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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

Equitable and Affordable Solutions to Electrification (EAS-E) Home Electrification Prize

The Equitable and Affordable Solutions to Electrification (EAS-E) Home Electrification Prize, EAS-E Prize, seeks novel, cost-effective technology solutions for whole-home electrification of all types of residential buildings. EAS-E Prize competitors will develop and demonstrate "easy electrification" approaches that are faster and more affordable for homeowners and simplify electrification processes for contractors and implementers.

EAS-E

Automated Identification of Initial Storm Electrification and End-of-Storm Electrification Using Electric Field Mill Sensors

Kennedy Space Center (KSC) operations are located in a region which experiences one of the highest lightning densities across the United States. As a result, on average, KSC loses almost 30 minutes of operational availability each day for lightning sensitive activities. KSC is investigating using existing instrumentation and automated algorithms to improve the timeliness and accuracy of lightning warnings. Additionally, the automation routines will be warning on a grid to minimize under-warnings associated with not being located in the center of the warning area and over-warnings associated with encompassing too large an area. This study discusses utilization of electric field mill data to provide improved warning times. Specifically, this paper will demonstrate improved performance of an enveloping algorithm of the electric field mill data as compared with the electric field zero crossing to identify initial storm electrification. End-of-Storm-Oscillation (EOSO) identification algorithms will also be analyzed to identify performance improvement, if any, when compared with 30 minutes after the last lightning flash.

initial storm electrification

Informing electrification strategies of residential neighborhoods with urban building energy modeling

Electrifying end uses is a key strategy to reducing GHG emissions in buildings. However, it may increase peak electricity demand that triggers the need to upgrade the existing power distribution system, leading to delays in electrification and needs of significant investment. There is also concern that building electrification may cause an increase of energy costs, leading to further energy burden for low-income communities. This study uses the urban scale building modeling tool CityBES to assess the electrification impacts of more than 43,000 residential buildings in a neighborhood of Portland, Oregon, USA. Energy efficiency upgrades were investigated on their potential to mitigate the increase of peak electricity demand and energy burden. Simulation results from the calibrated EnergyPlus models show that electrification with heat pumps for space heating and cooling as well as for domestic water heating can reduce CO2e emissions by 38%, but increase peak electricity demand by about 9% from the baseline building stock. Combining electrification measures and energy efficiency upgrades can reduce CO2e emissions by 48% while reducing peak electricity demand by 6% and saving the median household energy costs by 28%. City and utility decision makers should consider integrating energy efficiency upgrades with electrification measures as an effective residential building electrification strategy, which significantly reduces carbon emissions, caps or even decreases peak demand while reducing energy burden of residents.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Electrification Within Wintertime Stratiform Regions Sampled During the 2020/2022 NASA IMPACTS Field Campaign

Two nor'easter events—sampled during the NASA Investigation of Microphysics and Precipitation for Atlantic Coast-Threatening Snowstorms (IMPACTS) field campaign—were examined to characterize the microphysics in relation to the underlying electrification processes within wintertime stratiform regions. A theoretical model was developed to determine whether accretion or diffusion growth regimes were preferential during periods of greatest electrification. Model simulation with electrification parameterization was used to provide supplemental context to the physical processes of in-cloud microphysics and electrification. The strongest electric fields (i.e., ∼80 V m −1 at 20 km) during the 2020 NASA IMPACTS deployment was associated with large non-rimed ice crystals colliding with each other. During the 29–30 January 2022 science flight, the NASA P-3 microphysical probe data demonstrated that non-inductive charging was possible off the coastline of Cape Cod, Massachusetts. Later in the science flight, when the NASA P-3 and ER-2 were coordinating with each other, measured electric fields consistently were less than 8 V m −1 and electrification was subdued owing to reduced concentrations of graupel and large ice hydrometeors. Altogether, the in-situ observations provide evidence for the non-riming collisional charging mechanism and demonstrates that graupel and supercooled liquid water may not be necessary for weak electrification within wintertime stratiform regions. Model output from simulation of both events suggested that the main synoptic snowbands were associated with elevated hydrometeor snow charge density and electric fields.

snowfall

Assessing electrification readiness in U.S. single-family homes based on a nationwide survey of electrical panel capacities

