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DOE OSTI2022

Electrification potential of U.S. industrial boilers and assessment of the GHG emissions impact

Electrification is a key strategy for decarbonizing the industrial sector. Industrial process heating, which still relies heavily on fossil fuel combustion and accounts for the majority of sector wide GHG emissions, is a particularly attractive electrification target. Electrifying industrial boilers represents a cross-cutting opportunity for GHG emissions reductions, given their widespread use in most manufacturing industries. Yet, there are gaps in the understanding of the current population of conventional industrial boilers in the United States that preclude a characterization of boiler electrification's technical potential to reduce fuel consumption and GHG emissions. In this study, we develop an up-to-date dataset of the industrial boiler population in the U.S. and quantify the county-level electricity requirements and net changes in fuel use and GHG emissions under the current electric grid and theoretical future grid scenarios. Our results show an increase of 105 MMmtCO 2 e and 73 MMmtCO 2 e in GHG emissions from boiler electrification, with and without the replacement of byproduct fuels, respectively, under the current electric grid, and a reduction of 19 MMmtCO2e and 7 MMmtCO2e in GHG emissions under a future high renewables electric grid. GHG emissions savings are currently possible only in certain regions of the U.S. unless future grids are decarbonized. We also provide discussion that could be useful for policy makers and manufacturing facilities for advancing the electrification of industrial boilers in locations and industries toward fuel savings and GHG emissions reductions.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2018

The geography of solar energy in the United States: Market definition, industry structure, and choice in solar PV adoption

The solar photovoltaic (PV) installation industry comprises thousands of firms around the world who collectively installed nearly 200 million panels in 2015. Spatial analysis of the emerging industry has received considerable attention from the literature, especially on the demand side concerning peer effects and adopter clustering. However this research area does not include similarly sophisticated spatial analysis on the supply side of the installation industry. The lack of understanding of the spatial structure of the PV installation industry leaves PV market research to rely on jurisdictional lines, such as counties, to define geographic PV markets. We develop an approach that uses the spatial distribution of installers' activity to define geographic boundaries for PV markets. Our method is useful for PV market research and applicable in the contexts of other industries. We use our approach to demonstrate that the PV industry in the United States is spatially heterogeneous. Despite the emergence of some national-scale PV installers, installers are largely local and installer communities are unique from one region to the next. The social implications of the spatial heterogeneity of the emerging PV industry involve improving understanding of issues such as market power, industry consolidation, and how much choice potential adopters have.

14 SOLAR ENERGY↗

DOE OSTI2025

Opportunities for iron and steel industrial wastewater treatment and reuse in the United States

Concerns around water security in the United States have heightened the interest in industrial water treatment and reuse to improve water efficiency and operational reliability. Alongside nationwide efforts to expand industrial capacity, primary manufacturing sectors are adopting more resource-efficient technologies. This transition is expected to shift industrial water consumption patterns, driving the need for improved treatment and reuse practices. This study investigates opportunities for water use, treatment, and reuse in the iron and steel sector through a review of academic and industry literature and interviews with industry representatives. It identifies key challenges in water and wastewater management and outlines the conditions under which innovative treatment technologies could be deployed. Based on these insights, the study presents a practical water management action plan. Furthermore, it assesses water quality targets across different process operations, evaluates existing treatment technologies, and highlights challenges and opportunities for improvement relative to future performance expectations. Although water is often perceived as a low-cost commodity, industry feedback suggests that improvements in water use and treatment efficiency are typically prioritized only when they also reduce energy use, carbon emissions, or costs. This study advocates for a direct two-way partnership between industry and research audiences to bring their attention toward sustainable industrial water use, treatment, and reuse.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2016

Generation and Use of Thermal Energy in the Industrial Sector and Opportunities to Reduce its Carbon Emissions

