ExxonMobil’s new burner technology for steam crackers can operate using up to 100% hydrogen (H2) fuel, marking a significant advancement in industrial-scale emissions reduction. The Baytown Olefins Plant is the first facility to showcase this technology at scale, achieving a 90%* reduction in direct carbon dioxide (CO2) emissions during the demonstration.This milestone aligns with ExxonMobil’s commitment to lowering emissions across hard-to-decarbonize industries.
The chemical sector, in particular, has proven challenging to decarbonize due to the immense heat required for olefins production. Olefins, which are essential building blocks for plastics and other modern materials, are produced by “cracking” hydrocarbon molecules in furnaces that reach temperatures exceeding 2,000°F.However, ExxonMobil is paving the way by exploring the use of H2—a fuel that emits no CO2 when burned.
At its Baytown, Texas facility, ExxonMobil has successfully designed and installed pyrolysis burners capable of operating on up to 100% H2. A total of 44 burners were integrated into one of the site’s steam cracking furnaces.Commercial testing of these burners began in December, with operations reaching 98% H2—the highest H2 concentration currently available for commercial testing at the site. The company was able to produce ethylene and other olefins identical to those made using conventional methods.
ExxonMobil proudly claims the title of the first company to demonstrate this technology at an industrial scale. “We’re at the forefront of hydrogen innovation because, with global demand for plastics continuing to rise, reducing emissions from olefins production is critical,” said Dan Holton, Senior Vice President of ExxonMobil Low Carbon Solutions.
Scaling H2-ready technology: ExxonMobil plans to deploy these 100% H2-compatible burners in additional steam cracking furnaces at the Baytown Olefins Plant in the coming years. This initiative is supported by the company’s plan to construct a hydrogen plant at Baytown, designed to produce up to 1 billion cubic feet per day of H2. Notably, this hydrogen will be low-carbon, with more than 98% of the associated CO2 emissions captured and stored.Switching to H2 has already demonstrated significant CO2 reductions. For instance, the furnace equipped with the new burners recorded a 90%* reduction in direct CO2 emissions during testing.ExxonMobil hopes the success of this commercial trial will inspire other manufacturers to adopt similar approaches. By incorporating H2 into olefins production, the carbon footprint of essential products—including food packaging, car components, and medical supplies—can be significantly reduced.Currently, pyrolysis burners in steam crackers are primarily powered by hydrocarbons, particularly natural gas.
The development of these advanced burners represents the culmination of over four years of dedicated research and innovation by ExxonMobil’s scientists, engineers, and specialists.ExxonMobil takes pride in leading the way in H2 technology. According to a landmark report by the National Petroleum Council, hydrogen offers a cost-effective approach to reducing emissions, while also boosting economic growth, creating jobs, and enhancing energy security.
Additional facts about the new burner technology:
Size: Each burner has a heat output more than 500 times that of the largest kitchen stove burners.
Innovation: Traditional pyrolysis burners are not designed to handle the unique properties of H2, which burns faster and hotter than natural gas. ExxonMobil’s burners are engineered to safely and reliably manage these challenges, while the furnaces themselves are built to endure such extreme temperatures.
Proprietary design: ExxonMobil not only operates the burners but also designed them in-house. As the only operator of steam cracking furnaces with proprietary furnace and burner technology, the company brings over 45 years of design and operational expertise to the table.
