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Decarbonizing The Most Polluting Heavy Industries | Earth Wise

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The production of steel, cement, and ammonia accounts for about 20% of the carbon dioxide humans pour into the atmosphere.  Modern cities are largely constructed from concrete and steel and most of our food is grown using fertilizer made from ammonia. 

The most widely discussed solutions to decarbonizing these industries are green hydrogen and carbon capture and storage or CCS.

Steel manufacture is responsible for 11% of society’s emissions.  Most production starts by burning coal in a blast furnace. Using CCS could reduce emissions from burning the coal.  But the blast furnace could be eliminated entirely by the use of electrolysis to produce the pure iron needed to make steel.  This would be extremely energy-intensive but using a low-carbon source like green hydrogen could greatly reduce the emissions from making steel.

Ammonia is made by producing hydrogen from natural gas and then combining it with atmospheric nitrogen.  Both the hydrogen production and ammonia synthesis are energy intensive.  Using green hydrogen would eliminate emissions from the hydrogen production itself and new research on catalysts aims at lower-temperature, less-energy intensive ammonia synthesis.

Decarbonizing cement manufacturing is perhaps the toughest challenge.  Cement is made in a high-temperature kiln, typically heated by burning fossil fuels.  The process converts calcium carbonate and clay into a hard solid called clinker.  The main byproduct of that is even more carbon dioxide.  Burning green hydrogen and capturing carbon emission are about the best hope for reducing cement manufacturing emissions.

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Can the World’s Most Polluting Heavy Industries Decarbonize?

Photo, posted June 30, 2009, courtesy of Portland Bolt via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

A Solar-Powered Steel Mill | Earth Wise

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The steel industry is an essential part of modern society.  Economically, the U.S. steel industry produces goods valued at more than $100 billion a year and employs more than 80,000 people.  The steel industry is also a major contributor to greenhouse gas emissions.   On average, 1.85 tons of CO2 are emitted for every ton of steel produced.  Overall, the steel industry generates between 7 and 9% of the direct emissions that come from the global use of fossil fuel.

The industry is determined to reduce its environmental impact.  Steel is 100% recyclable and indeed much of it is recycled.  Over 2 billion tons of steel were produced in 2019. Meanwhile, more than 700 million tons of steel scrap are recycled each year.  Recycling greatly reduces the energy impact of the steel industry.

The industry has also significantly reduced its energy usage over the years using sophisticated energy management systems and energy recovery efforts.  Since 1960, the amount of energy needed to produce a ton of steel has dropped by 60%.  But making steel is still very energy intensive.

Recently, Lightsource bp announced that its 300 megawatt Bighorn Solar project in Colorado will be used to allow EVRAZ’s Pueblo steel mill to be the world’s first steel mill to run almost entirely on solar power.

The solar project, which will be fully online this month, is the largest on-site solar facility in the U.S. dedicated to a single customer.  (The Bighorn Solar project features 750,000 solar panels located on 1,800 acres).

The project demonstrates that even challenging industrial sectors can be decarbonized when companies work together on innovative solutions.

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Colorado steel mill becomes ‘world’s first’ to be run almost entirely on solar

Photo, posted October 16, 2017, courtesy of UC Davis College of Engineering via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

Scaling Up Green Hydrogen | Earth Wise

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The global hydrogen market generates about $150 billion dollars a year.  The bulk of the market consists of hydrogen used to produce ammonia, refine oil, and produce methanol.  Advocates for hydrogen foresee a $600 billion a year market based on power and industry uses, mobility and transport uses, chemical feedstocks, and construction.  But the problem with expanding the use of hydrogen is that the vast majority of hydrogen in use today is produced from fossil fuels such as natural gas and coal and producing it creates carbon dioxide emissions.

The great hope of the industry is “green hydrogen”- hydrogen produced either without using fossil fuels at all or by capturing and storing the emissions generated. The most likely approach is electrolysis – using electricity to produce hydrogen from water.

Billions of dollars are being invested by both governments and by large oil companies in a race to scale up electrolysis and make it economically attractive.  According to the Hydrogen Council industry lobby group, at least $300 billion is expected to be invested globally over the next decade aimed at developing the green hydrogen that could one day meet almost a fifth of global energy demand.

Many argue that producing green hydrogen with electrolysis is an extremely inefficient way to utilize renewable energy.  Critics of hydrogen-powered vehicles particularly make this argument.   But industrial applications of hydrogen that currently use large amounts of fossil fuels – such as steel manufacturing – may be places where green hydrogen would make a real dent in global emissions.

The race to clean up hydrogen is definitely on.

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The Race to Scale Up Green Hydrogen to Help Solve Some of the World’s Dirtiest Energy Problems

Photo, posted December 16, 2020, courtesy of Sharon Hahn Darlin via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

Superstrong Nanofibers | Earth Wise

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Self-assembly is a ubiquitous process in the natural world that leads to the formation of the DNA double helix, the creation of cell membranes, and to many other structures.   Scientists and engineers have been working to design new molecules that assemble themselves in water for the purpose of making nanostructures for biomedical applications such as drug delivery or tissue engineering.  For the most part, the materials created in this way have been chemically unstable and tended to degrade rapidly, especially when the water is removed.