Electrification of residential buildings is a key strategy for increasing the use of renewable energy sources. Central to this transition is understanding the capacity of existing electrical infrastructure—specifically electrical panels—to safely and effectively manage increased electricity demands from electrification technologies. However, comprehensive nationwide data on electrical panel capacities in U.S. single-family homes is currently lacking. To address this gap, we conducted a nationwide survey of single-family homes, collecting detailed data on electrical panel capacities, breaker slot availability, major electric and gas appliances, electrical panel models, and home characteristics such as construction year and floor area. Photographic documentation was used to verify electrical panel data and appliance information. Results show that approximately 60% of surveyed homes have electrical panels rated at ≥200 amperes (A), indicating that a significant portion of the existing housing stock can accommodate additional electric loads. However, 31% of homes possess panels rated at ≤100 A, potentially restricting their ability to adopt new electric appliances without significant upgrades. Panel capacities positively correlate with both home size and construction year, with newer and larger homes generally better suited for electrification. Homes with higher-capacity panels tend to have fewer gas appliances, reflecting a gradual shift toward electric technologies. Conversely, homes with lower-capacity panels frequently rely on multiple gas appliances, highlighting substantial electrification challenges. Additionally, approximately 3% of surveyed homes had potentially hazardous electrical panel models, emphasizing important safety considerations in the residential electrification process. Our findings underscore the need for targeted policies, financial incentives, and infrastructure investments designed specifically to address infrastructural and safety barriers, particularly in older and smaller homes, to support equitable and efficient electrification across the U.S. residential sector.

Gul, Sadia

Long-term impact of electrification and retrofits of the U.S residential building in diverse locations

The U.S. buildings sector contributes 30% of operational carbon emissions, with residential buildings accounting for 56%. Reducing residential carbon emissions is crucial for achieving net-zero carbon goal. While many studies examine energy efficiency retrofit (EER) and electrification, few explore their long-term impacts across diverse climates and dynamic grid clean energy penetrations, as well as their economic effects on households. Here, this study proposes a method to assess how EER and electrification affect long-term decarbonization and economics across different climates, focusing on carbon emissions, energy burden (the percentage of household income spent on energy), and payback period in four locations: Tampa, San Diego, Denver, and Great Falls. The study also introduces the concept of implicit energy burden by considering investment costs. Results show that while electrification can reduce long-term emissions with increased clean energy penetration, it may not always achieve decarbonization due to mismatches between clean energy availability and demand. In cooling-dominant locations, electrification lowers energy burden and peak demand, but in heating-dominant locations, it increases energy burden to 8.24%, raises peak demand by 632.78%, and shifts it from summer to winter. After integrating investment costs, the implicit energy burden can reach 8.35% in cold climates. For already highly electrified buildings in Denver and Great Falls, the payback period of EER measures can be shortened by up to 48.98%. The study highlights a tradeoff between decarbonization and energy burden alleviation, showing that while EER measures can reduce the energy burden, they only achieve one-quarter of the carbon emission reduction of electrification.

24 POWER TRANSMISSION AND DISTRIBUTION

Electrification Analysis: All Aboard America!

This one-page highlight details the key takeaways from a project that utilized NREL's Fleet Research, Energy Data, and Insights (FleetREDI) data analysis pipeline, an electrification analysis for the Bustang motorcoach fleet operated by All Aboard America! Holdings Inc. (AAA). NREL installed logging devices and collected operational data on nine 40-foot Bustang motorcoaches operating on fixed routes from May 2022 through August 2022. The analysis determined that partial fleet electrification may be feasible with electrified motorcoach options currently on the market. While this fleet faces significant challenges to electrification given current market options due to demanding range requirements and relatively limited charging opportunities, vehicles operating on the shorter, lower-grade routes along the I-25 corridor show more immediately available electrification potential. Increases in available battery capacity and the availability of fast-charging locations along I-70 routes are likely critical for electrification of the full fleet.