Changes are occurring throughout the U.S. economy, especially in regard to how energy is generated and used in the electricity, buildings, industrial, and transportation sectors. These changes are being driven by environmental and energy security concerns and by economics. The electric-sector market share of natural gas and variable renewable generation, such as wind and solar photovoltaics (PV), continues to grow. The buildings sector is evolving to meet efficiency standards, the transportation sector is evolving to meet efficiency and renewable fuels standards, and the industrial sector is evolving to reduce emissions. Those changes are driving investment and utilization strategies for generation and other assets. Nuclear and renewable energy sources are important to consider in the energy sector’s evolution because both are considered to be clean and non-carbon-emitting energy sources. The Idaho National Laboratory (INL) and the National Renewable Energy Laboratory (NREL) are jointly investigating potential synergies between technologies exploiting nuclear and renewable energy sources. The two laboratories have held several joint workshops since 2011. Those workshops brought together experts in both areas to identify synergies and potential opportunities to work together. Workshop participants identified nuclear-renewable hybrid energy systems (N-R HESs) as one of the opportunities and recommended investigating whether N-R HESs could both generate dispatchable electricity without carbon emissions and provide clean energy to industrial processes. They also recommended analyzing the potential for N-R HESs to provide dispatchable capacity to a grid with high penetrations of non-dispatchable resources and to investigate whether real inertia provided by thermal power cycles within N-R HESs provides value to the grid. This report is one of a series of reports INL and NREL are producing to investigate the technical and economic aspects of N-R HESs. Previous reports focused on tightly coupled N-R HESs. Previously, INL analyzed the dynamic performance of two hypothetical N-R HESs and NREL analyzed the optimal economic configurations and operation of the same two N-R HESs. The first of those two is a Texas-synthetic gasoline scenario that includes four subsystems: a nuclear reactor, thermal power cycle, wind power plant, and synthetic gasoline production technology. The second hypothetical N-R HES is an Arizona-desalination scenario with four subsystems: a nuclear reactor, thermal power cycle, PV, and a desalination plant. INL analyzed the technical performance of the same two N-R HESs in another report. In another report NREL used the Texas-synthetic gasoline scenario provides the basis; however, the industrial process was removed. Instead, that N-R HES sells heat directly to an industrial customer. Subsystems that convert electricity to heat were also included. Future analyses are planned for other N-R HES options including one where hydrogen is produced within an N-R HES. This report quantifies greenhouse gas (GHG) emissions from the industrial sector and identifies opportunities for non-GHG-emitting thermal energy sources, such as N-R HESs, to replace the most significant GHG-emitting U.S. industries based on targeted, process-level analysis of industrial heat requirements.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2018

MFIX-DEM Phi: Performance and Capability Improvements Towards Industrial Grade Open-source DEM Framework with Integrated Uncertainty Quantification

Two major challenges hinder the effective use and adoption of multiphase computational fluid dynamics tools by the industry. The first is the need for significant computational resources, which is inversely proportional to the accuracy of solutions due to computational intensity of the algorithms. The second barrier is assessing the prediction credibility and confidence in the simulation results. In this project, a multi-tiered approach has been proposed under four broad activities to overcome these challenges while addressing all of the objectives outlined in FOA-0001238 through Phases 1 and 2 of the project. The present report consists of the results for only Phase 1, which was the funded performance period. From the start the project, all of the objectives outlined in FOA were addressed through four major activity tasks in an integrated and balanced fashion to improve adoption of MFIX suite of solvers for industrial use. The first task aimed to improve the performance of MFIX-DEM specifically targeting to acquire the peak performance on Intel Xeon and Xeon Phi based systems, which are expected to be one of the primary high-performance computing platforms both affordable and available for the industrial users in the next two to five years. However, due to a number of changes in course of the project, the scope of the performance improvements related task was significantly reduced to avoid duplicate work. Hence, more emphasis was placed on the other three tasks as discussed below. The second task aimed at physical modeling enhancements through implementation of polydispersity capability and validation of heat transfer models in MFIX. An extended verification and validation (V&V) study was performed for the new polydispersity feature implemented in MFIX-DEM both for granular and coupled gas-solid flows. The features of the polydispersity capability and results for an industrially relevant problem were disseminated through journal papers (one published and one under review at the time of writing of the final technical report). As part of the validation efforts, another industrially relevant problem of interest based on rotary drums was studied for several modes of heat transfer and results were presented in conferences. Third task was aimed towards an important and unique contribution of the project, which was to develop a unified uncertainty quantification framework by integrating MFIX-DEM with a graphical user interface (GUI) driven uncertainty quantification (UQ) engine, i.e., MFIX-GUI and PSUADE. The goal was to enable a user with only modest knowledge of statistics to effectively utilize the UQ framework offered with MFIX-DEM Phi to perform UQ analysis routinely. For Phase 1, a proof-of-concept demonstration of the proposed framework was completed and shared. Direct industry involvement was one of the key virtues of this project, which was performed through forth task. For this purpose, even at the proposal stage, the project team received strong interest in the proposed capabilities from two major corporations, which were further expanded throughout Phase 1 and a new collaboration with another major corporation from chemical industry was also initiated. The level of interest received and continued collaboration for the project during Phase 1 clearly shows the relevance and potential impact of the project for the industrial users.

