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ZeroCAL: Eliminating Carbon Dioxide Emissions from Limestone’s Decomposition to Decarbonize Cement Production

Limestone (calcite, CaCO 3 ) is an abundant and cost-effective source of calcium oxide (CaO) for cement and lime production. However, the thermochemical decomposition of limestone (~800 °C, 1 bar) to produce lime (CaO) results in substantial carbon dioxide (CO 2(g) ) emissions and energy use, i.e., ~1 tonne [t] of CO 2 and ~1.4 MWh per t of CaO produced. Here, we describe a new pathway to use CaCO 3 as a Ca source to make hydrated lime (portlandite, Ca(OH) 2 ) at ambient conditions (p, T) while nearly eliminating process CO 2(g) emissions (as low as 1.5 mol. % of the CO 2 in the precursor CaCO 3 , equivalent to 9 kg of CO 2(g) per t of Ca(OH) 2 ) within an aqueous flowelectrolysis/ pH-swing process that coproduces hydrogen (H 2(g) ) and oxygen (O 2(g) ). Because Ca(OH) 2 is a zero-carbon precursor for cement and lime production, this approach represents a significant advancement in the production of zero-carbon cement. The Zero CArbon Lime (ZeroCAL) process includes dissolution, separation/recovery, and electrolysis stages according to the following steps: (Step 1) chelator (e.g., ethylenediaminetetraacetic acid, EDTA)-promoted dissolution of CaCO 3 and complexation of Ca 2+ under basic (>pH 9) conditions, (Step 2a) Ca enrichment and separation using nanofiltration (NF), which allows separation of the Ca-EDTA complex from the accompanying bicarbonate (HCO 3 – ) species, (Step 2b) acidity-promoted decomplexation of Ca from EDTA, which allows near-complete chelator recovery and the formation of a Ca-enriched stream, and (Step 3) rapid precipitation of Ca(OH) 2 from the Ca-enriched stream using electrolytically produced alkalinity. These reactions can be conducted in a seawater matrix yielding coproducts including hydrochloric acid (HCl) and sodium bicarbonate (NaHCO 3 ), resulting from electrolysis and limestone dissolution, respectively. Careful analysis of the reaction stoichiometries and energy balances indicates that approximately 1.35 t of CaCO 3 , 1.09 t of water, 0.79 t of sodium chloride (NaCl), and ~2 MWh of electrical energy are required to produce 1 t of Ca(OH) 2 , with significant opportunity for process intensification. This approach has major implications for decarbonizing cement production within a paradigm that emphasizes the use of existing cement plants and electrification of industrial operations, while also creating approaches for alkalinity production that enable cost-effective and scalable CO 2 mineralization via Ca(OH) 2 carbonation.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

Decision support for United States—Canada energy integration is impaired by fragmentary environmental and electricity system modeling capacity

The renewable energy transition is leading to increased electricity trade between the United States and Canada, with Canadian hydropower providing firm lower-carbon power and buffering variability of wind and solar generation in the U.S. However, long-term power purchase agreements and transborder transmission projects are controversial, with two of four proposed transmission lines between Quebec, Canada and the northeast U.S. cancelled since 2018. Here, we argue that controversies are exacerbated by a lack of open-source data and tools to understand tradeoffs of new hydropower generation and transmission infrastructure in comparison to alternatives. This gap includes impacts that incremental transmission and generation projects have on the economics of the entire system, for example, how new transmission projects affect exports to existing markets or incentivize new generation. We identify priority areas for data synthesis and model development, such as integrating linked hydropower and hydrologic interactions in energy system models and openly releasing (by utilities) or back-calculating (by researchers) hydropower generation and operational parameters. Publicly available environmental (e.g. streamflow, precipitation) and techno-economic (e.g. costs, reservoir size,) data can be used to parameterize freely usable and extensible models. Existing models have been calibrated with operational data from Canadian utilities that are not publicly available, limiting the range of scientific and commercial questions these tools have been used to answer and the range of parties that have been involved. Studies conducted using highly resolved, national-scale public data exist in other countries, notably, the United States, and demonstrate how greater transparency and extensibility can drive industry action. Improved data availability in Canada could facilitate approaches that (1) increase participation in decarbonization planning by a broader range of actors; (2) allow independent characterizations of environmental, health, and economic outcomes of interest to the public; and (3) identify decarbonization pathways consistent with community values.