AAA

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

A numerical study of thunderstorm electrification - Model development and case study

A numerical model was developed for examining the thunderstorm electrification process in which it is assumed that the electrification is entirely due to noninductive charge transfer between colliding ice crystals and hail. Since this ice-hail charge mechanism is very dependent on particle sizes and distributions, an explicit microphysical framework is used. To maintain simplicity, the electrification model is kinematic; thus the temperature and velocity fields are input into the electrification model. The cloud model of Taylor (1989) was used to generate the temperature and velocity fields to examine the July 19, 1981, Cooperative Convective Precipitation Experiment thundercloud. Using these fields, the electrification model produced time-dependent ice particle concentrations, radar reflectivities, charge, and vertical electric field distributions in good general agreement with those observed. The model produced a maximum electric field strength of 1.27 kV/cm, which is on the order of that needed for lightning initiation, and this maximum occurred very close to the time of the observed discharge. Thus, the ice-hail charge mechanism appears to have played an important role in the electrical development of the July 19 cloud.

Norville, K.

On the Electrification of Pyrocumulus Clouds

The electrification (or lack thereof) of pyrocumulus clouds is examined for several different wildfires that occurred during 2012‐2013. For example, pyrocumulus clouds above three Colorado wildfires (Hewlett Gulch, High Park, and Waldo Canyon; all occurred during summer 2012) electrified and produced small intracloud discharges whenever the smoke plumes grew to high altitudes (over 10 km above mean sea level, or MSL). This occurred during periods of rapid wildfire growth, as indicated by the shortwave infrared channel on a geostationary satellite, as well as by incident reports. In the Hewlett Gulch case, the fire growth led to increased updrafts within the plume, as inferred by multiple‐Doppler radar syntheses, which led to the vertical development and subsequent electrification ‐ a life cycle as short as 30 minutes. The lightning, detected by a three‐dimensional lightning mapping network, was favored in high‐altitude regions (~10 km MSL) containing modest reflectivities (25 dBZ and lower), ~0 dB differential reflectivity, and reduced correlation coefficient (~0.6‐0.7). This indicated the likely presence of ice particles (crystals and aggregates, possibly rimed) mixed with ash. Though neither multiple‐Doppler nor polarimetric observations were available during the electrification of the High Park and Waldo Canyon plumes, their NEXRAD observations showed reflectivity structures consistent with Hewlett Gulch. In addition, polarimetric and multiple‐Doppler scanning of unelectrified High Park plumes indicated only irregularly shaped ash, and not ice, was present (i.e., reflectivities < 25 dBZ, differential reflectivity > 5 dB, correlation < 0.4), and there was no broaching of the 10 km altitude. Based on these results, the electrification likely was caused by ice‐based processes that did not involve significant amounts of graupel. Results for pyrocumulus clouds above notable 2013 wildfires that also experienced rapid growth (e.g., Black Forest, Yarnell Hill, West Fork, Tres Lagunas, etc.) will be compared against the 2012 cases, with special emphasis on polarimetric NEXRAD and available lightning measurements, in order to better understand the physical processes responsible for pyrocumulus electrification.

Lang, Timothy J.

Overview of Building Electrification Technologies and Market Opportunities

This report provides an overview of building electrification drivers and select building electrification technologies and their markets and performance. Covered topics: Building Electrification Drivers and Context; Heat Pumps for Space Conditioning; Heat Pump Market Opportunities; Life Cycle GHG Emissions Impacts of Heat Pump Space Conditioning Technologies; Heat Pump Water Heaters; Electrification of Gas Loads: Commercial and Residential; Residential Panel Capacity; Electric Vehicle Impacts and Connections to Buildings; and Building Envelope Improvements and Thermal Energy Storage (TES) Opportunities.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

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

Impact of truck electrification on air pollution disparities in the United States

Electrifying heavy-duty trucks reduces on-road diesel emissions but shifts the burden of supplying energy to power-generation facilities. The combined effect of Inflation Reduction Act investments in grid decarbonization and truck electrification will alter the magnitude and distribution of air pollution burdens across the United States. These investments are intended to facilitate a just energy transition, with 40% of the benefits flowing to disadvantaged communities per the Justice40 Initiative. Here we evaluate the combined effects of Inflation Reduction Act grid decarbonization and truck electrification investments on a national scale to determine whether the air pollution benefits would meet this 40% goal for both disadvantaged communities and the most exposed racial–ethnic groups. We find that truck electrification and decarbonization reduce air-pollution-related premature mortality in disadvantaged communities. However, the relative disparity between disadvantaged and non-disadvantaged communities increases, suggesting that a disproportionate share of benefits accrue to non-disadvantaged communities. Whereas absolute disparity in grid emissions decreases over time for all racial–ethnic groups, relative disparity remains largely unchanged, with Black populations being the most exposed. Electrifying drayage corridors would result in comparatively large health benefits for disadvantaged communities, suggesting that increasing targeted electrification investments in short-haul routes near urban areas (for example, ports) could be promising.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Simulation & Analysis of the Hydronic Shell Retrofit System as a Solution for Deep Energy Retrofits and Electrification of Large Multifamily Housing Communities in Cold Climate