42 ENGINEERING↗

DOE OSTI2024

Generating Emissions Inventory for Carbon Capture and Storage Analysis for Carbon-Intensive Industrial Sectors

Decarbonizing the industrial sector is critical to achieve carbon dioxide (CO2) emissions reductions goals of the Biden Administration. Currently available decarbonization options include electrification, fuel switching to zero carbon fuels like green hydrogen (H2) and carbon capture and storage (CCS). Application of post-combustion carbon capture (PCCC) technology in the power sector, as well as research at the U.S. Department of Energy's Fossil Energy and Carbon Management (FECM) Office has shown that its application in the industrial sector could have co-benefits in the form of emissions reductions of non-CO2 regulated pollutants. For example, solvent based PCCC systems require pre-conditioning of flue gas to remove sulfur and particulate matter (PM) upstream of the CO2 absorber. However, there is a lack of understanding about the type of non-CO2 pollutants which can be captured and the amount of reduction possible. PCCC application differs across industrial sectors as it depends on the availability of decarbonization options, characteristics of industrial processes and the amount and composition of pollutant flows. Certain facilities can also have multiple effluent flows with or without a CO2 stream. As such, understanding industrial processes and their effluent flows in detail is required to quantify the co-benefits opportunities presented by PCCC. Considering this requirement, the goal of this analysis is to develop a high-resolution inventory of effluent flows from facilities of 8 industrial sectors in the U.S. These industrial sectors - ethanol, ammonia, cement, steel, natural gas processing, hydrogen, petroleum refining and wood and pulp products - have carbon-intensive effluent flows, and thus are prime candidates for PCCC applications. In this study, we map the composition of pollutant flow from flue stacks across the identified facilities. Using data available in three Environmental Protection Agency (EPA) databases - the Green House Gas Reporting Program (GHGRP), the National Emissions Inventory (NEI) and the Toxic Release Inventory (TRI), we create a combined inventory which lists the type, amount, and concentration of pollutant flows. Using total weight of the pollutant flow back calculated from observed data for CO2 concentrations in flue gas for individual sectors, we calculate the concentration of each pollutant in the flue gas stream. Thus, the resultant emissions inventory includes the following details for each facility in the sector: facility-level and if possible, process-level pollutant flows, concentrations of pollutants in the flue gas, and geographical coordinates of the facilities. A detailed statistical analysis and summary allows us to search for erroneous data and remove them from the final inventory. The generation of the inventory is achieved using a python-based framework which can recreate this inventory for other industrial sectors as well as using newer releases of emission inventories from EPA. The statistical analysis performed on the inventory is also calibrated and automated to identify outliers efficiently.

air pollutants↗

DOE OSTI2017

Updated Estimates of the Remaining Market Potential of the U.S. ESCO Industry

The energy service company (ESCO) industry has a well-established track record of delivering energy and economic savings in the public and institutional buildings sector, primarily through the use of performance-based contracts. The ESCO industry often provides (or helps arrange) private sector financing to complete public infrastructure projects with little or no up-front cost to taxpayers. In 2014, total U.S. ESCO industry revenue was estimated at $5.3 billion. ESCOs expect total industry revenue to grow to $7.6 billion in 2017—a 13% annual growth rate from 2015-2017. Researchers at Lawrence Berkeley National Laboratory (LBNL) were asked by the U.S. Department of Energy Federal Energy Management Program (FEMP) to update and expand our estimates of the remaining market potential of the U.S. ESCO industry. We define remaining market potential as the aggregate amount of project investment by ESCOs that is technically possible based on the types of projects that ESCOS have historically implemented in the institutional, commercial, and industrial sectors using ESCO estimates of current market penetration in those sectors. In this analysis, we report U.S. ESCO industry remaining market potential under two scenarios: (1) a base case and (2) a case “unfettered” by market, bureaucratic, and regulatory barriers. We find that there is significant remaining market potential for the U.S. ESCO industry under both the base and unfettered cases. For the base case, we estimate a remaining market potential of $92-$201 billion ($2016). We estimate a remaining market potential of $190-$333 billion for the unfettered case. It is important to note, however, that there is considerable uncertainty surrounding the estimates for both the base and unfettered cases.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2020

