Investigation of the sustainable production of ethylene oxide by electrochemical conversion: Techno-economic assessment and CO2 emissions

Ethylene oxide (EO) is a pivotal intermediate in the chemical industry owing to its versatility and high demand. Currently, direct oxidation is the most important technical process to produce EO. This conventional process, in which ethylene is partially oxidized with air or oxygen, has limited selectivity for EO of 65–90%, leading to significant CO₂ emissions. This study explores an alternative method involving the electrochemical selective oxidation of ethylene powered by renewable electricity. The electrochemical oxidation technology is expected to reduce CO₂ emitted during EO production. Process models were developed based on existing literature data. A techno-economic evaluation and sensitivity analysis focusing on the electrochemical cell variables were conducted. In this assessment, the investment and production costs of the electro-oxidation process for EO production were compared with those of the conventional process. This assessment also compared processes producing of mono-ethylene glycol and ethylene carbonate from EO. These analyses reveal that the separation energy has a significant impact on the carbon footprint. While current economic and environmental benefits are not favorable, this study identifies key descriptors of the technology for further reducing the carbon footprint. Based on the evaluation results, this study demonstrates the potential to cut CO₂ emissions in half compared to conventional plants by utilizing the electro-oxidation of ethylene via a direct route.