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Industrial Electrification Assessment Framework

Electrification refers to the process of transitioning from fuel-powered systems to electric-powered systems, or electrotechnologies. This document first provides an overview of industrial electrification, including possible advantages and common applications. Next, it provides a comprehensive, step-by-step framework for assessing the potential for electrification at an individual industrial facility. The steps in this framework include inventorying current fuel-powered systems, evaluating a manufacturing facility’s electrification readiness, and identifying, evaluating, and prioritizing strategies and technologies. This document also contains information about project implementation, and the appendices provide tools and resources to support organizations pursuing electrification.

29 ENERGY PLANNING, POLICY, AND ECONOMY

Industrial Electrification Technologies Booklet

Electrification refers to transitioning from fuel-powered systems to electrically-powered alternatives. In an industrial context, this primarily refers to the electrification of process heat, but there are also widespread opportunities to electrify space heating and cooling as well as onsite transportation (e.g., forklifts). Electrification does not refer to one particular technology, but a wide range of technologies that use different methods to transfer electrical energy into a usable form – usually heat.

29 ENERGY PLANNING, POLICY, AND ECONOMY

Transforming the Process Industries through Electrification: Challenges and Opportunities

For the more than 70 years, the process industries have provided essential fuels and materials for global growth. Increased manufacturing production comes with substantial environmental impact. Reducing environmental impact through process electrification, carbon capture, and other emerging technologies would require large changes throughout the process industries. We review opportunities and challenges related to electrification, focusing on technical, operational, and economic considerations. Here, we conclude that electrification could completely eliminate scope 1 CO 2 emissions, increase product quality, and reduce the equipment size and cost. On the other hand, it calls for a significant expansion of power generation capacity, as well as new paradigms for process design and operations.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Integrated Distribution Planning

The contemporary distribution planning landscape is comprised of an increasing number of factors that require integration into the engineering of the modern electric grid. Expectations for electric utilities to accommodate heightened awareness of stakeholders' interest in things like decarbonization, resilience and equity are growing. As these interests are formed into objectives, many jurisdictions will experience increasing levels of load modifying technologies like DER, building and industrial electrification and electric vehicles which prove not only to challenge the capabilities of the grid; but the processes by which planning for it is traditionally done. Other related factors that strain the conventional distribution planning mold are the swelling amount and sources of data associated with these technologies and the need it creates for improved capabilities in the processes and tools that manage it. As the complexity of the distribution system expands, so will the distribution system's effects on the transmission and generation systems that it is a part of. Forecasting distribution system load and DER are examples of areas where this complexity will manifest, and harmonizing distribution forecasting with transmission and generation forecasting requires higher amounts of intentionality as these typically separate processes become a solitary one. Of course, core activities do not cease as a utility begins to integrate these other factors, and in this webinar we explore specifics of how distribution planning can be expected to evolve as progress towards Integrated Distribution System Planning is made.

24 POWER TRANSMISSION AND DISTRIBUTION

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

Benchmarking thermal energy storage cost for industrial process heat

Process heat accounts for roughly half of industrial energy demand, and currently 95% of process heat is derived from the combustion of natural gas, oil, and coal. Electrification of industrial heating could be an alternative, potentially expanding locations suitable for manufacturing; however, industrial facility owners may desire energy storage to stabilize energy costs. In this work, the economic benefits of pairing thermal storage with electrified process heat to reduce the average price paid for energy are analyzed. Cost savings focus on energy arbitrage, or leveraging flexible energy pricing schemes, alone. The cost of natural gas combustion across decades (2019-2060) is compared to the costs of electricity and thermal energy storage in four United States Independent System Operator (ISO) regions. Systems installed today may not yield positive net present value (NPV) compared to the use of natural gas. However, using estimated electricity prices, systems installed in 2030 using arbitrage alone could be profitable when compared to natural gas in some regions of the U.S. Furthermore, if capital expenditures could be reduced by 50% for sensible thermal storage systems by 2030, profitable systems are found across all regions. This implies that electrification of industrial process heat, when paired with inexpensive thermal energy storage systems, could be less expensive than brownfield natural gas systems, using arbitrage as the only source of revenue and without a dependency on any future policy drivers such as pricing externalities that could further incentivize the electrification of industrial process heat.