Outcomes of the DOE Workshop on Atmospheric Challenges for the Wind Energy Industry

The U.S. Department of Energy-funded Mesoscale-to-Microscale Coupling (MMC) project team planned and conducted a virtual Workshop on Atmospheric Challenges for the Wind Energy Industry on October 19 and 20, 2020. The goal of the workshop was to forge a dialog with the community, including industry representatives, on how modeling tools are currently being used, the present active atmospheric modeling research in support of wind energy, and required advancements in capabilities and technology to continue to advance wind energy deployment. The workshop was planned in collaboration with an industry advisory panel that included representatives from wind power plant developers, turbine manufacturers, and companies that provide resource assessment and forecasting services. The format of the workshop included panels from government research sponsors, visionaries from industry, and mixed panels of researchers discussing research status and needs. A shared keynote presentation from the Technical University of Denmark experts anchored the second day of the workshop. An emphasis was placed on understanding the research needs in the offshore environment. In addition, breakout opportunities were provided each day. On the first day, the breakout discussions addressed predesigned questions configured to elicit participants’ thoughts on needed research directions. The second-day breakouts treated three important technical topics through a combination of presentations and group conversations. Each workshop participant chose their breakout preference from among downscaling details, modeling for turbines, and using artificial intelligence for atmospheric modeling. The discussions were robust and productive. The outcomes of the workshop include archiving a series of recommendations from industry and the research community on research directions required to further advance wind energy deployment. Discussions confirmed the need for high-fidelity modeling but that there are specific areas of applicability and other areas where the time and cost of computation is prohibitive. In those cases, the high-fidelity models can inform low-order models that are more practical for real-time or widely deployed applications. Industry must consider the financial cost of performing more expensive modeling approaches, but industry engineers and researchers are using these approaches where there appears to be a return on investment. An emerging type of low-order model is based on machine learning (ML). Participants confirmed that there are many atmospheric phenomena that need to be modeled better, including low-level jets, cold air outbreaks, land-sea induced circulations, diurnal variability, thin stable boundary layers, dynamic changes such as from frontal passage, interaction of wakes and blockage, and more. For the offshore environment, there is wide agreement that some level of ocean-wave-atmospheric coupling is necessary to capture variations in rotor-level winds needed to plan and operate offshore wind plants. Another recurring recommendation is that more observations are needed, particularly for the offshore environment. Those observations should consider the needs for model improvement, both for physically based models and for ML models. Observations must capture atmospheric profiles of variables that are important to understanding and modeling atmospheric and oceanic phenomena that impact boundary layer winds. Models must be validated with data and the uncertainty quantified, particularly those that are sensitive to initial and boundary conditions. Finally, a repeated request was to consider the holistic needs of hybrid plants of wind, solar, and storage resources because those types of plants are likely to be the wave of the future. In addition, industry wishes to understand impacts of the resource under a changing climate for long-term planning.

17 WIND ENERGY↗

DOE OSTI2024

Hazards and Probabilistic Risk Assessments of Advanced Nuclear Reactors Coupled with Industrial Facilities

This report provides a roadmap and tool kit for site specific risk assessments across a broad range of industrial customers co-located with advanced nuclear power plants (ANPP) that are not currently built and operating in the U.S. This report builds upon the body of work sponsored by the Department of Energy (DOE) Integrated Energy Systems Pathway that has produced industrial requirements studies and techno-economic assessments on the topics of feasibility of ANPP supported industrial processes. This report also leverages the DOE Light Water Reactor Sustainability (LWRS) program that has presented hazards assessment and generic probabilistic risk assessments (PRAs) for the addition of a heat extraction system (HES) to light-water reactors (LWRs) co-located with hydrogen production facilities. Many of the hazard assessments and risk assessments performed for the LWRS report are agnostic to whether the nuclear reactor is an ANPP or were adapted to the ANPP focus. The report performs hazards assessments to include industrial facilities: an oil refinery, a methanol plant, a synthetic fuel (synfuel) plant, the production of synthetic gas (syngas) as part of the methanol and synfuel plants, wood pulp and paper mills, and hydrogen production. Hydrogen production facilities are assessed in depth through prior reports in the LWRS program and the results are leveraged in this report. All these facilities are specified through industrial process and requirements research performed by national laboratories, universities, and interaction with industry. Many of the processes used in this report are pre-conceptual designs to use for decarbonization of the current technology facilities. A process of failure modes and effects analysis (what can go wrong) and accidentology (what has historically gone wrong) was used to determine the hazards presented to the nuclear power plant by the addition of the HES and the industrial customer. Chemical properties of feedstocks and products are summarized as part of the hazards assessment. Example analysis procedures are provided for each of the hazard types identified. These deterministic analyses can be used to assess adherence to licensing criteria. They can also be used to meet other safety goals like protection of the public, workers, or industrial facility equipment. A modular high temperature gas-cooled reactor (MHTGR) PRA only existing on paper was modeled and verified in modern PRA software. This will provide a tool for representative ANPP probabilistic analyses for future research.

