Current state and future projections of drying processes in the US food and pulp and paper sectors: Energy, economic, and environmental assessment
The pulp and paper (P/P) and food sectors are the third- and fifth-largest industrial energy consumers in the United States, with total on-site energy consumption of 2,039 TBtu and 1,144 TBtu, respectively. Thermal drying processes for moisture removal, which are energy-intensive, play a critical role in both industries. This study is the first to evaluate state- and national-level US drying energy demand for these sectors from 2020 to 2050. To complete this evaluation, we developed a thermodynamic modeling framework integrated with economic and environmental models to compute product-specific drying energy intensity and estimate the sector-specific costs and emissions profiles associated with drying operations. The model-predicted energy intensity was validated against the literature. Using current and projected annual production volumes in these sectors, we estimated total drying energy use. Results indicate that drying accounts for 22 % of total energy consumption in the P/P sector and 10 % in the food sector. The estimated annual energy cost (2020) to operate thermal dryers is $\$$919 M in the P/P sector and $\$$417 M in the food sector. Additionally, drying contributes to 25 % of total CO 2 e emissions in the P/P sector (including biogenic) and 15 % of emissions in the food sector. Regional performance shows that the Southern US is the leading energy consumer for P/P drying, whereas the Midwest leads in food drying. This study presents both potential solutions to enhance drying efficiency and barriers to implementation. Energy efficiency improvements, low-carbon fuels, and electrification are discussed as key pathways for reducing costs and optimizing industrial drying processes.