According to the 2020 residential energy consumption survey, there are 32 million multi-family buildings in the United States, and approximately 42% of these have poor or no insulation (US EIA 2020). Electrification of buildings with heat pump is one of the key strategies to achieve the goal of 90% reduction of greenhouse gas emissions in buildings by 2050 (U.S. Department of Energy 2024a). Building electrification will also enable greater penetration of variable renewable energy sources. However, replacing the natural gas dominated heating system by electrical appliance will increase the electrical load in heating dominated climate. It is crucial to well-insulate the building envelope to mitigate the stress in the grid from electrification. The hydronic shell (HS) system discussed next can achieve dual objective of envelope retrofit with space heating system electrification.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Airport Ground Support Equipment Infrastructure & Logistics Electrification Assessment Tool: 2025 Data Development, Modeling and Analysis for DFW

The aviation industry is increasingly turning to modernize freight facilities by integrating electric Ground Support Equipment (eGSE) to enhance operational efficiency of freight facility moving vehicles and equipment. Airports worldwide are adopting eGSE to streamline cargo movement, reduce fuel and maintenance costs, and improve logistics coordination.1 North America, with its advanced aviation infrastructure, leads this transition, leveraging Internet of things (IoT)-enabled automation and zero emission technologies to boost reliability and reduce human errors.2 Electrification of freight facility moving vehicles and equipment boosts turnaround times, improves equipment reliability, and optimizes logistics coordination, giving operators a competitive advantage. With rising fuel price volatility and the pressure to meet stringent performance benchmarks, airports are focusing on cost-effective, scalable solutions for long-term financial and operational gains. To further accelerate electrification, airports are integrating Zero Emission Vehicles (ZEVs) into rental car fleets and deploying electric baggage carts, requiring strategic investments in charging infrastructure. 3 The shift, however, presents challenges, such as limited technical expertise, high capital costs, and complex procurement processes. By forging strategic partnerships, leveraging advanced technologies, and optimizing infrastructure investments, airports can create a resilient, future-ready ecosystem that enhances the movement of people and goods through electrification-driven efficiency. Supported by the U.S. Department of Energy (DOE) Vehicle Technologies Office (VTO), this electrification effort provides a scalable, cost-effective solution to improve airport freight operations. Through targeted investments and innovation, airports enhance efficiency, reduce costs, and meet performance benchmarks while advancing toward a resilient, electrified future.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI

Electrification: Mid-term (1985 - 2000)

Electrification, intended to provide a basis for the mid term period of the energy conservation program, was defined as a set of actions and/or policies that leads to an increasing proportion of total energy used in the form of electricity. The important actions within electrification are those with the greatest impacts (coal and nuclear), the greatest technological requirements (peak shaving and transmission) and the greatest response from the decision makers (economic health and growth of utilities in an era of increasing energy costs). The following areas were discussed: increased power generation from coal action, increased use of nuclear power action, improved operation of public utilities action, actions to be taken in industry, transportation and residential/commercial areas. The various ways in which electrification leads to energy conservation were clarified, and a number of specific recommendations relative to electrification were suggested.

Source record

Tropospheric electrification

The solid Earth carried a negative charge of approximately 10 C to the 6 th power and the lower atmosphere an equal, opposite charge. While a number of charging processes in the lower atmosphere are involved, such as erupting volcanoes, snow, sand and dust storms, and the bubbles bursting from the oceans, the primary cause of the Earth's electrification is activity of thunderstorms. Although it is known that the electrification of these clouds is caused by the accumulation of regions of charged water particles, there is no general agreement concerning which process is the cause of the electrification within the cloud and what role this electrification plays in the meteorological processes that take place in the lower atmosphere. The development of thunderclouds and the electric fields and currents above them are discussed.

Vonnegut, B.