The benefits of using a residual hydrogen rich stream as a clean combustion fuel in order to reduce Carbon dioxide emissions and cost is quantified. A residual stream containing 86% of hydrogen, coming from the top of the demethanizer column of the cryogenic separation sector of an ethylene plant, is recycled to be mixed with natural gas and burned in the boilers of the utility plant to generate high pressure steam and power. The main advantage is due to the fact that the hydrogen rich residual gas has a higher heating value and less CO(2) combustion emissions than the natural gas. The residual gas flowrate to be recycled is selected optimally together with other continuous and binary operating variables. A Mixed Integer Non Linear Programming problem is formulated in GAMS to select the operating conditions to minimize life cycle CO(2) emissions. (C) 2009 Professor T. Nejat Veziroglu. Published by Elsevier Ltd. All rights reserved.