Abstract
Decarbonization of the industrial heat demand through electrification could contribute significantly to climate change mitigation efforts. In the US industry, thermal processes accounted for 75% of the total final energy demand in 2018, of which 17% is consumed by conventional industrial boilers (excluding cogeneration) for steam generation. Electric boilers have a small share in the US industrial steam generation due to several techno-economic reasons. This study employs a bottom-up approach to investigate the sector-level and state-level techno-enviro-economic potentials of deploying electric boilers in the US industry in different timeframes. The results show that the technical potential energy and CO2 savings by electrifying industrial boilers are 595 PJ and 200 MtCO2 per year in 2050, respectively; however, these incur additional costs in each sector. Although there may be individual cost-effective opportunities for electrifying boilers in specific industrial sites, the overall costs are high in all industrial sectors and states due to the large disparity between electricity and combustion fuel prices. To overcome the highlighted techno-economic barriers, a comprehensive action plan for different stakeholders is also formulated. This study provides novel insights that should inform policymakers’ and executives’ decisions about the electrification of the current and future US industrial boiler systems.
This is a preview of subscription content, log in via an institution to check access.
Similar content being viewed by others
Notes
Boiler efficiency does not only depend on the type of technology (e.g., fire-tube or water-tube and/or whether or not an economizer is present) employed in different sectors but also varies by the type of combustion fuels used in these sectors. In addition, sector-specific boiler size distribution and part load conditions also affect boiler efficiencies. The weighted average sectoral boiler efficiencies in Fig. 9 are reflecting on all these aspects.
Since the carbon-neutrality of biomass fuels is debated due to the concerns about origin of biomass feedstock supply, its sustainable aspects, and whether the associated air-quality impacts from biomass utilization are tolerable, this study does not consider biomass fuels as carbon–neutral.
The boiler-related CO2 emissions in different industrial sectors exclude indirect emissions due to electricity use in boilers.
References
Abbasi, M. H., Abdullah, B., Ahmad, M. W., Rostami, A., & Cullen, J. (2021). Heat transition in the European building sector: Overview of the heat decarbonisation practices through heat pump technology. Sustainable Energy Technologies and Assessments, 48, 101630. https://doi.org/10.1016/j.seta.2021.101630
Arpagaus, C., Bless, F., Uhlmann, M., Schiffmann, J., & Bertsch, S. S. (2018). High temperature heat pumps: Market overview, state of the art, research status, refrigerants, and application potentials. Energy, 152, 985–1010. https://doi.org/10.1016/j.energy.2018.03.166
Bühler, F., Holm, F. M., & Elmegaard, B. (2019a). Potentials for the electrification of industrial processes in Denmark. Wroclow, Poland. https://orbit.dtu.dk/en/publications/potentials-for-the-electrification-of-industrial-processes-in-den. Accessed 5 August 2021
Bühler, F., Zühlsdorf, B., Nguyen, T.-V., & Elmegaard, B. (2019b). A comparative assessment of electrification strategies for industrial sites: Case of milk powder production. Applied Energy, 250, 1383–1401. https://doi.org/10.1016/j.apenergy.2019.05.071
Deason, J., Wei, M., Leventis, G., Smith, S., & Schwartz, L. (2018b). Electrification of buildings and industry in the United States Drivers, barriers, prospects, and policy approaches. Berkeley: Lawrence Berkeley National Laboratory. https://emp.lbl.gov/publications/electrification-buildings-and. Accessed 5 August 2021
EEA. (2005). Characterization of the U.S. Industrial/Commercial Boiler Population. Virginia: Energy and Environmental Analysis, Inc. https://www.energy.gov/sites/prod/files/2013/11/f4/characterization_industrial_commerical_boiler_population.pdf. Accessed 5 August 2021
Hasanbeigi, A., Kirshbaum, L. A., Collison, B., & Gardiner, D. (2021). Electrifying U.S. industry: Technology and process-based approach to decarbonization. https://www.globalefficiencyintel.com/electrifying-us-industry. Accessed 5 August 2021
Heinen, S., Mancarella, P., O’Dwyer, C., & O’Malley, M. (2018). Heat electrification: The latest research in Europe. IEEE Power and Energy Magazine, 16(4), 69–78. https://doi.org/10.1109/MPE.2018.2822867
