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All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Demand-side solutions in the US building sector could achieve deep emissions reductions and avoid over $100 billion in power sector costs

Buildings are energy-intensive and a primary source of US end-use sector carbon emissions. Although building emissions today are 25% below their 2005 peak, far deeper reductions are needed to reach the US 2050 net-zero emissions goal. However, plausible decarbonization pathways that consider both buildings and their interactions with the power grid remain poorly understood. Here, we couple detailed modeling of building energy use and the grid to quantify building decarbonization potential and associated grid impacts. We find up to a 91% reduction in building CO 2 emissions from 2005 levels by 2050 using a portfolio of building efficiency, demand flexibility, and electrification measures alongside rapid grid decarbonization. Building efficiency and flexibility could generate up to $107 billion in annual power system cost savings by 2050, offsetting over a third of the incremental cost of full grid decarbonization. Our results underscore multiple benefits of demand-side solutions for deep decarbonization of US buildings.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Sustainable aviation fuel from ethanol: Techno-economic analysis and life cycle analysis

Sustainable aviation fuel (SAF) is crucial for improving energy security, enhancing domestic production, and reducing carbon emissions in the aviation sector. Among various SAF production technologies, the ethanol-to-jet (ETJ) pathway is a promising option due to its economic viability and technological maturity. This study integrates a techno-economic analysis (TEA) and a life cycle analysis (LCA) to evaluate emissions reduction strategies for SAF production via the ETJ pathway, considering use of ethanol derived from both corn grain and corn stover. Conventional corn grain-derived ETJ fuel reduces greenhouse gas (GHG) emissions by 22 % compared to fossil jet fuel, with potential reductions of 26 %–96 % when incorporating renewable energy sources, with a 6 %–32 % increase in the minimum fuel selling price (MFSP). Corn stover-derived ETJ achieves a 77 % GHG reduction but with higher MFSPs compared to corn grain ETJ. Carbon capture and storage (CCS without considering the cost for piping and sequestration, only compression) reduces the emissions of corn grain-derived ETJ by up to 32 gCO 2 e/MJ and enables negative emissions for corn stover-derived ETJ, with MFSP increases ranging from 1 % to 22 %. While carbon capture and utilization (CCU) increase ethanol yield by 47 %, it raises MFSPs by 54 % due to high electricity demand. Sustainable farming practices provide only limited carbon intensity (CI) reductions individually but do offer cumulative benefits when combined. These findings highlight the trade-offs between cost and environmental impact, providing insights to optimize SAF production strategies and support aviation sector goals for emissions reduction.

09 BIOMASS FUELS↗
DOE OSTI2022

Direct Air Capture and Sequestration of CO 2 by Accelerated Indirect Aqueous Mineral Carbonation under Ambient Conditions

Mineralization of gaseous carbon dioxide into solid carbonates using alkaline industrial residues such as coal fly ash has a dual advantage of reducing the carbon dioxide footprint of coal power plants and improving ash utilization. However, the slow mineral carbonation rate under atmospheric conditions is a major challenge, especially when using natural minerals or industrial residues for direct air capture (DAC) of CO 2 . In this study, using coal fly ash samples and concentrated alkali carbonate aqueous solutions as a recyclable solvent, we show the feasibility of coupling mineral carbonation with DAC under atmospheric conditions. Findings show that carbonation efficiency is best under alkaline conditions, achieving as high as ~80% conversion to calcium carbonates within 1 h in a 1.9 M sodium carbonate solution. Based on the experimental results, a process coupling DAC and mineral carbonation that operates entirely under ambient conditions is proposed. Here, the techno-economic and life cycle assessments for the proposed process project a levelized cost of $\$116$–133/t-CO 2 -sequestered (US $\$2019$) and process carbon emissions (GWP) in the range of 0.03–0.25 t-CO 2 e/t-CO 2 -sequestered. Considering the low cost, simplicity, and gigaton-scale sequestration potential, we believe that DAC based on alkaline industrial residue carbonation can be considered a “low-hanging fruit” in the pursuit of negative emissions to combat climate change.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2025