24 POWER TRANSMISSION AND DISTRIBUTION

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

Chemical and electrochemical pathways to low-carbon iron and steel

Currently, the iron and steel industry is responsible for 7% of global CO 2 emissions. In this review, we summarize the operational principles of current emissions-intensive steelmaking technologies and review emerging low- and zero-carbon technologies that could substantially reduce emissions. Current technologies that are discussed include blast furnaces, electric arc furnaces, and smelting. Promising low-carbon routes include use of alternative reductants for ore processing (hydrogen direct reduction, hydrogen plasma-smelting, hydrogen smelting, and ammonia-based reduction), electrolytic iron production (with aqueous and molten oxide electrolytes) and biocarbon-based electric arc furnace operation. Advantages of each approach are presented, and remaining research hurdles are identified.

36 MATERIALS SCIENCE

SCRES Energy Quest Workshop (Technical Report)

Energy Quest: Sitka’s Path to 2050 is a game based public engagement tool developed as part of the Sitka Community Renewable Energy Strategy and the U.S. Department of Energy’s Energy Transitions Initiative Partnership Project Cohort 3. Designed for Sitka’s isolated island microgrid, which is powered primarily by hydropower and depends on imported diesel for backup, the game translated complex long term energy planning questions into an interactive format. In facilitated workshops, residents built energy roadmaps to 2050, explored tradeoffs, and expressed priorities around four themes: affordability, reliability, self sufficiency, and innovation. Across sessions, participants showed strong support for increasing local self sufficiency and resilience, even when this required balancing near term affordability with long term investments. They emphasized reducing dependence on imported diesel, making better use of existing hydropower, and considering new renewable generation such as solar, wind, and additional hydropower. Survey and game responses also highlighted interest in using surplus hydropower to support new industries, expanding electrification of heating and transportation, and exploring emerging technologies and green fuels. The report organizes these findings into four scenario themes to guide Sitka’s 2050 energy planning. Affordability focuses on managing rate impacts, efficiency, and conservation. Reliability addresses diversified generation, backup power, and energy security. Self sufficiency emphasizes distributed generation and reduced reliance on imported fuels. Innovation explores new technologies, marine based energy solutions, and low carbon fuels. By grounding future planning in these community derived themes, Energy Quest shows how a game based approach can make technical energy planning more accessible and inclusive for remote communities. For questions about the game board and piece production email Dr. Sarah Troise (sarah.troise@pnnl.gov)

29 ENERGY PLANNING, POLICY, AND ECONOMY

Introductory Review of the Maritime Nuclear Regulatory Landscape

The successful deployment of nuclear technology for maritime applications, including the ability to provide energy to land-based projects at ports, has the potential to assist the International Maritime Organization’s pursuit of 2050 targets while simultaneously bringing low-cost nuclear power closer to where it is needed. The benefits of low-cost nuclear power include, but are not limited to, effective resource extraction and processing, more efficient and productive industrial applications through electrification, and increased energy abundance. In addition, the maritime sector presents unique opportunities for nuclear. For example, by leveraging the maritime sector’s experience with modular shipyard manufacturing, the nuclear industry can achieve significant cost and schedule reductions, increased productivity, and improved quality control.

