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Frontiers of Chemical Science and Engineering

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ISSN 2095-0187(Online)

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Front. Chem. Sci. Eng.    2022, Vol. 16 Issue (12) : 1713-1725    https://doi.org/10.1007/s11705-022-2210-y
RESEARCH ARTICLE
Life cycle assessment and economic analysis of HFC-134a production from natural gas compared with oil-based and coal-based production
Suisui Zhang1,2,3,4,5, Gang Li1, Boyang Bai1,2,3,4,5, Luyao Qiang1,2,3,4,5, Xiaoxun Ma1,2,3,4,5,6(), Jingying Li1,2,3,4,5()
1. School of Chemical Engineering, Northwest University, Xi’an 710069, China
2. Chemical Engineering Research Center of the Ministry of Education (MOE) for Advanced Use Technology of Shanbei Energy, Xi’an 710069, China
3. Shaanxi Research Center of Engineering Technology for Clean Coal Conversion, Xi’an 710069, China
4. Collaborative Innovation Center for Development of Energy and Chemical Industry in Northern Shaanxi, Xi’an 710069, China
5. International Scientific and Technological Cooperation Base of the Ministry of Science and Technology (MOST) for Clean Utilization of Hydrocarbon Resources, Xi’an 710069, China
6. Longdong University, Qingyang 745000, China
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Abstract

China is the largest producer and consumer of HFC-134a (1,1,1,2-tetrafluoroethane) in the world. Coal-based route is mainly adopted to produce HFC-134a, which suffers from large waste and CO2 emissions. Natural gas is a low-carbon and clean energy resource, and no research has been found on the environment and economy of producing HFC-134a from natural gas. In this study, CML 2001 method was used to carry out the life cycle assessment of natural gas (partial oxidation)-based and natural gas (plasma cracking)-based routes (abbreviated as gas(O)-based and gas(P)-based routes, respectively), and their environmental performances were compared with coal-based and oil-based routes. Meanwhile, considering that China is vigorously promoting the transformation of energy structure, and the application of electric heating equipment to replace fossil-based heating equipment in industrial field, which has a great impact on the environmental performance of the production processes, the authors conducted a scenario analysis. The results showed that the gas(O)-based route had the most favourable environmental benefits. However, the gas(P)-based route had the highest potential for reducing environmental burdens, and its environmental benefit was the most favourable in scenario 2050. Additionally, the economic performance of the gas(P)-based route was significantly better than that of gas(O)-based and coal-based routes.
Keywords life cycle assessment      economic performance      HFC-134a      natural gas      oil      coal     
Corresponding Author(s): Xiaoxun Ma,Jingying Li   
Online First Date: 03 November 2022    Issue Date: 19 December 2022
 Cite this article:   
Suisui Zhang,Gang Li,Boyang Bai, et al. Life cycle assessment and economic analysis of HFC-134a production from natural gas compared with oil-based and coal-based production[J]. Front. Chem. Sci. Eng., 2022, 16(12): 1713-1725.
 URL:  
https://academic.hep.com.cn/fcse/EN/10.1007/s11705-022-2210-y
https://academic.hep.com.cn/fcse/EN/Y2022/V16/I12/1713
Fig.1  HFC-134a production routes.
Fig.2  System boundaries of the gas(O)-based and gas(P)-based routes.
Fig.3  System boundary of the oil-based route.
Fig.4  System boundary of the coal-based route.