Energy efficiency in industrial drying: A hybrid ultrasonic system with a novel dynamic optimization framework

Drying processes are among the most energy-consuming operations in industrial and manufacturing settings, demanding strategic selection, design, and control for enhanced efficiency. Advancing drying technologies is critical for improving sustainability, lowering energy use, reducing carbon emissions, and minimizing waste. This study explores two innovative strategies aimed at transforming drying processes into sustainable, low-carbon systems by reducing energy consumption, minimizing waste, and maintaining a strong emphasis on preserving product quality. The first strategy showcases a sub-pilot scale hybrid ultrasonic-convective dryer for agrifood products. This technology, powered by electricity (process electrification), integrates non-thermal ultrasonic dehydration with convective heating and is presented as a sustainable and energy-efficient solution that enhances eco-friendly practices. The second strategy involves introducing and implementing a novel, multiobjective, mixed integer dynamic optimization technique to determine the optimal time-dependent process parameter values for the drying operation. This optimization technique yields operating conditions that are piecewise constant in time aiming to maximize the energy efficiency of the hybrid ultrasonic-convective dryer while ensuring strict adherence to product quality constraints. By adopting the hybrid ultrasonic-convective dryer, a notable 35% improvement in energy efficiency was achieved compared to conventional hot-air drying systems for drying apple slices. The proposed optimization framework further enhanced energy efficiency by nearly 14% over the most efficient process on the identical testbed, under static operating conditions. The reported enhancements have been experimentally validated. Regarding drying time (thereby improving production yield), the developed hybrid ultrasonic-convective dryer demonstrates as much as a 41% reduction in total processing time, which is further optimized by an additional 10% using our proposed optimization framework. The research outcomes have profound implications for the design and operation of drying systems, encompassing crucial aspects such as process electrification, cost-effectiveness, energy savings, time efficiency, product yield, product quality, and process automation.

Dynamic optimization↗
DOE OSTI2025

Biomass for Carbon Removal and Storage (BiCRS) Counterfactual Decision Tree

Counterfactual is the term used to describe a "business-as-usual" scenario which used as a baseline to compare against a new project, allowing the calculation of net impacts for a life cycle analysis (LCA). The choice of counterfactual is critical for determining the results from LCA and must be carefully justified to ensure a fair and accurate comparison. Using forest residues as an example, this decision tree illustrates decision points to be considered for sustainable biomass sourcing and provides a framework for estimating the carbon emissions or storage under the "business-as-usual” scenarios for biomass otherwise destined for use in Biomass for Carbon Removal and Storage (BiCRS) projects.

09 BIOMASS FUELS↗
DOE OSTI2024

Novel PCM-based fin and tube heat exchanger system for building heating and cooling applications

In the United States, the building sector accounts for 40% of all energy use, and buildings are responsible for more than two-thirds of electricity consumption. Buildings remain the major driver of energy-related carbon emissions, and such emissions are projected to increase in the years ahead because of urbanization and population growth. To accomplish the low carbon energy goal in the building sector, phase change material (PCM)–based thermal energy storage (TES) is increasingly being adopted because it offers several advantages, such as reducing building peak load and energy consumption, enabling large scale deployment of renewables, and improving grid stability. The integration of TES with thermally anisotropic building envelopes (TABEs) is a promising solution because, TABE can redirect natural thermal energy from a building using hydronic loops to TES, and the stored energy can be used later for heating and cooling applications. In this study, we experimentally investigate the thermal performance of a novel fin-tube heat exchanger TES system designed for potential integration with a TABE. An experimental rig for a 5-gal PCM fin-tube heat exchanger system with water as the heat transfer medium is described which records temperatures at the heated and cooled boundaries of the system. Experimental observations provide insight into the role a TES system can play in offsetting a building’s heating and cooling demand and also offer a means to characterize the performance of PCMs for building applications. The scale and study presented in this work will help in the design of future thermal storage systems optimized for storage capacity while also accounting for overall system costs for building applications.

