Global methane emissions hit 350MT in 2023, with 37% derived from the energy sector, the majority of which from oil and gas operations.  Flaring from onshore oil operations alone accounted for 6.2MT (cold flaring and incomplete hot flaring).  Responsible operators around the world are increasingly seeking practical and effective ways to address this problem.

While regulations obliging operators to take action are being introduced in many parts of the world, some countries are already dialling back on these measures, meaning the case for change needs to be self-evident, both commercially as well as ethically.

Boeing-led Aerospace Xelerated (Boeing’s accelerator and innovation programme) recognised the potential impact of addressing this issue and saw an opportunity to support upstream producers in reducing flaring while contributing to the aviation industry’s decarbonisation efforts. Boeing and Aerospace Xelerated supported HiiROC in undertaking a pioneering study of how its proprietary technology, Thermal Plasma Electrolysis (TPE), could be a viable solution in the aerospace industry.

TPE uses an electrical field to split gaseous hydrocarbons – natural gas, biomethane, flare and other hydrocarbon-rich waste streams – into their component parts of solid inert carbon and hydrogen gas. Using waste gas that would otherwise have been flared avoids the production of CO2 and creates two valuable products – hydrogen and carbon black.

The primary challenge in addressing flares is related to operability – being able to mitigate emissions over a wide range of flow rates and compositions – so the main aim was to determine whether TPE could successfully deliver in these conditions.  To assess this, HiiROC tested synthetic gas compositions based on real data from customers’ flares in the UK and the Middle East, covering a range of compositions, flow rates and intermittencies.  It was found that, with careful system integration, TPE could mitigate over 99% of hydrocarbon emissions and up to 95% of potential CO2emissions – it is expected that even better results could be achieved with simple tuning. TPE was also able to accommodate variable flows due to its modular nature.

The secondary challenges of costs and practicality – being able to integrate with existing systems on site – were also of interest. Life cycle analyses showed that TPE can produce enough low carbon hydrogen to be self-sustaining, thus keeping operating costs to a minimum.  Together with its small modular design, this means that TPE can be deployed in remote locations that do not have a reliable grid connection, including locations where emissions restrictions are in place.  Further techno-economic analyses of different concept designs showed that the business case for TPE is compelling when compared with alternative solutions, largely driven by arising from its ability to eliminate hydrocarbons and CO2 emissions, as well as generate revenue from carbon sales.

In summary, TPE is a low-cost solution to the issue of both hot and cold flares, while bringing the following benefits:

New and protected income streams

  • New revenue from sales of hydrogen and carbon black
  • Eligibility for CO2 credits or other incentives for decarbonisation
  • Protected revenue from increased project longevity

Reduced costs

  • Avoided penalties for CO2 / methane emissions
  • Generating power from hydrogen reduces need for diesel generators

Increased flexibility

  • Ability to operate in remote locations with poor grid infrastructure

Protected licence to operate

  • Emissions eliminated and air quality improved
  • Job protection through increased project longevity
  • Improved access to new projects / permits

Beyond flare, HiiROC is exploring CO2 mitigation applications in other industrial settings, with potentially suitable waste streams in the automotive and aerospace value chains.

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