13 HYDRO ENERGY↗

The status and prospects of materials for carbon capture technologies

In order to combat climate change, carbon dioxide (CO 2 ) emissions from industry, transportation, buildings, and other sources need to be captured and long-term stored. Decarbonization of these sources requires special types of materials that have high affinities for CO 2 . Potassium hydroxide is a benchmark aqueous sorbent that reacts with CO 2 to convert it into K 2 CO 3 and subsequently precipitated as CaCO 3 . Another class of carbon capture materials is solid sorbents that are usually functionalized with amines or have natural affinities for CO 2 . The next wave of materials for carbon capture under investigation includes activated carbon, metal–organic frameworks, zeolites, carbon nanotubes, and ionic liquids. In this issue of MRS Bulletin, some of these materials are highlighted, including solvents and sorbents, membranes, ionic liquids, and hydrides. Other materials that can capture CO2 from low concentrations of gas streams, such as air (direct air capture) are also discussed. Also covered in this issue are machine learning-based computer algorithms developed with the goal to speed up the progress of carbon capture materials development, and to design advanced materials with high CO 2 capacity, improved capture and release kinetics, and improved cyclic durability.

36 MATERIALS SCIENCE↗

An Action Plan for Maritime Energy and Emissions Innovation

The Action Plan for Maritime Energy and Emissions Innovation (the action plan) lays out a strategy to reduce and eliminate nearly all greenhouse gas (GHG) emissions in the U.S. maritime sector by 2050, in line with the U.S. economy-wide goal of net-zero GHG emissions by 2050. To reach this goal, the action plan outlines actions, objectives, targets, and activities to scale low- and net-zero emissions fuels, energies, and technologies; strengthen the maritime workforce; bolster shipbuilding capacity; and expand complementary landside infrastructure. The action plan supports industry, mariners, communities, civil society, sub-national governments, and other interested parties that will decarbonize the maritime sector alongside the U.S. government.

09 BIOMASS FUELS↗

Deep Electrification Analysis: The Role of the U.S. Power Grid for Sustainable Transportation

This project attempts to quantify the size of electric generation for the entire nation to transition from a fossil fuel based transportation sector to a zero GHG emission-based energy source. The scope of this analysis is limited to decarbonizing the transportation sector, leaving the remaining sectors, such as power (for those that are still fossil based), industry, and building sectors, for later phases of study. The study year for this analysis is 2050, with expected escalation in transportation services and naturally occurring evolutions in the electric power sector and the entire economy. This analysis uses the projections of the Energy Information Administration’s (EIA’s) Annual Energy Outlook (AEO 2020) Reference Case for study year 2050 [EIA/AEO2020] as a base-case. The transportation sector is disaggregated by the following modes and classes: (1) on-road (divided into light-duty, medium-duty, heavy-duty vehicles), (2) aviation, (3) maritime, and (4) rail. The decarbonization case was based on only 2 pathways: (1) electrification of on-road transportation except for 30% of heavy-duty vehicles, and (2) power-to-liquid for the remaining transportation modes. The study estimated for 11 US regions what the additional wind and storage capacities requirements are to replace the fossil-based fuels with renewable wind capacity. Considered were the utilization of the existing idle capacity particularly during the load valley at night and any additional new generation capacity in EIA projections for the reference case. To balance the additional wind capacity required significant energy storage capabilities which were estimated in terms of power capacity (GW) and energy capacity (GWh). The paper further characterizes the energy requirements by a relation of power capacity to duration, allowing the analyst to gain insights into what the best technology portfolio might be to meet the new balancing or flexibility needs.