A team at MIT recently published a paper describing a new class of small molecules they have designed that spontaneously assemble into nanoribbons with unprecedented strength and that retain their structure outside of water.

The material is modeled after a cell membrane.  Its outer part is hydrophilic (it likes to be in water) and its inner part is hydrophobic (it tries to avoid water.)  This configuration drives the self-assembly to create a specific nanostructure and by choosing the appropriate chemicals to form the structures, the result was nanoribbons in the form of long threads that could be dried and handled.  The resultant material in many ways resembles Kevlar.   In particular, the threads could hold 200 times their own weight and have extraordinarily high surface areas.  The fibers are stronger than steel and the high surface-to-mass ratio offers promise for miniaturizing technologies for such applications as pulling heavy-metal contaminants out of water and for use in electronic devices and batteries.

The goal of the research is to tune the internal state of matter to create exceptionally strong molecular nanostructures.  The potential for important new applications is considerable and exciting.

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Researchers construct molecular nanofibers that are stronger than steel

Photo, posted June 19, 2007, courtesy of Andrew Hitchcock via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

Green Hydrogen | Earth Wise

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Saudi Arabia is a country built around oil, but it is now placing a big bet on green hydrogen as the next big thing in its energy future.  The country is constructing a $500 billion futuristic city called Neom in the desert along the Red Sea.  The brand-new city will be home to a million people, and it will be powered by green hydrogen.

The U.S. company Air Products & Chemicals has been building a green hydrogen plant there for the last four years.  The giant plant will be powered by 4 gigawatts of wind and solar projects.

Green hydrogen is hydrogen produced without carbon emissions.  Most hydrogen produced commercially is made from natural gas, which results in CO2 emissions.  Green hydrogen is made by using electricity to split water into its component elements using renewable energy to power the process.

Saudi Arabia is an ideal place for a giant green hydrogen plant.  The Middle East has the world’s cheapest wind and solar power.  The sun reliably shines there almost every day and the wind blows almost every night.

While some proponents argue that hydrogen should fuel the entire energy system, other experts see it as a more targeted solution.  The view is that wind and solar power can provide the electricity we need to power homes and electric cars.  However, green hydrogen could be ideal to power energy-intensive industries like concrete and steel manufacturing, as well as parts of the transportation sector that are more difficult to electrify.

While green hydrogen is barely on the radar in the US, around the world a green hydrogen rush is underway, developing it as an energy source that could help end the reign of fossil fuels.

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Green Hydrogen: Could It Be Key to a Carbon-Free Economy?

Photo, posted November 6, 2020, courtesy of RSM Chrystie via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

Renewables Surpass Coal | Earth Wise

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In 2019, energy consumption in the U.S. from renewable sources exceeded consumption from coal for the first time since before 1885.  This has come about from a combination of the continued decline in the amount of coal used for electricity generation as well as the continued growth in renewable energy, mostly from wind and solar.

Until the mid-1800s, burning wood was the main source of energy in the U.S. and, in fact, it was the only commercial-scale renewable energy source until the first hydroelectric plants came online in the 1880s.  Coal was used as fuel for steamboats and trains and making steel but only started to be used to generate electricity in the 1880s.

In 2019, U.S. coal consumption decreased for the sixth consecutive year and fell to its lowest level in 42 years.  Natural gas has displaced much of the energy generation from retired coal plants.

At the same time, renewable energy consumption in the U.S. grew for the fourth year in a row to a record high level, almost entirely as a result of the growing use of wind and solar power.  In 2019, wind power surpassed hydroelectric power for the first time and is now the most-used source of renewable energy for electricity generation in the U.S.

Coal was once commonly used in the industrial, transportation, residential, and commercial sectors.  Today, in the U.S., it is mostly used to generate electricity, and that use is rapidly declining.

Electricity consumption for 2020 is likely to be anomalous in many ways as a result of the Covid-19 pandemic shutdowns.  From all indications, however, the role of renewable energy will only have been increased during the shutdown period.

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U.S. renewable energy consumption surpasses coal for the first time in over 130 years

Photo, posted July 26, 2013, courtesy of Don Graham via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

An Incentive For Carbon Capture | Earth Wise

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Convincing industries to reduce their carbon dioxide emissions has not been easy.  Many approaches have been debated, including carbon taxes, carbon tax-and-trade schemes, and passing a giant Green New Deal.  Most economists agree that putting a price on carbon is likely to be the most effective approach.

But there is already in place an adjustment to the US tax code that is more of a carrot than a stick.  It is a tax credit that is designed to make capturing CO2 a financial winner for a number of high-emitting industries.  The credit, called 45Q, was enacted in February 2018.