22 - GENERAL STUDIES OF NUCLEAR REACTORS

Creep Performance of Novel Composite Heating Elements for Reheat Furnace Electrification

The iron and steel industry is critical for the modern world but is also very energy intensive and is a low margin industry. Hot rolling requires reheating steel slabs to ~1250 °C for hot rolling and involves yield loss due to scale formation. Electrification of this process using resistive heating could improve yield but is currently not possible due to the poor creep resistance of MoSi2 heating elements, which need to be operated well below their maximum temperatures when mounted horizontally. To solve this problem, novel MoSi2 composite heating elements with SiBCN ceramic reinforcements are being developed using high energy ball milling and spark plasma sintering. The creep performance of different heating elements and their corresponding microstructures and electrical properties will be presented.

36 - MATERIALS SCIENCE

North America’s Potential for an Environmentally Sustainable Nickel, Manganese, and Cobalt Battery Value Chain

The Detroit Big Three General Motors (GMs), Ford, and Stellantis predict that electric vehicle (EV) sales will comprise 40–50% of the annual vehicle sales by 2030. Among the key components of LIBs, the LiNixMnyCo1−x−yO2 cathode, which comprises nickel, manganese, and cobalt (NMC) in various stoichiometric ratios, is widely used in EV batteries. This review reveals NMC cathodes from laboratory research. Furthermore, this study examines the environmental effect of NMC cathode production for EV batteries (including coating technologies), encompassing aspects such as energy consumption, water usage, and air emissions. Although gaps persist in NMC cathode environmental assessments (NMC111, NMC532, NMC622, and NMC811), limited life cycle assessments “(LCA)” have been conducted. Most available data originate from Asia (primarily China), accounting for 85% of the production of EV LIB cathode materials. The concept of battery passports for data collection on LIB components has been proposed to facilitate material traceability as a system for ensuring a sustainable supply chain for critical minerals. The automotive industry’s shift to electrification necessitates a sustainable supply chain from mine to vehicle end-of-life. As the critical mineral supply moves from Asia to North America, environmentally friendly industrial methods must be studied to provide this supply chain direction.

25 ENERGY STORAGE

Proactive Regulatory Approaches to Electrification and Load Growth: Workshop Report

On July 10 and 11, 2024, Pacific Northwest National Laboratory and RMI led a workshop in Aurora, Colorado, to explore novel and proactive approaches to electrification and load growth while minimizing risks and costs to customers. Over the next decade, a unique opportunity exists to invest strategically in the electricity system to enable electrification across the transportation, industrial, and building sectors and respond to data and technology-based load growth. However, current utility and regulatory planning practices are insufficient to identify and enable the right investments, and work must be done to reduce the risk and decisional uncertainty faced by utility regulatory commissions and utilities. Ensuring timely electrification investments may require new approaches to address risk, uncertainty, prudence, and cost recovery. Understanding the decision-making process and information needs of utilities and regulators is critical. New policies (or application of policies), financial tools, systems analysis, regulatory mechanisms, and enhanced process transparency may be required. The workshop's goal was to identify proactive regulatory approaches for electrification and load growth that minimize costs and risks to customers. Our intention was that the conversations and the resulting solutions and takeaways would be specific and tactical rather than general and theoretical and that together we would create actionable next steps for key actors in the system, including utilities, regulators, thought leaders, researchers, and the U.S. Department of Energy (DOE). This report is intended to provide workshop attendees with a record and summary of the discussion and proposals raised at the workshop and to provide interested entities who did not attend, such as other regulators, policymakers, utilities, and U.S. DOE offices, with an understanding of what was discussed and with ideas to explore in their organizations.

24 POWER TRANSMISSION AND DISTRIBUTION

Technoeconomic Analysis of a Novel Microwave Process to Produce Ethylene from Methane

Ethylene is a critical feedstock in industrial processes, serving as a raw material in the petrochemical industry to produce plastics and commodity chemicals. Conventional ethylene production routes are energy-intensive and contribute substantially to the carbon footprint of chemical manufacturing. In this study, an industrial-scale novel microwave process was simulated using ASPEN Plus to assess its economic viability. Technoeconomic analysis confirmed the economic competitiveness of the novel microwave process, with a levelized cost of ethylene of USD 0.51/kg compared to USD 0.56/kg for the conventional base case. Key economic drivers of the process were identified, and sensitivity analyses were conducted to evaluate their impact on project economics. Furthermore, 87.7% of the total utility consumption in the novel microwave process is electricity, highlighting its potential to contribute to the electrification of the chemical industry. The findings of this study confirm the economic feasibility of both industrial-scale microwave reactors and modular plant configurations for the production of ethylene from methane, offering a promising alternative to conventional processes.

