers are used to steam cracking. Adopting a new process takes time.
- Competition from biomethane – Ethanol supplies could also be used to produce low carbon biomethane.
- Catalyst lifespan – The longevity and replacement rate of the catalyst at scale needs to be proven.
Overcoming these challenges will require continued technology refinement and demonstrating reliable economics versus existing ethylene production. But the sustainability benefits of displacing fossil fuels make this an attractive option.
Conclusion
Hummingbird’s ethanol to ethylene technology provides a promising pathway for more sustainable production of this key building block chemical. By using renewable ethanol feedstocks and an innovative catalyst system, it offers reduced greenhouse gas emissions compared to conventional steam cracking of petroleum. While moving from pilot to full-scale commercialization will take time, the companies developing this process see strong potential. With the right technological and market conditions, hummingbird could play an important role in supporting a circular bioeconomy.