The 45Q credit earns industrial manufacturers $50 per metric ton of CO2 stored permanently or $35 per ton if the CO2 is put to use.  An earlier credit for capturing carbon dioxide was limited to only $20 per metric ton and was capped at 75 million tons.  Some large fossil fuel companies did make use of the earlier credit.

The new version does not have a cap, but to qualify, companies need to start constructing carbon-capture facilities within 7 years and have 12 years to claim their money.

Companies with emission-intensive operations are busy figuring out how to take advantage of the credit.  These include cement makers, steel and power plants, corn ethanol producers, and ammonia plants.

Because the credit mandates that companies start constructing their carbon-capture facilities within seven years, most companies will tend to rely on mature technologies.  But the tax credit should also drive demand for next-generation carbon-capture technologies, of which there are many under development.  Saving lots of money on taxes is likely to lure US companies to capture carbon dioxide.

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45Q, the tax credit that’s luring US companies to capture CO2

Photo, posted October 2, 2014, courtesy of Sask Power via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

Extreme Heat From Solar Power | Earth Wise

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Renewable sources are playing a growing role in meeting our energy needs, but one place where they have continued to fall short is in industrial processes that require extreme heat.  These include the cement, steel, and glass industries, among others.  These industries account for a significant amount of CO2 emissions because the most effective way to reach the necessary temperatures continues to be combustion of fossil fuels.  The cement industry alone accounts for 7% of global emissions and the need for cement continues to grow.

A previously stealthy startup company backed by Bill Gates and fellow billionaire Soon-Shiong has made a breakthrough in the area of using solar energy to achieve high temperatures.  The company, called Heliogen, has created a solar oven that is capable of generating heat above 1800 degrees Fahrenheit, which is enough for high-temperature industrial processes.

The Heliogen technology uses concentrated solar power to generate heat.  Concentrated solar power uses arrays of mirrors to reflect sunlight and focus it to a single point.  That technology is not new;  there are systems that use it to produce electricity and, to some extent, heat for industry.  But it could not achieve high enough temperatures for producing cement or steel.

The new system uses computer vision software, automatic edge detection and other sophisticated technologies to focus the sun’s rays far more finely than ever before and thereby generate far higher temperatures at the focal point.

Heliogen is now focused on demonstrating how the technology can be used in a large-scale application, such as cement-making.  The selling points to industry are that not only will there be no emissions generated, but that the fuel needed to obtain their extreme heat will be free.

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Secretive energy startup backed by Bill Gates achieves solar breakthrough

Photo courtesy of Heliogen.

Earth Wise is a production of WAMC Northeast Public Radio.

Mass Timber

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Mass timber is a type of construction typically characterized by the use of large solid wood panels for wall, floor, and roof construction. Large structural panels, posts, and beams glued under pressure or nailed together in layers, with the wood’s grain stacked perpendicular for extra strength – are prized as innovative building materials, superior to concrete and steel in many ways.  Mass timber has pushed the perceived boundaries of wood construction, leading to building heights and spans that traditionally have required concrete, steel or masonry for structural support. The move to mass timber has become something of a construction revolution and many see it as a significant part of a climate change solution. 

The question is just how green is mass timber construction?  How sustainable is it in terms of the forest management, logging, manufacture and transportation of wood products involved?

A number of environmental groups are very skeptical.  There is not yet comprehensive data on the subject.  Only recently have interdisciplinary scientists begun to study the potential climate impacts of the wide use of mass timber.

Despite these questions, the mass timber industry is taking off.  Demand for mass timber posts and beams has led to new sawmills opening in the U.S. Northwest and many new jobs for loggers.

The aesthetics and economics of mass timber are both very attractive compared with conventional large-scale construction materials.  The real unknowns relate to the environmental impact of its widespread use.  If that can take place in a sustainable and environmentally conscientious way, it would be very important in the fight against climate change.  Carbon dioxide emissions from the building industry account for more than a third of global emissions, primarily from the concrete and steel industries.

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As Mass Timber Takes Off, How Green Is This New Building Material?

Photo, posted March 19, 2018, courtesy of Freres Lumber Co via Flickr.

Earth Wise is a production of WAMC Northeast Public Radio.

The Chinese War On Pollution

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For years, China has been struggling with some of the worst air pollution in the world.  According to the European Union, only 1% of the country’s half a billion city dwellers were considered safe because almost all of its major cities were covered with what was described as a toxic grey cloud.

[Read more…] about The Chinese War On Pollution

Spider Silk

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Spider silk – the protein fiber spun by spiders to make webs, nests, cocoons, and wrapping for prey that they stash away – is a remarkable substance.  Its mechanical properties combine high tensile strength and high extensibility or ductility.  This allows spider silk to absorb a lot of energy before breaking.   It is stronger than steel, but not as strong as Kevlar, for example.  On the other hand, it is tougher than either.

[Read more…] about Spider Silk

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