What Is Driving Low-Carbon Transformation in the Petrochemical Industry?

As global climate challenges intensify, China’s “Dual-Carbon” goals are pushing all industries toward aggressive energy-saving and emission-reduction measures.

For the petrochemical sector—one of the most energy-intensive industries—technological upgrades are essential for competitiveness, compliance, and long-term operational efficiency.

Ethylene, known as the “mother of the petrochemical industry,” depends heavily on three major compressors:

◉Cracked gas compressor

◉Propylene compressor

◉Ethylene compressor

Traditionally steam-turbine driven, these machines consume large amounts of energy and produce significant emissions.

To modernize these systems, many operators adopt ABB Automation Solutions, including ABB 800xA, ABB Freelance, and advanced Distributed Control System replacement parts, ensuring full visibility and strong control capabilities throughout production.

Why Replace Steam Turbines with Electric Drive Systems?

Customers upgrade for three primary reasons:

❶Significant Energy Reduction and Lower Carbon Emissions

Switching from steam turbines to high-power synchronous motors and variable-frequency drives greatly lowers fuel consumption and emissions.

❷Higher Reliability, Avoided Shutdowns, and Lower Costs

Ethylene plants operate continuously, where a single shutdown can cause multi-million-dollar losses.

Electric drives, combined with DCS platforms like ABB 800xA or ABB Freelance, enhance reliability and integrate seamlessly with DCS spare parts to ensure long-term system stability.

❸Alignment With National Low-Carbon Policies

Upgrades support China’s sustainability roadmap and help petrochemical companies remain compliant and competitive.

Where Does ABB’s Solution Deliver the Most Customer Value?

ABB solutions are ideal for:

◉Coastal plants experiencing grid fluctuations

◉Large-scale refinery-chemical integration projects

◉Facilities undergoing low-carbon modernization

◉Plants targeting multi-year continuous operation

Customers using ABB control platforms—such as ABB 800xA, ABB Freelance, or ABB DCS systems—benefit from strong compatibility with ABB’s electric-drive equipment and reliable access to Distributed Control System replacement parts from a trusted DCS module supplier.

When Should Customers Upgrade to Electric Drive Systems?

Consider upgrading when:

◉Facing new carbon-reduction requirements

◉Steam turbine energy expenses are rising

◉Voltage disturbances frequently cause shutdowns

◉Implementing smart manufacturing initiatives

◉Planning long-cycle continuous operation (e.g., 5-year runtime)

Many customers take the opportunity during major DCS upgrades using ABB Automation Solutions and when securing new DCS spare parts for lifecycle support.

Which ABB Technologies Solve These Pain Points?

ABB provides a complete drive + motor package designed for petrochemical ethylene compressors, including:

❶100% + 100% Redundant System for Maximum Reliability

◉Two 34 MW LCI variable-frequency drives

◉One 30 MW AMS synchronous motor

◉One active drive + one hot standby

◉Millisecond-level automatic switchover

◉Engineered for five-year continuous, uninterrupted operation

❷Strong Voltage Sag Ride-Through Capability

LCI drives continue operating even when grid voltage drops to 20%, preventing downtime due to lightning or coastal grid disturbances.

❸High Starting Torque + Excellent Efficiency

◉Delivers 100% torque at zero speed

◉Meets ethylene compressor demand (~200 kNm torque)

◉Achieves total system efficiency of 96.03%

(including transformers, filters, drives, and motors)

These advanced systems integrate smoothly with ABB’s automation and DCS solutions, supported by a global supply of DCS spare parts and Distributed Control System replacement parts.

Who Is Already Benefiting From ABB’s Electric-Drive Transformation?

ABB technologies are widely implemented in:

◉Major ethylene production plants

◉Refining–chemical integration complexes

◉Coastal petrochemical hubs

◉Enterprises advancing smart and sustainable manufacturing

Many rely on ABB 800xA, ABB Freelance, and complete inventories of ABB DCS spare parts from reliable DCS module suppliers, ensuring operational continuity and long-term maintenance support.

Customers consistently report:

lower energy usage, improved reliability, and substantial economic benefits.

How Does ABB Help Customers Achieve Low-Carbon and High-Efficiency Goals?

With ABB’s energy-efficient solutions, petrochemical plants can achieve:

✅ Enhanced operation stability and control precision

Ideal when paired with ABB Automation Solutions and DCS upgrades.

✅ Reduced carbon emissions

Switching from steam turbines to electric drives significantly cuts energy consumption.

✅ Continuous operation cycles

Achieves the industry goal of multi-year uninterrupted production.

✅ Lower maintenance and lifecycle costs

Electric-drive systems require less maintenance, supported by accessible Distributed Control System replacement parts.

✅ Improved economic returns

Less energy waste + fewer shutdowns = sustained long-term benefits.

Conclusion: ABB Powers the Petrochemical Industry’s Carbon-Neutral Future

In the carbon-neutral era, petrochemical companies need solutions that deliver both sustainability and reliability.

With comprehensive ABB Automation Solutions, including ABB 800xA, ABB Freelance, and high-performance electric-drive systems backed by global access to DCS spare parts from trusted DCS module suppliers, ABB enables plants to reduce emissions, enhance efficiency, and build safer, smarter, greener industrial operations.