10 SYNTHETIC FUELS↗

NASA NTRS1971

A continuing program for technology transfer to the apparel industry

A six month program has been carried out to investigate various mechanisms for transferring technology to industry. This program has focused on transfer to the apparel industry through the Apparel Research Foundation. The procedure was to analyze the problem, obtain potentially relevant aerospace technology, and then transfer this technology to the industry organization. This was done in a specific case. Technology was identified relevant to stitchless joining, and this technology was transferred to the Apparel Research Foundation. The feasibility and ground rules for carrying out such activities on a broader scale were established. A specific objective was to transfer new technology from the industry organization to the industry itself. This required the establishment of an application engineering program. Another transfer mechanism tested was publication of solutions to industry problems in a format familiar to the industry. This is to be distinguished from circulating descriptions of new technology. Focus is on the industry problem and the manager is given a formula for solving it that he can follow. It was concluded that this mechanism can complement the problem statement approach to technology transfer. It is useful in achieving transfer when a large amount of application engineering is not necessary. A wide audience is immediately exposed to the technology. On the other hand, the major manufacturing problems which require a sophisticated technical solution integrating many innovations are less likely to be helped.

Clingman, W. H.↗

NASA NTRS2016

Kickstarting a New Era of Lunar Industrialization via Campaign of Lunar COTS Missions

To support the goals of expanding our human presence and current economic sphere beyond LEO, a new plan was constructed for NASA to enter into partnerships with industry to foster and incentivize a new era of lunar industrialization. For NASA to finally be successful in achieving sustainable human exploration missions beyond LEO, lessons learned from our space history have shown that it is essential for current program planning to include affordable and economic development goals as well as address top national priorities to obtain much needed public support. In the last 58 years of NASA's existence, only Apollo's human exploration missions beyond LEO were successful since it was proclaimed to be a top national priority during the 1960's. However, the missions were not sustainable and ended abruptly in 1972 due to lack of funding and insufficient economic gain. Ever since Apollo, there have not been any human missions beyond LEO because none of the proposed program plans were economical or proclaimed a top national priority. The proposed plan outlines a new campaign of low-cost, commercial-enabled lunar COTS (Commercial Orbital Transfer Services) missions which is an update to the Lunar COTS plan previously described. The objectives of this new campaign of missions are to prospect for resources, determine the economic viability of extracting those resources and assess the value proposition of using these resources in future exploration architectures such as Mars. These missions would be accomplished in partnership with commercial industry using the wellproven COTS Program acquisition model. This model proved to be very beneficial to both NASA and its industry partners as NASA saved significantly in development and operational costs, as much as tenfold, while industry partners successfully expanded their market share and demonstrated substantial economic gain. Similar to COTS, the goals for this new initiative are 1) to develop and demonstrate cost-effective, cis-lunar commercial services, such as lunar transportation, lunar mining and lunar ISRU operations; 2) enable development of an affordable and economical exploration architecture for future missions to Mars and beyond; and 3) to incentivize the creation of new lunar markets through use of lunar resources for economic benefit to NASA, commercial industry and the international community. These cost-effective services would not only enable NASA to economically and sustainably achieve its human exploration missions to the Moon, Mars and beyond but it would also kickstart a new era of lunar industrialization. This paper will describe the goals, objectives and approach for implementing this new campaign of missions. It will also describe the potential benefits and progress that can be accomplished with these low-cost, Lunar COTS missions. Lastly, a preliminary economic analysis approach is proposed for understanding the cost and potential return on investment in the use of lunar resources to reach the goal of lunar industrialization and an expanded and sustainable human presence into cis-lunar space and beyond.