electromagnetic radiation

Addressing Rising Energy Demand Through Innovation

The U.S. is facing a significant increase in energy demand, driven by AI advancements, the rapid expansion of data centers, manufacturing and industrial growth, and the electrification of transportation and buildings. Buildings alone account for approximately 75% of U.S. electricity consumption and 40% of total energy use. To address these challenges, NLR leverages its state-of-the-art research facilities, advanced energy modeling, hardware-in-the-loop emulation, and real-world demonstrations to provide data-driven insights that de-risk emerging energy solutions, increase efficiency and demand flexibility, optimize grid controls, and identify vulnerabilities to enhance energy security. This presentation will highlight our research ecosystem and its role in supporting a more reliable, affordable, and adaptive energy infrastructure in the face of accelerating demand.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Evolving Electricity Supply and Demand to Achieve Net-Zero Emissions: Insights from the EMF-37 Study

This paper explores the role of electricity in achieving economy-wide net-zero CO2 emissions by 2050 in the United States based on results from 17 models as part of the 37th Stanford Energy Modeling Forum (EMF-37). In the study's Net-Zero scenario, the models use diverse pathways to achieve net-zero emissions by 2050, with gross energy-related residual emissions ranging from 17.2 to 66.6 % of 2020 levels. Electricity consistently emerges as central to achieving net-zero, with models projecting rapid electrification of end-uses and rapidly declining CO2 intensity of electricity. However, the extent of electrification and the technology mix to decarbonize the power sector vary considerably across models. In the Net-Zero scenario, electricity is projected to evolve from ~20 % of final energy in 2020 to 17-63 % in 2050 across the models driven by electrification in all sectors-buildings, industry, and transportation-and, to a lesser extent by direct air capture. By 2050, total electricity consumption increases by 24-176 % (relative to 2020), accompanied by significant expansion in renewable electricity production. Together, solar and wind generation grows by 175-834 %, supplying 45-90 % of total electricity in 2050, with wind achieving slightly higher shares than solar. Electricity storage technologies are deployed at scale to support wind and solar generation. The electricity generation mix varies across models: some project almost complete reliance on renewables, while others see a substantial role for natural gas, often with carbon capture and storage. This paper synthesizes the rich diversity of modeling approaches and results, highlighting differing views on how key drivers of electricity demand and supply might evolve.

29 ENERGY PLANNING, POLICY, AND ECONOMY

Topotaxially grown composite cathodes for cobalt-free high-energy long-life Li-ion batteries

The vehicle industry’s increasing demand for electrification necessitates the removal of expensive and rare cobalt from current high-energy batteries. However, eliminating cobalt poses challenges due to its vital role in maintaining the layered structural ordering and cycling stability of commonly used Li(NiMnCo)O 2 cathodes. As an alternative to conventional layered oxide designs, we report a lithium nickelate cathode with a composite structure comprising major stoichiometric layered and minor rocksalt phases within the same oxygen lattice. This material outperforms conventional designs by maintaining stable battery operation at voltages up to 4.8 V vs. Li|Li + , with 88% capacity retention after 1000 cycles at 2C. The topotaxial-growth-enabled interlock between the two components mitigates chemo-mechanical degradation, offering a promising pathway to cobalt-free cathodes. Additionally, we reveal a miscibility gap in the Li-Ni-O system that enables kinetic adjustment of composition and structure during sintering, thereby tuning the functionality of high-energy cathodes.

25 ENERGY STORAGE