Tamraparni, Achutha↗
DOE OSTI2022

Moving beyond 90% Carbon Capture by Highly Selective Membrane Processes

A membrane-based system with a retentate recycle process in tandem with an enriching cascade was studied for >90% carbon capture from coal flue gas. A highly CO 2 -selective facilitated transport membrane (FTM) was utilized particularly to enhance the CO 2 separation efficiency from the CO 2 -lean gases for a high capture degree. A techno-economic analysis showed that the retentate recycle process was advantageous for ≤90% capture owing to the reduced parasitic energy consumption and membrane area. At >90% capture, the enriching cascade outperformed the retentate recycle process since a higher feed-to-permeate pressure ratio could be applied. An overall 99% capture degree could be achieved by combining the two processes, which yielded a low capture cost of USD47.2/tonne, whereas that would be USD 42.0/tonne for 90% capture. This FTM-based approach for deep carbon capture and storage can direct air capture for the mitigation of carbon emissions in the energy sector.

42 ENGINEERING↗
DOE OSTI2024

Development of New Reactor Core Configuration for Power Uprate - Fuel Reload & Heat Processing Analyses, Core Design, System Safety Assessments, and Fuel Performance Analyses

With the passage of the Infrastructure Investment and Jobs Act in 2021 and the Inflation Reduction Act (IRA) in 2022, the United States stands at a critical juncture for the future of nuclear power. These landmark policies provide significant support for clean energy initiatives, positioning nuclear power as a key component of the nation’s strategy to reduce carbon emissions and achieve energy security. This growing emphasis on nuclear energy is driven by the need for reliable, low-carbon power sources as the country transitions away from fossil fuels. Federal policy, along with increasing state-level support, is encouraging investment in nuclear technology advancements to meet these demands. Building new nuclear power plants (NPPs), however, presents significant challenges due to high costs and long construction timelines. As a result, increasing the power output of existing NPPs through power uprates has emerged as a more feasible and cost-effective strategy. One key area of advancement is the development of accident-tolerant fuel (ATF), such as chromium-coated zirconium alloy cladding, which offers enhanced material performance, enabling power uprates in light water reactors (LWRs). Given the growing demand for nuclear energy fueled by federal policies and state initiatives, it is essential to evaluate the feasibility and benefits of significant power uprates in existing pressurized water reactors (PWRs) using advanced fuel technologies. The introduction of ATF concepts opens new opportunities for safely and economically achieving these power increases. Assessing whether these innovations can support substantial power uprates while maintaining operational safety is crucial to maximizing the potential of the nation’s existing nuclear infrastructure. This project aims to explore how power uprates can be achieved by boosting reactor thermal power output and optimizing reactor core design, while ensuring the safety and economic viability of NPPs. Specifically, it will focus on demonstrating the technical and economic feasibility of power uprates in a PWR using low 5-10% enrichment uranium (LEU+) high burnup (HBU) fuel combined with ATF concepts. In fiscal year 2024 (FY24), the research and development focus on building foundational models and conducting multi-physics performance and safety analyses to support the power uprate. The findings of the study would be shared through LWRS Seasonal Meetings, conferences and workshops with utility companies and researchers. These also serve as a basis for further study of fuel reloading optimization with ATF claddings.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Site demonstration and performance evaluation of MPC for a large chiller plant with TES for renewable energy integration and grid decarbonization