Acetylene production stage using partial oxidation method
Input Output
Substance Value Substance Value
Natural gas/Nm3 2035.91 Acetylene/t 0.35
Electricity/kWh 1169.76 Syngas/Nm3 3103.52
Steam/t 1.60 CO2/t 0.28
Fresh water/t 1.10 Particle matters to air/g 88.96
NMP/kg 2.66 SO2 to air/g 22.88
NOx to air/g 169.12
NMVOCa) to air/g 10.64
Trichloroethylene production stage from acetylene
Input Output
Substance Value Substance Value
Acetylene/t 0.35 Trichloroethylene/t 1.32
Chlorine/t 1.72 Tetrachloroethylene/kg 47.91
Electricity/kWh 237.78 31% hydrochloric acid/t 1.45
Steam/t 5.28 Cl2 to air/g 133.29
Fresh water/t 9.25 HCl to air/g 28.80
Compressed air/Nm3 29.06 NMVOC to air/g 29.24
Nitrogen/Nm3 165.13
Coal/kg 132.11
NaOH/kg 2.11
HFC-134a production stage
Input Output
Substance Value Substance Value
Trichloroethylene/t 1.32 HFC-134a/t 1
HF/t 0.84 31% hydrochloric acid/t 3.20
Sodium hydroxide/kg 6.06 HFC-143a/kg 4.90
Electricity/kWh 1875.20 HF to air/g
Fresh water/t 5.19 HCl to air/g
Steam/t 7.01 NMVOC to air/g 7.69
Trichloroethylene to air/g 230.13
Tab.1  LCI of the gas(O)-based route based upon 1 t of HFC-134a
Input Output
Substance Value Substance Value
Natural gas/Nm3 709.38 Acetylene/t 0.35
Electricity/kWh 3901.57 H2/Nm3 886.72
Steam/t 1.42 CO2 to air/kg 25.01
Fresh water/t 2.13 Particle matters to air/g 82.15
NMP/kg 2.48 SO2 to air/g 25.64
NOx to air/g 159.72
NMVOC to air/g 12.59
Tab.2  LCI of acetylene production stage by plasma method in the gas(P)-based route based upon 1 t of HFC-134a
Input Output
Substance/t Value Substance Value
Ethylene/t 0.4 Trichloroethylene/t 1.3
Chlorine/t 1.4 Tetrachloroethylene/kg 211.4
Steam/t 6.6 HCl/kg 184.9
Water/t 7.9 CO2 to air/kg 169.1
Oil/kg 54.2 NOx to air/g 53.5
Electricity/kWh 383.1 VOCsa) to air/g 26.8
Nitrogen/Nm3 99.1
Tab.3  LCI of trichloroethylene production stage from ethylene in the oil-based route based upon 1 t of HFC-134a
Calcium carbide production stage
Input Output
Substance Value Substance Value
Limestone/t 1.87 Calcium carbide/t 1.19
Coke/t 0.77 Particle matters to air/g 191.10
Electrode paste/kg 29.72 SO2 to air/g 530.96
Iron sheet/kg 2.97 NOx to air/g 295.01
Electricity/kWh 3894.8 CO2 to air/t 1.37
Fresh water/t 2.38
Compressed air/Nm3 63.60
Nitrogen/Nm3 53.50
Trichloroethylene production stage from calcium carbide
Input Output
Substance Value Substance Value
Calcium carbide/t 1.19 Trichloroethylene/t 1.32
Chlorine/t 1.72 Tetrachloroethylene/kg 39.63
NaClO/kg 64.4 HCl (≥ 98%)/kg 360.63
NaOH/kg 2.11 Cl2 to air/g 133.29
Electricity/kWh 356.67 HCl to air/g 28.80
Steam/t 5.28 NMVOC to air/g 130.28
Fresh water/t 18.49 Trichloroethylene to air/g 142.67
Compressed air/Nm3 67.37
Nitrogen/Nm3 126.82
Coal/kg 132.10
Ferric chloride/kg 0.22
Tab.4  LCI of calcium carbide and trichloroethylene production stage in the coal-based route based upon 1 t of HFC-134a
Component Basis
(1) Raw material Coke 546 CNY·t–1; natural gas 2.5 CNY·Nm–3; ethylene 7100 CNY·t–1; hydrogen fluoride 8550 CNY·t–1; chlorine 550 CNY·t–1
(2) Utilities Steam 80 CNY·t–1; water 1 CNY·t–1; electricity 0.6 CNY·kWh–1
(3) Operating & maintenance
(3.1) Operating labor Coal-based route 319 labors; gas(O)-based route 288 labors; gas(P)-based route 284 labors; oil-based route 211 labors; 100000 CNY·labor–1·year–1
(3.2) Direct supervisory & clerical labor 20% of operating labor
(3.3) Maintenance and repairs 2% of fixed capital investment
(3.4) Operating supplies 0.7% of fixed capital investment
(3.5) Laboratory charge 15% of operating labor
(4) Depreciation Life period 20 years, salvage value 4%
(5) Plant overhead cost 60% ((3.1) + (3.2) + (3.3))
(6) Administrative cost 2% of production cost
(7) Distribution and selling cost 2% of production cost
(8) By-product Syngas 0.56 CNY·Nm–3; H2 1.2 CNY·Nm–3; perchloroethylene 3000 CNY·t–1; R143a 20000 CNY·t–1; 31% hydrochloric acid 280 CNY·t–1; HCl 1400 CNY·t–1
(9) PC (1) + (2) + (3) + (4) + (5) + (6) + (7) – (8)
Tab.5  Assumptions for the estimation of PC
Fig.5  Relative contribution of each process to the environment in (a) gas(O)-based, (b) gas(P)-based, (c) oil-based and (d) coal-based routes.