Jadun, P., McMillan, C. A., Steinberg, D., Muratori, M., Vimmerstedt, L., & Mai, T. (2017). Electrification futures study: End-use electric technology cost and performance projections through 2050 (No. NREL/TP-6A20–70485). Colorado: National Renewable Energy Laboratory. https://www.nrel.gov/docs/fy18osti/70485.pdf. Accessed 5 August 2021
Madeddu, S., Ueckerdt, F., Pehl, M., Peterseim, J., Lord, M., Kumar, K. A., et al. (2020). The CO2 reduction potential for the European industry via direct electrification of heat supply (power-to-heat). Environmental Research Letters, 15(12), 124004. https://doi.org/10.1088/1748-9326/abbd02
McMillan, C. A., & Narwade, V. (2018). United States County-Level Industrial Energy Use. Colorado: National Renewable Energy Laboratory. https://data.nrel.gov/submissions/97. Accessed 5 August 2021
NCSL. (2021, July). State Renewable Portfolio Standards and Goals. https://www.ncsl.org/research/energy/renewable-portfolio-standards.aspx. Accessed 5 August 2021
Panos, E., & Kannan, R. (2016). The role of domestic biomass in electricity, heat and grid balancing markets in Switzerland. Energy, 112, 1120–1138. https://doi.org/10.1016/j.energy.2016.06.107
Rightor, E., Whitlock, A., & Elliott, N. (2020). Beneficial electrification in industry. Washington D.C.: ACEEE. https://www.aceee.org/research-report/ie2002. Accessed 5 August 2021
Rodrigues, A. L. P., Seixas, & Sonia, R. C. (2022). Battery-electric buses and their implementation barriers: Analysis and prospects for sustainability. Sustainable Energy Technologies and Assessments, 51, 101896. https://doi.org/10.1016/j.seta.2021.101896
Roelofsen, O., Somers, K., Speelman, E., & Witteveen, M. (2020). Plugging in: What electrification can do for industry. McKinsey & Company. https://www.mckinsey.com/industries/electric-power-and-natural-gas/our-insights/plugging-in-what-electrification-can-do-for-industry#. Accessed 5 August 2021
Schlosser, F., Arpagaus, C., & Walmsley, T. G. (2019). Heat pump integration by pinch analysis for industrial applications: A review. Chemical Engineering Transactions, 76, 7–12. https://doi.org/10.3303/CET1976002
Schoeneberger, C., Zhang, J., McMillan, C., Dunn, J. B., & Masanet, E. (2022). Electrification potential of U.S. industrial boilers and assessment of the GHG emissions impact. Advances in Applied Energy, 5, 100089. https://doi.org/10.1016/j.adapen.2022.100089
Schüwer, D., & Schneider, C. (2018). Electrification of industrial process heat: Long-term applications, potentials and impacts. Berlin, Germany. https://www.eceee.org/library/conference_proceedings/eceee_Industrial_Summer_Study/2018/4-technology-products-and-system-optimisation/electrification-of-industrial-process-heat-long-term-applications-potentials-and-impacts/. Accessed 5 August 2021
Smith, M., Bevacqua, A., Tembe, S., & Lal, P. (2021). Life cycle analysis (LCA) of residential ground source heat pump systems: A comparative analysis of energy efficiency in New Jersey. Sustainable Energy Technologies and Assessments, 47, 101364. https://doi.org/10.1016/j.seta.2021.101364
Soini, M. C., Bürer, M. C., Parra, D., Patel, M. K., Rigter, J., & Saygin, D. (2017). Renewable Energy in District Heating and Cooling a Sector Roadmap for REMAP. Bonn, Germany: International Renewable Energy Agency (IRENA). https://www.irena.org/publications/2017/Mar/Renewable-energy-in-district-heating-and-cooling. Accessed 5 August 2021
S&P Global Platts. (2020, December). Commodities 2021: States racing to set goals toward net-zero emission, 100% renewable electricity. https://www.spglobal.com/platts/en/market-insights/latest-news/electric-power/122420-commodities-2021-states-racing-to-set-goals-toward-net-zero-emission-100-renewable-electricity. Accessed 5 August 2021
Steinberg, D., Bielen, D., Eichman, J., Eurek, K., Logan, J., Mai, T., et al. (2017). Electrification & Decarbonization: Exploring U.S. Energy Use and Greenhouse Gas Emissions in Scenarios with Widespread Electrification and Power Sector Decarbonization (No. NREL/TP-6A20–68214). Colorado: National Renewable Energy Laboratory. https://www.nrel.gov/docs/fy17osti/68214.pdf. Accessed 5 August 2021
The White House. (2021). FACT SHEET: President Biden Sets 2030 Greenhouse Gas Pollution Reduction Target Aimed at Creating Good-Paying Union Jobs and Securing U.S. Leadership on Clean Energy Technologies. The White House. https://www.whitehouse.gov/briefing-room/statements-releases/2021/04/22/fact-sheet-president-biden-sets-2030-greenhouse-gas-pollution-reduction-target-aimed-at-creating-good-paying-union-jobs-and-securing-u-s-leadership-on-clean-energy-technologies/. Accessed 4 April 2022.