Thermal energy storage (TES) for a cooling plant is a crucial resource for load flexibility. Traditionally, simple, heuristic control approaches, such as the storage priority control which charges TES during the nighttime and discharges during the daytime, have been widely used in practice, and shown reasonable performance in the past benefiting both the grid and the end-users such as buildings and district energy systems. However, the increasing penetration of renewables changes the situation, exposing the grid to a growing duck curve, which encourages the consumption of more energy in the daytime, and volatile renewable generation which requires dynamic planning. The growing pressure of diminishing greenhouse gas emissions also increases the complexity of cooling TES plant operations as different control strategies may apply to optimize operations for energy cost or carbon emissions. This paper presents a model predictive control (MPC), site demonstration and evaluation results of optimal operation of a chiller plant, TES and behind-meter photovoltaics for a campus-level district cooling system. The MPC was formulated as a mixed-integer linear program for better numerical and control properties. Compared with baseline rule-based controls, the MPC results show reductions of the excess PV power by around 25%, of the greenhouse gas emission by 10%, and of peak electricity demand by 10%.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2025

Electrochemical Cycling of Liquid Organic Hydrogen Carriers as a Sustainable Approach for Hydrogen Storage and Transportation

Hydrogen (H 2 ), as a high-energy-density molecule, offers a clean solution to carry energy. However, the high diffusivity and low volumetric density of H 2 pose a challenge for long-term storage and transportation. Liquid organic hydrogen carriers (LOHCs) have been suggested as a strategic way to store and transport hydrogen in stable molecules. More so, electrochemical LOHC cycling renders an opportunity to utilize renewable energy for hydrogen storage and transportation toward the goal of eliminating carbon emissions. In this Perspective, examples of electrochemical reactions of organic molecules and their suitability for LOHC couples are examined. A comparative carbon footprint assessment of electrochemical LOHC cycling processes against thermochemical and hybrid LOHC cycling processes was performed. The electrochemical LOHC cycling process had the lowest relative carbon footprint only when highly concentrated LOHCs were used as the feed or when purification of the LOHC product was not required. The carbon footprint in electrochemical cycling of diluted LOHC was primarily contributed to by the LOHC distillation separation process. A sensitivity analysis showed the carbon footprint LOHC concentration dependence during the electrochemical cycling process. Moreover, the electrolyte composition significantly affects the carbon footprint during electrochemical LOHC cycling. Energy utilization, water usage, and toxicity for electrochemical LOHC cycling are discussed to provide an overview for better economic and environmental practices. There are significant opportunities in the electrochemical cycling of LOHCs if appropriate conditions such as high concentrations of reactant, reversible redox cycling ability, high Faradaic efficiencies, and catalyst stabilities are achieved.

25 ENERGY STORAGE↗
DOE OSTI2024

CO 2 fixation into carbon nanofibres using electrochemical–thermochemical tandem catalysis

Carbon dioxide (CO 2 ) fixation into value-added solid carbon such as carbon nanofibres (CNF) for longer-term storage represents a promising avenue for achieving net-negative carbon emissions. However, directly converting CO 2 to CNF via thermocatalytic approaches faces thermodynamic constraints, while electrocatalytic methods typically lead to amorphous carbon with limited yields or require energy-intensive conditions (>720 °C). Here, we present an electrocatalytic-thermocatalytic tandem strategy for CNF production, which circumvents the aforementioned thermodynamic limitations by integrating the co-electrolysis of CO 2 and water into syngas (CO and H 2 ) with a subsequent thermochemical process at relatively mild conditions (370-450 °C, 1 atm), yielding CNF at a high production rate (average 2.5 g carbon g metals -1 h -1 ). Further, the optimal coordinated actions of FeCo alloy and extra metallic Co were ascertained to enhance the dissociative activation of syngas and favour the carbon-carbon bond formation to produce CNF. This tandem strategy opens a door to leverage renewable energy for decarbonizing CO 2 into valuable solid carbon products while producing renewable H 2 .

