Crude-to-Chemical Revolution: Integrating Technologies, Economic Feasibility, and Policy Frameworks for Sustainable Light Olefin Production

Light olefins such as propylene and ethylene are vital building blocks for producing plastics, fibers, resins, and numerous other chemical products. The global demand for basic chemicals is estimated at 700 million tons annually and is projected to reach one billion tons by 2050. Converting crude oil directly to light olefins offers significant advantages, including reduced energy consumption, faster processing times, and the ability to meet growing market demands. This review provides a comprehensive analysis of crude-to-chemical (C2C) conversion technology, with a focus on economic sustainability, environmental impact, and policy implications. Key aspects include catalyst engineering, reaction mechanisms, and strategies to enhance light olefin selectivity. The review delves into the catalytic cracking reaction mechanisms, catalyst design and optimization, the roles of surface acidity and mesoporosity, and the effects of metal incorporation on selectivity. Additionally, a technoeconomic feasibility analysis is provided, highlighting the current challenges and future outlook for advancing C2C conversion technologies.