24 POWER TRANSMISSION AND DISTRIBUTION↗

Industrial Load Flexibility, the U.S. Power Grid and Ammonia

A variable renewable power grid is a new technological regime that involves real time harvesting and low-cost availability of energy resources coupled with storage to meet additional needs. Decarbonization through electrification of end uses formerly met by combustion processes will be a concurrent trend. Taken together, these two changes may make flexibility on the demand side more valuable to the grid and to industrial users. Industry accounted for 26% of US power demand in 2021. Traditionally, industrial processes for producing ammonia and other basic materials have been optimized for a system based on fossil resources, where energy can be called upon according to needs. Large capital expenditures as well as safety considerations have favored plants running at steady state at close to their maximum capacity. It is possible, however, that the renewable energy transition will offer opportunities to sectors that can operate in a more flexible manner. Innovations that make use of flexibility to enhance their business model to move forward, individuals and groups active in their development, use and regulation, together with institutions and infrastructures, can be considered as a technological innovation system (TIS). Beyond economic and technical factors on their own, the TIS is an important analysis framework for studying the development and diffusion of technologies. This work attempts to map the TIS of flexible industrial loads and their interaction with electric power in the US, with a particular focus on ammonia as a case study. We have conducted interviews with stakeholders involved in ammonia projects, working in system operators, trade groups, regulators and utilities. We assess to what extent a technological innovation system is functioning and document characteristics that allow industries to operate flexibly.

ammonia↗

Nuclear Thermal Energy Storage Configurations for Industrial Combined Heat and Power Supply: Conceptual Study and Engineering Designs

The industries examined in this report primarily rely on moderate-temperature heat provided by gas- or coal-fired boilers and combined heat and power (CHP) plants, delivered through standard process steam systems. High-temperature energy demands are often industry-specific and typically exceed the capabilities of high-temperature gas-cooled reactors (HTGRs). While it is technically feasible to replace process steam from fossil-based heat sources with nuclear energy, certain industries, such as methanol production and pulp and paper, face technoeconomic challenges in integrating nuclear energy without major changes or a technological shift. This is mainly due to the limited external energy demand remaining after the use of internal byproducts, waste heat recovery, and simple efficiency improvements. Achieving full decarbonization of these processes with nuclear energy would require significant technological advancements, involving experimental technology and substantial investments, making widespread adoption in existing industrial plants unlikely in the near term. This study reviews TES options in the context of enabling a flexible CHP supply while maintaining a steady nuclear heat input. Heat storage systems that interface between the reactor primary fluid and the CHP system offer superior performance and flexibility. Specifically, steam extraction downstream of the reheater with a two-tank molten-salt TES appears as the best solution regarding thermodynamic system benefits and system drawbacks. Using selected system configurations, a conceptual design of an industrial energy park was developed for industries with varying energy demands, such as steel production plants utilizing electric arc furnaces (EAFs) and chemical plants, as well as for those with constant energy demands, like petroleum refineries. This design highlights the capabilities of TES and explores its potential business cases. The study also conceptually develops the potential for integrating additional energy sources with nuclear systems through the implementation of TES. The potential of the HTGR-TES-CHP system was also evaluated considering key uncertainties such as industrial demand profiles, external grid access availability, and eligible tax credit levels, using the Holistic Energy Resource Optimization Network. Sensitivity of net present value to these uncertainties was analyzed to determine the optimal number of nuclear reactors (and CHP systems) and the suitable TES capacity. The results were interpreted from a decision-maker’s perspective, focusing on three key areas: deployment strategy (oversized units vs. undersized units with TES support), industrial process characteristics (thermal-intensive single profiles vs. electricity-intensive combined profiles), and operational goals (maximizing profits vs. minimizing natural gas (NG) consumption or external grid dependence). The optimization results indicate that the HTGR-TES-CHP system significantly reduces reliance on NG boilers for individual industrial processes by 9-60% (in NG capacity factor), with an average reduction of 38%, compared to standalone NG boiler operation case (Business As Usual [BAU]). For combined industrial processes, the reduction ranges from 37-77%, with an average of 60%. Additionally, the system greatly reduces dependence on external grids. In meeting industrial electrical demands, a 33-100% self-sufficient internal electricity supply is achieved for single industrial process, with an average of 74%, compared to the BAU scenario, where 100% of electricity is imported. For combined processes, 35-100% of internal electricity demands are met by the reactor, with an average of 73%. At last, the relative NG price levels at which the proposed HTGR-TES-CHP system can cost-effectively enter the market currently dominated by existing NG boilers were estimated. For a moderate HTGR CAPEX level ($\$$2500/kWth, $\$$6329/kWe), the analysis suggests that NG prices must be 2.5 to 7 times higher than HTGR variable operating and maintenance costs for single industrial process, and 5.5 to 9.5 times higher for a combined process scenario. Tax credit modeling shows that the Investment Tax Credit significantly reduces the price threshold needed to break even, making the system competitive with NG boilers in certain cases.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