TNO. (2018). Technology Factsheet. The Hague. https://energy.nl/wp-content/uploads/2018/12/Technology-Factsheet-Electric-industrial-boiler-1.pdf. Accessed 5 August 2021
U.S. DOE/Energetics. (2018). Manufacturing Energy and Carbon Footprints (2014 MECS). Energy.gov. https://www.energy.gov/eere/amo/manufacturing-energy-and-carbon-footprints-2014-mecs. Accessed 5 August 2021
U.S. EIA. (2021). 2018 Manufacturing Energy Consumption Survey (MECS) - Data. https://www.eia.gov/consumption/manufacturing/data/2018/. Accessed 5 August 2021
U.S. EIA. (2019a). Annual Energy Outlook 2019a. https://www.eia.gov/outlooks/archive/aeo19/. Accessed 5 August 2021
U.S. EIA. (2019b). State Energy Data System (SEDS): 1960–2019b (complete). https://www.eia.gov/state/seds/seds-data-complete.php?sid=US. Accessed 5 August 2021
U.S. EPA. (2012). 2012 Climate Registry Default Emission Factors. Washington D.C. https://theclimateregistry.org/wp-content/uploads/2015/01/2012-Climate-Registry-Default-Emissions-Factors.pdf. Accessed 5 August 2021
Wei, M., McMillan, C. A., & de la Rue du Can, S. (2019). Electrification of Industry: Potential, Challenges and Outlook. Current Sustainable/renewable Energy Reports, 6(4), 140–148. https://doi.org/10.1007/s40518-019-00136-1
Wiertzema, H., Åhman, M., & Harvey, S. (2018). Bottom-up methodology for assessing electrification options for deep decarbonisation of industrial processes (pp. 389–397). Berlin, Germany. https://www.eceee.org/library/conference_proceedings/eceee_Industrial_Summer_Study/2018/4-technology-products-and-system-optimisation/bottom-up-methodology-for-assessing-electrification-options-for-deep-decarbonisation-of-industrial-processes/. Accessed 5 August 2021
Zuberi, M. J. S., Chambers, J., & Patel, M. K. (2021). Techno-economic comparison of technology options for deep decarbonization and electrification of residential heating. Energy Efficiency, 14(7), 75. https://doi.org/10.1007/s12053-021-09984-7
Acknowledgements
The work described in this study was conducted at Lawrence Berkeley National Laboratory and supported by the US Department of Energy Advanced Manufacturing Office under Contract No. DE-AC02-05CH11231. The authors would like to thank Joe Cresko of US DOE’s Advanced Manufacturing Office, Colin McMillan of National Renewable Energy Laboratory, Eric Masanet of University of California, Santa Barbara, Jingyi Zhang, and Carrie Schoeneberger of Northwestern University for their contributions. The views and opinions of the authors expressed herein do not necessarily state or reflect those of the US Government or any agency thereof, or The Regents of the University of California.
Author information
Authors and Affiliations
Contributions
The authors’ roles are as follows:
Dr. M. Jibran S, ZUBERI: Conceptualization, methodology, data curation, resources, formal analysis, visualization, writing—original draft.
Dr. Ali HASANBEIGI: Conceptualization, methodology, data curation, writing—review and editing.
Dr. William R. MORROW: Supervision, project administration, funding acquisition, resources, writing—review, and editing.
Corresponding author
Ethics declarations
Conflict of interest
The authors declare no competing interests.
Additional information
Publisher's note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Highlights
1. Bottom-up approach to study the sector- and state-level potentials of electric boilers.
2. The potential energy savings by electrifying ind. boilers are 595 PJ p.a. in 2050.
3. The potential CO2 savings by electrifying ind. boilers are 200 Mt p.a. in 2050.
4. Ind. boiler elec. can initially increase the CO2 emissions by 43 Mt p.a. in 2018.
5. The costs are high due to the large disparity between electricity and fuel prices.
Rights and permissions
Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Zuberi, M.J.S., Hasanbeigi, A. & Morrow, W. Electrification of industrial boilers in the USA: potentials, challenges, and policy implications. Energy Efficiency 15, 70 (2022). https://doi.org/10.1007/s12053-022-10079-0
Received:
Accepted:
Published:
DOI: https://doi.org/10.1007/s12053-022-10079-0