Lunar Exploration↗

DOE OSTI2020

INDUSTRY ENGAGEMENT TO ESTABLISH A ROBUST SECURITY APPROACH TO MOBILE RADIOACTIVE SOURCES

The mobile radiological sources used in the well-logging and radiography industries are of sufficient curie quantities to be categorized as desirable material for malicious actors. Beyond the security risk posed by these sources, there is also an understanding of the potential damage, both reputational and monetary, that a lost source would have on the licensee and the industry overall. Identifying and communicating the risk these sources pose with impacted stakeholders is a critical first step in developing a security approach. Common day-to-day operations within both industries drive the unique security challenge of mobile sources. From storage facilities, transportation vehicles, temporary storage locations, and use in the field, each phase creates challenges regarding source control and accountability. All aspects of the operational use of these sources needs to be fully understood in order to address security equipment enhancements, policies, procedures, and training. This paper will leverage more than ten years of experience that ORS has gained working closely with industry partners and mobile radiological source users across the well-logging and radiography industries. It will identify the risk posed by mobile radiological sources, clearly define the operational phases of each industry, identify security best practices of mobile sources, and discuss what long-term, sustainable security looks like within these industries. In addition, it will explore areas of a robust security approach that are not commonly given priority in these industries, such as alarm adjudication and response.

Office of Radiological Security↗

DOE OSTI2015

2015 Summary Report on Industrial and Regulatory Engagement Activities

The Advanced Instrumentation, Information, and Control (II&C) Systems Technologies pathway of the Light Water Reactor Sustainability(LWRS) Program conducts a vigorous engagement strategy with the U.S. nuclear power industry, including the nuclear operating companies, major support organizations, the Nuclear Regulatory Commission (NRC), and suppliers. The goal of this engagement strategy is to develop a shared vision and common understanding across the nuclear industry of the need for II&C modernization, the performance improvement that can be obtained, and the opportunities for collaboration to enact this vision. The primary means of engaging the nuclear operating companies is through a Utility Working Group (UWG), composed of utility representatives that participate in formal meetings and bi-monthly phone calls to provide input on nuclear plant needs and priorities for II&C technologies. Two working groups were initiated during FY 2015 to provide a means for UWG members to focus on particular technologies of interest. The Outage Improvement Working Group consists of eight utilities that participate in periodic conference calls and have access to a share-point web page for acccess to project materials developed in the Advanced Outage Control Center pilot project. In the area of computer-based procedures and automated work packages, the II&C Pathway has worked with the Nuclear Information Technology Strategic Leadership (NITSL) to set up a monthly conference call with interested utility members to discuss various aspects of mobile worker technologies. Twenty one technical and project reports were delivered to the UWG during FY 2015, reflecting the work of the II&C Pathway pilot projects during the year. Distribution of these reports is one of the primary means of transferring to the nuclear industry the knowledge and experience gained during the development of advanced II&C technologies in support of LWR sustainability. Site visits to discuss pilot project activities and future plans were made to Arizona Public Service, Exelon, Duke Energy, Pacific Gas & Electric, SCANA, Southern Nuclear, South Texas Project, STARS Alliance, Tennessee Valley Authority, and Xcel. Discussions were also held on the pathway goals and activities with major industry support organizations during FY 2102, including the Institute of Nuclear Power Operations (INPO), the Nuclear Information Technology Strategic Leadership (NITSL), the Nuclear Energy Institute (NEI), and the Electric Power Research Institute. The Advanced II&C Pathway work was presented at five major industry conferences and Informal discussions were held with key NRC managers at industry conferences. In addition, discussions were held with NRC senior managers on digital regulatory issues through participation on the NEI Digital I&C Working Group. Meetings were held with major industry suppliers and consultants, to explore opportunities for collaboration and to provide a means of pilot project technology transfer. In the international area, discussions were held with Electricite’ de France (EdF) concerning possible collaboration in the area NPP configuration control using intelligent wireless devices.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2025