Can section 45Q tax credit foster decarbonization? A case study of geologic carbon storage at Acid Gas Injection wells in the Permian Basin

Carbon capture, utilization, and storage (CCUS) is an important pathway for meeting climate mitigation goals. While the economic viability of CCUS is well understood, previous studies do not evaluate the economic feasibility of carbon capture and storage (CCS) in the Permian Basin specifically regarding the new Section 45Q tax credits. We developed a technoeconomic analysis method, evaluated the economic feasibility of CCS at the acid gas injection (AGI) wells, and assessed the implication of Section 45Q tax credits for CCS at the AGIs. We find that the compressors, well depth, and the permit and monitoring costs drive the facility costs. Compressors are the predominant contributors to capital and operating expenditure driving the levelized cost of CO 2 storage. Strategic cost reduction measures identified include 1) sourcing of low-cost electricity and 2) optimizing operational efficiency in well operations. In evaluating the impact of the tax credits on CCS projects, facility scale proved decisive. We found that facilities with an annual injection rate exceeding 10,000 MT storage capacity demonstrate economic viability contingent upon the procurement of inputs at the least cost. The new construction of AGI wells were found to be economically viable at a storage capacity of 100,000 MT. The basin is heavily focused on CCUS (tax credit – $\$$65/MT CO 2 ), which overshadows CCS ($\$$85/MT CO 2 ) opportunities. Balancing the dual objectives of CCS and CCUS requires planning and coordination for optimal resource and pore space utilization to attain the basin's decarbonization potential. We also found that CCS on AGI is a lower cost CCS option as compared to CCS on other industries.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

Comparing net zero pathways across the Atlantic A model inter-comparison exercise between the Energy Modeling Forum 37 and the European Climate and Energy Modeling Forum

Europe and North America account for 32 % of current carbon emissions. Due to distinct legacy systems, energy infrastructure, socioeconomic development, and energy resource endowment, both regions have different policy and technological pathways to reach net zero by the mid-century. Against this background, our paper examines the results from the net zero emission scenarios for Europe and North America that emerged from the collaboration of the European and American Energy Modeling Forums. Here, in our analysis, we perform an inter-comparison of various integrated assessments and bottom-up energy system models. A clear qualitative consensus emerges on five main points. First, Europe and the United States reach net zero targets with electrification, demand-side reductions, and carbon capture and sequestration technologies. Second, the use of carbon capture and sequestration is more predominant in the United States due to a steeper decarbonization schedule. Third, the buildings sector is the easiest to electrify in both regions. Fourth, the industrial sector is the hardest to electrify in the United States and transportation in Europe. Fifth, in both regions, the transition in the energy mix is driven by the substitution of coal and natural gas with solar and wind, but to a different extent.

100 % renewables↗

Abstract for CRADA between NETL and Equinor U.S. Holdings Inc.

The focus of this collaboration is to offer narrative and analysis across life cycle GHG emissions of the proposed hydrogen hub, techno-economic and market factor analyses informed insights on transportation and storage for hydrogen, and the development of social justice and workforce readiness plans to introduce the hydrogen economy to Appalachia. The proposed work also includes supporting narrative and analysis to achieve market adoption of hydrogen and follow-on investments to build out a national clean hydrogen network. The outcome of this collaboration will enable Equinor to respond to the Region Clean Hydrogen Hub FOA 2779 most effectively and to decarbonize and effectively develop a hydrogen market in Appalachia, while enhancing NETL’s modeling through direct industry collaboration. Learnings and improvements will be incorporated into future updates of NETL’s mechanisms, tools, and insights.