Fig.6  Comparison of normalized results for different HFC-134a production routes.
Fig.7  Comparison of weighted results for different HFC-134a production routes.
Category Scenario Gas(O)-based route Gas(P)-based route Oil-based route Coal-based route
ADP fossil/MJ Basic scenario 1.33 × 105 1.26 × 105 1.16 × 105 1.40 × 105
Scenario 2019 1.64 × 105 1.61 × 105 1.59 × 105 1.78 × 105
Scenario 2025 1.55 × 105 1.43 × 105 1.43 × 105 1.60 × 105
Scenario 2035 1.27 × 105 1.11 × 105 1.11 × 105 1.22 × 105
Scenario 2050 1.01 × 105 8.12 × 104 8.10 × 104 8.78 × 104
GWP/kg CO2 eq. Basic scenario 8.00 × 103 9.12 × 103 8.21 × 103 1.13 × 104
Scenario 2019 1.11 × 104 1.25 × 104 1.24 × 104 1.51 × 104
Scenario 2025 1.00 × 104 1.06 × 104 1.06 × 104 1.30 × 104
Scenario 2035 7.17 × 103 7.33 × 103 7.37 × 103 9.27 × 103
Scenario 2050 4.62 × 103 4.42 × 103 4.44 × 103 5.90 × 103
Tab.6  Fossil resource consumption and CO2 equivalent emissions of different HFC-134a production routes in different scenarios
Fig.8  Comparison of weighted results of different HFC-134a production routes in different scenarios.
Item Gas(O)-based route Gas(P)-based route Oil-based route Coal-based route
CR/CNY 12090 9605 10726 8929
CU/CNY 2797 3647 2185 4395
COM/CNY 2066 1868 1480 2088
CD/CNY 1370 1049 943 1160
CO/CNY 1034 944 742 1056
CM/CNY 344 304 296 332
CS/CNY 344 304 296 332
CB/CNY –2856 –2509 –1887 –1716
PC/CNY 17187 15212 14780 16574
Tab.7  PC of 1 t HFC-134a produced by different routes
Fig.9  Sensitivity analysis of production cost of HFC-134a produced by (a) gas(O)-based, (b) gas(P)-based, (c) oil-based and (d) coal-based routes.
Fig.10  Impact of different raw material prices on PCs: (a) hydrogen fluoride; (b) natural gas, ethylene and coke.
Item Acetylene production stage Trichloroethylene production stage HFC-134a production stage
Gas(O)-based route Economic value allocation,acetylene 65.2%,syngas 34.8% Mass allocation,trichloroethylene 73.3%, tetrachloroethylene 2.7%,31% hydrochloric acid 24.0% Economic value allocation,HFC-134a 95.1%,HFC-143a 0.5%,31% hydrochloric acid 4.4%
Gas(P)-based route Economic value allocation,acetylene 75.3%,H2 24.7%
Coal-based route – Mass allocation,trichloroethylene 73.8%,tetrachloroethylene 2.2%,hydrogen chloride 20.1%,high-boiling product 2.4%,low-boiling product were 1.5%
Oil-based route – Mass allocation,trichloroethylene 76.6%,tetrachloroethylene 12.5%,hydrogen chloride 10.9%
  Table A1 Allocation method and allocation factors involved in each route
Category 2025 2035 2050
Power generation Proportion Power generation Proportion Power generation Proportion
Coal 4515.5 48.9% 3045.8 26.0% 815.5 5.7%
Hydro 1483.2 16% 1915.7 16.4% 2248.4 15.7%
Wind 1019.3 11% 2413.3 20.6% 4357.8 30.5%
Nuclear 511.6 5.5% 872.3 7.4% 1228.8 8.6%
Natural gas 589.2 6.4% 605.5 5.2% 486.3 3.4%
Solar photovoltaic 853.3 9.2% 2342.5 20.0% 4305.7 30.1%
Solar thermal 30.0 0.3% 130.5 1.1% 352.9 2.5%
Biomass and others 253.9 2.7% 388.5 3.3% 503.5 3.5%
Total 9256.0 100% 11714.1 100% 14298.9 100%
  Table A2 China’s different types of installed power generation capacity (TWh) and their proportion in 2025–2050a)
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