Low-Cost Sulfur Thermal Storage for Solar Industrial Process Heat Applications

Industrial process heat (IPH) is one of the largest energy demands in U.S., representing about 10% of all domestic energy consumption. Fuel costs to generate this industrial process heat are generally a top three cost for industry, a major component in American manufacturing competitiveness. Roughly 60% of US IPH demand (about 6,500 TBtu annually) falls in the medium-temperature range of 100–250 °C. While concentrated solar thermal (CST) technologies can provide a cost-effective source of heat in this temperature range, solar intermittency limits their adoption in industries that operate 24/7. Element 16 Technologies, Inc. developed a low-cost sulfur thermal energy storage (TES) technology to bridge this gap by capturing excess solar heat during the day and dispatching it reliably during non-solar hours. The core innovation is the use of sulfur, an abundant, industrial waste byproduct that costs ten times less than molten salt used in commercial TES systems. The overall goal of the project was to advance the design and development of molten sulfur TES to a manufacturing-relevant prototype stage for solar industrial process heat applications, while establishing and validating a realistic pathway to commercial success. Key tasks included corrosion and mechanical durability testing to identify cost-effective materials, design investigations using physics-based simulation tools, techno-economic evaluations of system lifetime costs, and pilot-scale testing for performance verification. Corrosion testing of steel alloys under cyclic molten sulfur conditions showed that austenitic stainless steels in the 300 series performed particularly well, with no structural degradation of welds or joints. Thermal cyclic testing of pilot sulfur TES units up to 1.5 MWh quantified charge/discharge rates, heat losses, round-trip efficiency and validated the system's capability to operate effectively under intermittent charging conditions. A techno-economic model, informed by sulfur TES performance model validated using pilot test data, showed that hybrid solar+sulfur TES+NG boiler systems are economically competitive with incumbent natural gas boilers for multiple locations in the southwest US. In summary, this project established molten sulfur TES as a technically viable pathway to improve economic competitiveness of American manufacturing by lowering the cost of solar industrial process heat.

14 SOLAR ENERGY↗

DOE OSTI2023

Energy Efficiency as a Foundational Technology Pillar for Industrial Decarbonization

The U.S. government aims to achieve net-zero greenhouse gas emissions by 2050 to reduce the severe impacts of climate change. The U.S. industrial sector will become a focal point for decarbonization since it accounts for 33% of the nation’s primary energy use and 30% of its energy-related CO2 emissions. Industrial emissions are also expected to increase by 15% through 2050, making the industrial sector a logical target for decarbonization efforts. Energy efficiency technology pathways provide low-cost, foundational routes to decarbonization that can be implemented immediately. Energy efficiency technology pathways, such as strategic energy management, system efficiency, smart manufacturing, material efficiency, and combined heat and power, are well established and would immediately reduce energy use and emissions. However, their role in the aggressive net-zero decarbonization pathway for the industrial sector is still unclear. This study aims to address energy efficiency pathways for decarbonization, and reviews studies related to these technologies for industrial decarbonization through 2050. This study identifies different strategies for the industrial sector in general and that are specific to six energy-intensive industries: iron and steel; chemical; food and beverage; petroleum refining; pulp and paper; and cement. Finally, a path toward the successful implementation of energy efficiency technologies is outlined.