08 HYDROGEN↗

Uncovering hidden market opportunities for advanced nuclear reactors

Decarbonizing to meet aggressive climate change mitigation targets requires energy transition within all sectors. In the industrial sector, global emissions will need to decrease by 65–90% by 2050 to avert warming greater than 1.5°C (Pörtner et al., 2022). Recent U.S. laws, including the Inflation Reduction Act (IRA), Bipartisan Infrastructure Law (BIL), Defense Production Act, Creating Helpful Incentives to Produce Semiconductors (or CHIPS), state programs, and other recent laws, have clean energy requirements and provide financial incentives to accelerate the use of clean energy technologies in the industrial sector. These new laws include supporting mechanisms with direct financial support for nuclear power (e.g., advanced reactor development and hydrogen production). However, advanced nuclear could also gain these financial benefits by coupling with low-carbon industrial projects. For example, microreactors could supply low-carbon energy to producers of critical metals that (1) are eligible to receive investment and production tax credits and favorable loans, and (2) the low-carbon product could gain preference in emerging markets for green products.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Analyzing the Inflation Reduction Act and the Bipartisan Infrastructure Law for Their Effects on Nuclear Cost Data

Decarbonizing to meet aggressive climate change mitigation targets requires energy transition within all sectors. In the industrial sector, emissions will need to decrease by 65–90% by 2050 to avert global warming greater than 1.5°C (IPCC 2022). The Inflation Reduction Act (IRA), Bipartisan Infrastructure Law (BIL), and Defense Production Act (DPA) have clean energy requirements and provide financial incentives to accelerate the use of clean energy technologies in the industrial sector. It is important to note that IRA is the most extensive action ever taken by Congress and the U.S. government to combat climate change (US CBO 2021, 2022). The energy system provisions comprise most of the estimated climate and energy support. A better understanding of those provisions in the above mentioned acts and laws is crucial to assessing their impact on the equivalent energy costs to the power plant owners (impact on net revenue in $/MWh) across different energy technologies, market deployment potential offered to different energy technologies applications, and energy system research modeling. The purpose of the report is to shed light on IRA and BIL provisions with particular attention to impacts on the nuclear industry. The report also seeks to understand potential equivalent energy cost savings for nuclear energy technologies from other laws and programs in conjunction with IRA, BIL, loan program guarantees, and DPA. The report reviews recent legislation on energy policy and translates that policy to impacts on equivalent nuclear costs for the purpose of modeling policy in energy scenarios.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

Uruguay's Action Plan and Experience for Power Sector Decarbonization

A collaborative report from the Clean Energy Ministerial (CEM), Lessons Learned for Rapid Decarbonization of Power Sectors, was delivered to energy ministers and presented at the 13th CEM (CEM13) in the United States in September 2022. In light of these lessons learned and discussed at CEM13, several jurisdictions signaled intent to develop Action Plans for power sector decarbonization. The first cohort of Action Plans was released at CEM14 in India in July 2023. The Uruguay Ministry of Industry, Energy and Mining is pleased to release this Action Plan as a contribution to the second cohort of Action Plans released at CEM15 in Brazil in October 2024. The Action Plans, supported by the 21st Century Power Partnership, and other CEM workstreams via direct technical assistance and capacity building, are intended to focus on select implementation actions given each country's existing power sector goals and activities, and are an opportunity for countries to display leadership in power sector decarbonization. The Action Plans are organized in a framework for planning, building, and operating, as well as stakeholder engagement where appropriate based on country priorities. They complement, but are differentiated from, other international power sector initiatives such as the Breakthrough Agenda (whose broad purpose is to raise collective ambition) and the Global Power System Transformation Consortium (whose goals are to convene power system operators to accelerate research innovations and foster peer learning). These Action Plans are voluntary, developed by each country individually, not comprehensive of all activities within the jurisdiction, and are living documents that are subject to change.

21st Century Power Partnership↗

New Generation Resources: Advanced Reactors, Fusion, Hydrogen

Decarbonization of the global economy in the near term necessarily focuses on current energy options for industrial and consumer applications. In addition, new carbon-free energy resources with higher power density are essential for a full energy transition and continued energy evolution (Smil 2021). In this article we examine opportunities and challenges to be addressed for advanced nuclear, hydrogen, and fusion energy.