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2021

Land-use harmonization datasets for annual global carbon budgets

Abstract. Land-use change has been the dominant source of anthropogenic carbon emissions for most of the historical period and is currently one of the largest and most uncertain components of the global carbon cycle. Advancing the scientific understanding on this topic requires that the best data be used as input to state-of-the-art models in well-organized scientific assessments. The Land-Use Harmonization 2 dataset (LUH2), previously developed and used as input for simulations of the 6th Coupled Model Intercomparison Project (CMIP6), has been updated annually to provide required input to land models in the annual Global Carbon Budget (GCB) assessments. Here we discuss the methodology for producing these annual LUH2-GCB updates and extensions which incorporate annual wood harvest data updates from the Food and Agriculture Organization (FAO) of the United Nations for dataset years after 2015 and the History Database of the Global Environment (HYDE) gridded cropland and grazing area data updates (based on annual FAO cropland and grazing area data updates) for dataset years after 2012, along with extrapolations to the current year due to a lag of 1 or more years in the FAO data releases. The resulting updated LUH2-GCB datasets have provided global, annual gridded land-use and land-use-change data relating to agricultural expansion, deforestation, wood harvesting, shifting cultivation, regrowth and afforestation, crop rotations, and pasture management and are used by both bookkeeping models and dynamic global vegetation models (DGVMs) for the GCB. For GCB 2019, a more significant update to LUH2 was produced, LUH2-GCB2019 (https://doi.org/10.3334/ORNLDAAC/1851, Chini et al., 2020b), to take advantage of new data inputs that corrected cropland and grazing areas in the globally important region of Brazil as far back as 1950. From 1951 to 2012 the LUH2-GCB2019 dataset begins to diverge from the version of LUH2 used for the World Climate Research Programme's CMIP6, with peak differences in Brazil in the year 2000 for grazing land (difference of 100 000 km2) and in the year 2009 for cropland (difference of 77 000 km2), along with significant sub-national reorganization of agricultural land-use patterns within Brazil. The LUH2-GCB2019 dataset provides the base for future LUH2-GCB updates, including the recent LUH2-GCB2020 dataset, and presents a starting point for operationalizing the creation of these datasets to reduce time lags due to the multiple input dataset and model latencies.

Chini, Louise (ORCID:0000000290703505)↗
NASA NTRS2021

Land-Use Harmonization Datasets for Global Carbon Budget 2019 and Beyond

Land-use change has been the dominant source of anthropogenic carbon emissions for most of the historical period, and is currently one of the largest and most uncertain components of the global carbon cycle. Advancing the scientific understanding on this topic requires that the best data be used as input to the best models in well-organized scientific assessments. The Land-Use Harmonization dataset (LUH2), previously developed and used as input for CMIP6 simulations, has been updated annually to provide required input to land models in the annual Global Carbon Budget (GCB) assessment. These annual LUH2-GCB updates and extensions have incorporated annual FAO wood harvest data updates for dataset years after 2015 and HYDE gridded agriculture area data updates (based on annual FAO agricultural area data updates) for dataset years after 2012, along with extrapolations to the current year due to a lag of one or more years in the FAO data releases. The resulting updated LUH2-GCB datasets have provided global, annual gridded land-use and land-use change data relating toagricultural expansion, deforestation, wood harvesting, shifting cultivation, regrowth and afforestation, and crop rotationsand pasture managementand are used by both book-keeping models and Dynamic Global Vegetation Models (DGVMs) for the GCB. For GCB 2019,a more significant update to LUH2 was produced (LUH2-GCB2019) to correct cropland and grazing area errors in the underlying input datasets for the globally important region of Brazil, as far back as 1950. From 1951-2012 the LUH2-GCB2019 dataset begins to diverge from the LUH2 v2hdataset, with peak differences in Brazil in the year 2000 for grazing land (difference of 100,000 km2) and in the year 2009 for cropland (difference of 77,000 km2), along with significant sub-national reorganization of agricultural land-use patterns within Brazil. These LUH2-GCB2019 corrections for Brazil provide the base for future LUH2-GCB updates including the recent LUH2-GCB2020 dataset, and present a starting point for operationalizing the creation of these datasets toreduce time-lags due to the multiple input dataset and model latencies.

