Industrial Efficiency and Decarbonization Office

As a low-carbon fuel, feedstock, and energy source, hydrogen is expected to play a vital role in the decarbonization of high-temperature process heat during the pyroprocessing steps of clinker production in cement manufacturing. However, to accurately assess its potential for reducing CO2 emissions and the associated costs in clinker production applications, a techno-economic analysis and a study of facility-level CO2 emissions are necessary. Assuming that up to 20% hydrogen can be blended in clinker fuel mix without significant changes in equipment configuration, this study evaluates the potential reduction in CO2 emissions (scopes 1 and 2) and cost implications when replacing current carbon-intensive fuels with hydrogen. Using the direct energy substitution method, we developed an Excel-based model of clinker production, considering different hydrogen�blend scenarios. Hydrogen from steam methane reformer (gray) and renewable-based electrolysis (green) are considered as sources of hydrogen fuel for blend scenarios of 5%�20%. Metrics such as the cost of cement production, facility-level CO2 emissions, and cost of CO2 avoided were computed. Results show that for hydrogen blends (gray or green) between 5% and 20%, the cost of cement increases by 0.6% to 16%, with only a 0.4% to 6% reduction in CO2 emissions. When the cost of CO2 avoided was computed, the extra cost required to reduce CO2 emissions is $229 to $358/ metric ton CO2. In summary, although green hydrogen shows promise as a low-carbon fuel, its adoption for decarbonizing clinker production is currently impeded by costs.

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

Reviewers highlighted the importance of continual, forward-looking, and comprehensive analysis and project evaluation to inform IEDO's strategy.This recommendation aligns closely with our strategic analysis priorities and active program management to help us plan for the future.Our new framework shifts our analysis from a historic look back at the industrial sector and emissions data to one looking toward the industrial sector of the future.We recently launched an ambitious new effort 6 to identify cost-effective and industry-specific strategic pathways to achieve a thriving U.S. industrial sector with net-zero greenhouse gas emissions by 2050.In addition to assessing existing energy and emissions data and analyzing the challenges and opportunities for decarbonizing the current industrial sector, we're moving towards real-time analysis that will anticipate new and evolving opportunities and disruptors.This scenario planning for the future will help us remain agile and responsive to overcoming near-, medium-and long-term decarbonization barriers in a rapidly changing industry.5 Industrial Efficiency and Decarbonization Office.2023."Water, Energy, and the Future of Farming."U.S. Department of Energy.Posted Sept. 28, 2023.https://www.energy.gov/eere/iedo/articles/water-energyand-future-farming.