Strategic energy management↗

DOE OSTI2018

Environmental licensing in Brazilian's crushed stone industries

Highlights: • Failures in environmental reporting compromise the effectiveness of the environmental license process • The infrastructure of environmental agencies must be improved • The participation of society is essential for monitoring industries - Abstract: The crushed stone industries' activities are characterized by the extraction and processing of stones for use as aggregates in construction. The sector causes environmental impacts that can be mitigated by the implementation of control instruments, namely, environmental licensing, whose purpose is to carry out monitoring of potentially polluting activities. In this paper, it was analyzed the environmental studies of three industries located in Monsenhor Gil, Piauí, Brazil, elaborated as requisites for obtaining the environmental and mineral licenses. There were made visits to the State Department of Environment and Water Resources (SEMAR) and to the National Department of Mineral Production (DNPM) to verify the environmental reports and the environmental and mineral licensing processes. There were also made visits to the analyzed industries, with the aim of comparing the information contained in the studies, with the reality and verifying the implementation of the mitigating measures proposed in them, through the observation of the industries operation, and interviews with the responsible managers. Furthermore, it was made a research in the scientific literature, to know the licensing process in other countries, to compare with the Brazilian reality. From the research, in Brazilian industries, it was observed that, although all the legal steps to obtain the licenses have been fulfilled, the environmental reports have elaboration failures, such as the lack of a multidisciplinary team and the fact that some data diverge from the reality, decreasing the reliability of the evaluation of the environmental impacts caused by the projects. Also, the environmental replacement cost is not accounted in the final value of the product, and any of the industries have started the implementation of the proposed mitigation measures since they do not have mineral depletion areas. SEMAR was delayed in issuing licenses within the period established by law, and there are no periodic inspections by both the environmental agency and DNPM. It should also be pointed out that the community did not claim public hearings and there is no participation in environmental education projects, factors that compromise the effectiveness of the environmental licensing process. Regarding the process in other parts of the world, in some countries, such as Uruguay and Paraguay, the agency responsible for licensing and inspection is federal. In Argentina, as in Brazil and USA, states have autonomy to legislate on environmental issues. There is also divergence in the period of execution of the licenses, being 12 months in Brazil, while in Thailand it can be up to 56 days. In Peru, the society participation is much more representative than in Brazil, and there is differentiation in the collection form of environmental compensation fees, among countries. The failures pointed out in the Brazilian process, as well as the system of other countries, can serve as parameters for the improvement of the process' effectiveness, both in Brazil and in other parts of the world, aiming at the conservation of the environment.

54 ENVIRONMENTAL SCIENCES↗

DOE OSTI2022

Bottom-up assessment of industrial heat pump applications in U.S. Food manufacturing

Decarbonization of the industrial process heat supply through electrification could contribute significantly to climate change mitigation efforts. In the U.S. industry, thermal processes accounted for more than two-thirds of the total final energy demand in 2021. Cross-cutting electrification technologies like industrial heat pumps are suitable for the process heat supply to several industrial unit operations in a sustainable way while also improving overall energy efficiency. This study employs a bottom-up approach to investigate the techno-enviro-economic potentials of deploying high-temperature and steam-generating heat pumps in the major U.S. food manufacturing sectors in different timeframes. The results show that the annual technical potential energy and CO 2 savings by electrifying process heat supply are 325 PJ (or approximately 20% of the total final energy demand in U.S. food manufacturing) and 31 MtCO 2 (equivalent to the annual CO 2 emissions from over 6 million cars in the U.S.) in 2050, respectively; however, these incur additional costs in each sector. Although there may be individual cost-effective opportunities for electrifying heat supply in specific industrial sites, the overall costs are estimated to be high in the food sectors due to the large disparity between electricity and natural gas prices and low heat source temperatures. To overcome the identified techno-economic barriers, comprehensive action plans for different stakeholders are needed. In conclusion, this study provides novel insights that should inform policymakers’ and executives’ decisions about the electrification of the current and future U.S. industrial heat supply in relevant industrial sectors.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗

DOE OSTI2019

Cost curve of large-scale deployment of CO2-enhanced water recovery technology in modern coal chemical industries in China

China has emerged as a world leader in the coal chemical industry, which requires large amount of water and results in considerable CO2 emissions. This situation has led to the challenge of the CO2-Water nexus for China and particularly for the sustainable development of its coal chemical industry. CO2-enhanced water recovery (CO2-EWR) technology can provide large-scale CO2 mitigation and additional water supply in an integrated manner, especially in arid areas. Meanwhile, CO2 streams from industrial separation processes in the coal chemical industries are amenable to separation and can dramatically simplify or even dispense with the capture process. This study presents the first systematic assessment of a cost curve for onshore CO2-EWR potential using CO2 streams from industrial separation processes by an evaluation framework encompassing CO2 emission inventory, site suitability evaluation, and source–sink matching with techno-economic models. Preliminary results focused on the full capacity of several coal chemical processes as of 2015 suggest that CO2-EWR technology can mitigate 269 million tons of CO2 from industrial separation processes at relatively low cost ranging from 12 to 30 USD/t CO2 in China. Furthermore, 404 million tons of underground water could be produced for further desalination and utilization. When additional capacity under development could become fully operational, the emissions of 878 million tons of CO2 could be mitigated and provide 1318 million tons of vital water resources. Therefore, CO2-EWR technology can be essential to clean and sustainable development of the coal chemical industry and may provide low-cost opportunities to accelerate the deployment of large-scale CCUS projects in China.

CO2-enhanced water recovery, Modern coal chemical ↗