L Chini↗
DOE OSTI2023

Greenhouse gas emissions embodied in the U.S. solar photovoltaic supply chain

Abstract Solar photovoltaic (PV) electricity is considered to be an important source of electricity generation in the quest for net-zero carbon emissions. However, the growth of solar electricity is creating both increased material demands and increased greenhouse gas (GHG) emissions from silicon and PV manufacturing (also referred to as embodied GHG emissions of solar electricity). Here we analyze the silicon and solar PV supply chain for the United States (U.S.) market and find that the embodied GHG emissions of solar PV panel materials (such as silicon), manufacture, logistics, and installation in the U.S. given the current supply chain are 36 g CO 2 e kWh −1 of solar electricity generated. Eighty-five percent of the embodied GHG emissions are from PV panel production processes in China and other Asia–Pacific countries. Moving the silicon and PV manufacturing to the U.S. would reduce the embodied GHG emissions of solar electricity by 16% from its current level, primarily because of the lower GHG emission intensity of the U.S. electrical grid and the lower GHG emissions for aluminum electrolysis in North America. Future scenario analysis shows that by 2030, with the U.S. PV domestic supply chain and its decarbonized grid electricity and aluminum production, as well as improving PV conversion efficiency, the embodied GHG emissions of solar electricity in the U.S. will be reduced to 21 g CO 2 e kWh −1 .

14 SOLAR ENERGY↗
DOE OSTI2021

The evolving role of geothermal energy for decarbonizing the United States

Geothermal energy is often referred to as a niche technology that is too localized, too small or too expensive to make much of a difference in how renewable energy will be supplied in a fully decarbonized future. As a result, geothermal energy has been undervalued in terms of what it could provide to complement, rather than compete with, electricity generation from wind, solar photovoltaic, concentrating solar power and other renewables. Geothermal energy systems are fully dispatchable and can provide baseload or load-following electric power or heat suitable for a wide range of applications including supplying district heating for communities and cities, and heating and cooling of individual buildings. The focus of our study is on the potential of utilizing geothermal energy for providing heat for buildings and industry at lower temperatures, a substitute for the combustion of fossil fuels. Because heating represents about 20% (20 EJ per year) of the annual primary energy consumption in the U.S.—with most of it coming from burning natural gas, oil and/or propane in furnaces—deploying geothermal heating on a national scale could have a significant impact on lowering carbon emissions. In heating-dominated states in the U.S. Northern Tier, heating often is among the largest contributors to the state's carbon footprint. This review begins with a discussion of the motivation and rationale behind considering geothermal as a key low-carbon heating option for the U.S. The study summarizes the U.S. geothermal resource and describes the applications and main engineering components of using geothermal energy for heating and cooling, electric power generation, and co-generation using district heating, geothermal heat pumps, and power conversion with steam flashing and organic Rankine plants. Environmental benefits and impacts are described. An extensive discussion of geologic and thermal-hydraulic aspects of the subsurface is included in the review because of their critical role in determining reservoir designs at specific sites to ensure sufficient productivity that is both safe and economically viable. Models for estimating levelized costs of district heating are used to show how costs are affected by reservoir performance, infrastructure capital costs, and financial parameters. Here, the review concludes with an assessment of technical subsurface issues associated with reservoir performance and the economic requirements for providing geothermal heating in district heating systems at a sufficient scale to have an impact on decarbonizing the U.S.

15 GEOTHERMAL ENERGY↗
DOE OSTI2020

Using waste CO 2 from corn ethanol biorefineries for additional ethanol production: life‐cycle analysis