McCarthy, Kathryn A.↗

Supply and Demand Drivers of Global Hydrogen Deployment in the Transition toward a Decarbonized Energy System

The role of hydrogen in energy system decarbonization is being actively examined by the research and policy communities. We evaluate the potential ‘hydrogen economy’ in global climate change mitigation scenarios using the Global Change Analysis Model (GCAM). We consider major hydrogen production methods in conjunction with delivery options to understand how hydrogen infrastructure affects its deployment. We also consider a rich set of hydrogen end-use technologies and vary their costs to understand how demand technologies affect deployment. We find that the availability of hydrogen transmission and distribution infrastructure primarily affects the hydrogen production mix, particularly the share produced centrally versus onsite, whereas assumptions about end-use technology primarily affect the scale of hydrogen deployment. In effect, hydrogen can be a distributed energy vector, enabled by onsite renewable electrolysis and, to a lesser extent, by onsite industrial production using natural gas with carbon capture and storage (CCS). While the share of hydrogen in final energy is small relative to the share of other major energy carriers in our scenarios, hydrogen enables decarbonization in difficult-to-electrify end uses such as industrial high-temperature heat. Its contribution to greenhouse gas mitigation increases as the climate objective is tightened.

54 ENVIRONMENTAL SCIENCES↗

Net Zero World Initiative: Accelerating Global Energy System Decarbonization

The United States, partner countries and philanthropies are joining forces to accelerate the transition to clean, secure energy systems and build a Net Zero World. The Net Zero World Initiative leverages expertise across U.S. government agencies and Department of Energy (DOE) national laboratories, in partnership with other governments and philanthropies, to accelerate the decarbonization of global energy systems. This whole-of-government approach supports countries committed to raising their climate ambitions by creating and implementing highly tailored, actionable technical and investment strategies that put net zero within reach. The Net Zero World Initiative enables country partners to harness the power and technical expertise of U.S. and international industry, think tanks, and universities.

clean energy investment strategies↗

Decarbonizing nitrogen fertilizer production via the electrochemical nitrogen oxidation reaction

Nitric acid is an important commodity chemical with extensive applications in both agricultural and industrial sectors. However, current production methods involve a combination of the Haber–Bosch and Ostwald processes, which are both energy and carbon emission intensive. The electrochemical nitrogen oxidation reaction (NOR) to produce nitric acid or nitrates shows great potential as an environmentally friendly method for producing fertilizers under mild conditions. The key to progress in this field lies in understanding the fundamental mechanistic insights and establishing robust experimental methods, which is essential for the efficient design and synthesis of electrocatalysts for NOR. Additionally, poor gas mass transport in conventional electrochemical reactors at present lead to lower NOR activity, thereby limiting the progress in this field. In this work, we present a synergistic computational and experimental approach to map out the potential chemical and electrochemical steps and determine the energetics on PtO 2 catalyst to gain mechanistic insights into NOR. Here, this study marks the first attempt to perform NOR in a vapor-fed reactor designed using advanced (additive) manufacturing. The vapor-fed reactor significantly improved the N 2 mass transport to the catalyst, allowing us to report the highest rate for nitrate production to date at 3.3 μmol cm -2 h -1 at 2.01 V vs RHE.

30 DIRECT ENERGY CONVERSION↗

Techno-Economic Analysis of Cement Decarbonization Techniques: Oxygen Enrichment vs. Hydrogen Fuel

The Paris Agreement aims to limit global warming, and one of the most polluting sectors is heavy industry, where cement production is a significant contributor. This work briefly explores some alternatives, recycling, reducing clinker content, waste heat recovery, and carbon capture, discussing their advantages and drawbacks. Then, it examines the economic viability and benefits of increasing oxygen concentration in the primary burning air from 21 to 27 vol.%, which could improve clinker production by 7%, and the production of hydrogen through PEM electrolysis to make up 5% of the fuel thermal fraction, considering both in a cement plant producing 3000 tons of clinker per day. This analysis used reference values from Secil, an international company for cement and building materials, to determine the required scale of the oxygen and hydrogen production, respectively, and calculate the CAPEX of each approach. It is concluded that oxygen enrichment can provide substantial fuel savings for a relatively low cost despite a possible significant increase in NOx emissions. However, hydrogen production at this scale is not currently economically viable.

Domingues, Bruno C.↗