Industryweek 11716 Greeen Factory1

Exxon Mobil, Georgia Tech Breakthrough Raises Potential for Greener Future in Manufacturing Plastics

Aug. 18, 2016
The breakthrough ultimately may help chemical plants shrink their carbon footprint and help the world meet ambitious targets for paring the greenhouse gas emissions blamed for climate change.

Scientists at Exxon Mobil Corp. (IW 500/1) and the Georgia Institute of Technology have discovered an alternative to the most energy-hogging part of manufacturing plastics, potentially keeping 45 million tons of carbon dioxide out of the Earth’s atmosphere each year.

The breakthrough, set to be published in the Aug. 19 issue of the journal Science, ultimately may help chemical plants shrink their carbon footprint and help the world meet ambitious targets for paring the greenhouse gas emissions blamed for climate change. Although nearly 200 nations agreed last December to rein in carbon dioxide emissions by boosting energy efficiency and shifting to cleaner sources of electricity, experts say it’s also essential to green up industrial manufacturing.

Chemical plants account for about 8% of current global energy demand, with the share projected to grow dramatically as developing countries use more electronics, housing materials and plastic products.

"These types of breakthroughs can make an absolute step change in the amount of energy needed to convert a raw material to a plastic," said Vijay Swarup, vice president of research and development at ExxonMobil Research and Engineering Co., a subsidiary of the energy company.

The same basic approach is already used to desalinate seawater. Where heat-based techniques can be used to strip out salt, reverse-osmosis membranes do the same work with only a fraction of the energy the thermally driven processes require. The breakthrough membranes were discovered in the 1960s and began being mass manufactured in the mid 1970s. Now, about 60% of the desalination market uses that reverse osmosis process.

An Uncertain Milestone

If the new plastic-focused membrane can be mass-produced and widely adopted -- an uncertain milestone researchers openly acknowledge would require years more R&D -- it could save $2 billion in annual energy costs. The calculations reported in Science are based on the amount of energy used in separation processes globally, an assumption that half of it could be displaced by the new technology and the average greenhouse gas emissions for each kilowatt hour of electricity produced in the U.S.

Swarup cautioned that "this is very early stages" but stressed that "being published in a prestigious journal like Science speaks to the fact that we think the fundamentals are very strong."

Molecular separation processes are essential to produce clean water, pharmaceuticals, chemicals and fuels. About 40% to 60% of the energy used producing those materials is spent on separation and purification processes, the paper’s authors say.

"We’re confident that there could be really dramatic energy savings if this technology could be commercialized and adopted by the industry," said Benjamin McCool, an advanced research associate at Exxon, which funded the research.

Exxon’s collaboration with Georgia Tech -- formally initiated in 2014 -- comes as the company is aiming to green up its image, while its use of climate change research is being probed by a handful of state attorneys general. New York, Massachusetts and other states are investigating whether Exxon misled investors by not fully disclosing how climate change could affect its business.

By Jennifer A. Dlouhy

Popular Sponsored Recommendations

Process Mining For Dummies

Nov. 19, 2023
Here it is. Everything you need to know about process mining in a single book, written in the easy-to-understand, hard-to-forget style that ‘For Dummies’ manages so effortlessly...

3D Printing a More Efficient Factory Floor

Nov. 16, 2023
Today’s additive manufacturing platforms make it simple to print a wide range of high-performing industrial parts as soon as possible and right where you need them — unlocking...

The Realist Guide to Sustainable Supply Chains

Sept. 28, 2023
A ‘roll up your sleeves’ guide to driving green line performance at your organization. Learn with this easy-to-understand ebook how to implement green supply chain management ...

Legacy Phone Lines Are Draining Your Profits

Oct. 30, 2023
Copper wire phone line expenses that support emergency devices could be costing your company millions of dollars in wasteful overhead expenses. Rates have been skyrocketing while...

Voice your opinion!

To join the conversation, and become an exclusive member of IndustryWeek, create an account today!