Abstract Corn ethanol plants generate high‐purity carbon dioxide (CO 2 ) while producing ethanol. If that CO 2 could be converted into ethanol by carbon capture and utilization technologies it would be possible to increase ethanol production more than 37% without additional corn grain inputs. Gas fermentation processes use microbes to convert carbon‐containing gases into ethanol and so have the potential to be used with the CO 2 from biorefineries for this purpose. However, as CO 2 utilization technologies for converting thermodynamically stable CO 2 are typically energy intensive, it is necessary to evaluate the related life‐cycle greenhouse gas (GHG) emissions (carbon intensities or CIs) to see whether there are actual emission reduction benefits. In this study, we evaluate the CIs of ethanol produced from high‐purity CO 2 in corn ethanol plants by gas fermentation plus electrochemical reduction. Our analysis shows that the sources of electricity and hydrogen are key drivers of CO 2 ‐based ethanol's GHG emissions. With wind electricity, the design cases show the potential of near‐zero CI ethanol (1.1 g CO 2 e/MJ), but that can increase to up to 331–531 g CO 2 e/MJ when today's U.S. Midwest electricity mix is used. To avoid the renewable electricity intermittency issue, we considered a power purchase agreement option using wind electricity 40% of the time and using the regional mix for the rest, which provides a 42% GHG emission reduction from the CI of gasoline. © 2020 The Authors and UChicago Argonne, LLC, Operator of Argonne National Laboratory. Biofuels, Bioproducts and Biorefining published by Society of Chemical Industry and John Wiley & Sons, Ltd.

09 BIOMASS FUELS↗
DOE OSTI2022

Regional Variation in Light-Duty Plug-in Electric Vehicle Emissions

Automobile electrification is viewed as one of the key requirements for deep decarbonization of transportation. However, the exact magnitude of decarbonization from switching from a combustion of petroleum-based fuels to grid-derived electricity is a complex issue. Variations in local grid mixes lead to differing carbon intensities of electricity in different regions. This complexity is compounded by geographical differences in vehicle characteristics. This analysis considers these geographic differences to produce a historical assessment of the fuel-cycle carbon emissions of plug-in electric vehicles (PEVs) in the United States from 2011 to 2021. We find that PEVs in the United States decreased in electricity-derived carbon intensity, from 187 grams per mile to 110 grams per mile from 2011 to 2021 due to improvements in the electric grid and vehicle efficiency. Through 2021, PEVs emitted a total of 13.6 million metric tons of greenhouse gas (GHG) emissions in the United States, including both emissions from electricity and gasoline, while driving a total of 100 billion miles. Of this total, 8.39 million metric tons was due to electricity consumption. Over the same distance, comparable gasoline vehicles would have emitted between 29 and 41 million metric tons of GHG, leading to a reduction of 15 to 27 million metric tons. Relative to national-level assessments that do not factor in this regional difference, these electric vehicles resulted in 13% greater reductions in GHG emissions than previously calculated. In the future, announced goals to further decarbonize the electricity sector will continue to reduce the emissions of PEVs, including reducing emissions rates for vehicles already on the road, further improving the benefits relative to the unchanging emissions of contemporaneous gasoline vehicles.

02 PETROLEUM↗
DOE OSTI2023

Smart Manufacturing Pathways for Industrial Decarbonization and Thermal Process Intensification

Rapid decarbonization is fast becoming the primary environmental and sustainability initiative for many economic sectors. Industry consumes more than 30 % of all primary energy in the United States and accounts for nearly 25 % of all greenhouse gas (GHG) emissions. More than 70 % of energy consumed by the industrial sector is related to thermal processes, which are also the largest contributors of carbon emissions, overwhelmingly due to the combustion of fossil fuels. Thermal process intensification (TPI) seeks to dramatically improve the energy performance of thermal systems through technology pillars focusing on alternative energy sources and processes, supplemental technologies, and waste heat management. The impacts of TPI have significant overlap with the goals of industrial decarbonization (ID) that seeks to phase out all GHG emissions from industrial activities. Emerging supplemental technologies such as smart manufacturing (SM) and the industrial internet of things (IoT) enable significant opportunities for the optimization of manufacturing processes. Combining strategies for TPI and ID with SM and IoT can open and enhance existing opportunities for saving time and energy via approaches such as tighter control of temperature zones, better adjustment of thermal systems for variations in production levels and feedstock properties, and increased process throughput. Data collected by smart processes will also enable new advanced solutions such as digital twins and machine learning algorithms to further improve thermal system savings. Herein, this paper examines the individual pathways of TPI, ID, and SM and how the combination of all three can accelerate energy and GHG reductions.

42 ENGINEERING↗