More stories

  • in

    To decarbonize the chemical industry, electrify it

    The chemical industry is the world’s largest industrial energy consumer and the third-largest source of industrial emissions, according to the International Energy Agency. In 2019, the industrial sector as a whole was responsible for 24 percent of global greenhouse gas emissions. And yet, as the world races to find pathways to decarbonization, the chemical industry has been largely untouched.

    “When it comes to climate action and dealing with the emissions that come from the chemical sector, the slow pace of progress is partly technical and partly driven by the hesitation on behalf of policymakers to overly impact the economic competitiveness of the sector,” says Dharik Mallapragada, a principal research scientist at the MIT Energy Initiative.

    With so many of the items we interact with in our daily lives — from soap to baking soda to fertilizer — deriving from products of the chemical industry, the sector has become a major source of economic activity and employment for many nations, including the United States and China. But as the global demand for chemical products continues to grow, so do the industry’s emissions.

    New sustainable chemical production methods need to be developed and deployed and current emission-intensive chemical production technologies need to be reconsidered, urge the authors of a new paper published in Joule. Researchers from DC-MUSE, a multi-institution research initiative, argue that electrification powered by low-carbon sources should be viewed more broadly as a viable decarbonization pathway for the chemical industry. In this paper, they shine a light on different potential methods to do just that.

    “Generally, the perception is that electrification can play a role in this sector — in a very narrow sense — in that it can replace fossil fuel combustion by providing the heat that the combustion is providing,” says Mallapragada, a member of DC-MUSE. “What we argue is that electrification could be much more than that.”

    The researchers outline four technological pathways — ranging from more mature, near-term options to less technologically mature options in need of research investment — and present the opportunities and challenges associated with each.

    The first two pathways directly replace fossil fuel-produced heat (which facilitates the reactions inherent in chemical production) with electricity or electrochemically generated hydrogen. The researchers suggest that both options could be deployed now and potentially be used to retrofit existing facilities. Electrolytic hydrogen is also highlighted as an opportunity to replace fossil fuel-produced hydrogen (a process that emits carbon dioxide) as a critical chemical feedstock. In 2020, fossil-based hydrogen supplied nearly all hydrogen demand (90 megatons) in the chemical and refining industries — hydrogen’s largest consumers.

    The researchers note that increasing the role of electricity in decarbonizing the chemical industry will directly affect the decarbonization of the power grid. They stress that to successfully implement these technologies, their operation must coordinate with the power grid in a mutually beneficial manner to avoid overburdening it. “If we’re going to be serious about decarbonizing the sector and relying on electricity for that, we have to be creative in how we use it,” says Mallapragada. “Otherwise we run the risk of having addressed one problem, while creating a massive problem for the grid in the process.”

    Electrified processes have the potential to be much more flexible than conventional fossil fuel-driven processes. This can reduce the cost of chemical production by allowing producers to shift electricity consumption to times when the cost of electricity is low. “Process flexibility is particularly impactful during stressed power grid conditions and can help better accommodate renewable generation resources, which are intermittent and are often poorly correlated with daily power grid cycles,” says Yury Dvorkin, an associate research professor at the Johns Hopkins Ralph O’Connor Sustainable Energy Institute. “It’s beneficial for potential adopters because it can help them avoid consuming electricity during high-price periods.”

    Dvorkin adds that some intermediate energy carriers, such as hydrogen, can potentially be used as highly efficient energy storage for day-to-day operations and as long-term energy storage. This would help support the power grid during extreme events when traditional and renewable generators may be unavailable. “The application of long-duration storage is of particular interest as this is a key enabler of a low-emissions society, yet not widespread beyond pumped hydro units,” he says. “However, as we envision electrified chemical manufacturing, it is important to ensure that the supplied electricity is sourced from low-emission generators to prevent emissions leakages from the chemical to power sector.” 

    The next two pathways introduced — utilizing electrochemistry and plasma — are less technologically mature but have the potential to replace energy- and carbon-intensive thermochemical processes currently used in the industry. By adopting electrochemical processes or plasma-driven reactions instead, chemical transformations can occur at lower temperatures and pressures, potentially enhancing efficiency. “These reaction pathways also have the potential to enable more flexible, grid-responsive plants and the deployment of modular manufacturing plants that leverage distributed chemical feedstocks such as biomass waste — further enhancing sustainability in chemical manufacturing,” says Miguel Modestino, the director of the Sustainable Engineering Initiative at the New York University Tandon School of Engineering.

    A large barrier to deep decarbonization of chemical manufacturing relates to its complex, multi-product nature. But, according to the researchers, each of these electricity-driven pathways supports chemical industry decarbonization for various feedstock choices and end-of-life disposal decisions. Each should be evaluated in comprehensive techno-economic and environmental life cycle assessments to weigh trade-offs and establish suitable cost and performance metrics.

    Regardless of the pathway chosen, the researchers stress the need for active research and development and deployment of these technologies. They also emphasize the importance of workforce training and development running in parallel to technology development. As André Taylor, the director of DC-MUSE, explains, “There is a healthy skepticism in the industry regarding electrification and adoption of these technologies, as it involves processing chemicals in a new way.” The workforce at different levels of the industry hasn’t necessarily been exposed to ideas related to the grid, electrochemistry, or plasma. The researchers say that workforce training at all levels will help build greater confidence in these different solutions and support customer-driven industry adoption.

    “There’s no silver bullet, which is kind of the standard line with all climate change solutions,” says Mallapragada. “Each option has pros and cons, as well as unique advantages. But being aware of the portfolio of options in which you can use electricity allows us to have a better chance of success and of reducing emissions — and doing so in a way that supports grid decarbonization.”

    This work was supported, in part, by the Alfred P. Sloan Foundation. More

  • in

    Preparing global online learners for the clean energy transition

    After a career devoted to making the electric power system more efficient and resilient, Marija Ilic came to MIT in 2018 eager not just to extend her research in new directions, but to prepare a new generation for the challenges of the clean-energy transition.

    To that end, Ilic, a senior research scientist in MIT’s Laboratory for Information and Decisions Systems (LIDS) and a senior staff member at Lincoln Laboratory in the Energy Systems Group, designed an edX course that captures her methods and vision: Principles of Modeling, Simulation, and Control for Electric Energy Systems.

    EdX is a provider of massive open online courses produced in partnership with MIT, Harvard University, and other leading universities. Ilic’s class made its online debut in June 2021, running for 12 weeks, and it is one of an expanding set of online courses funded by the MIT Energy Initiative (MITEI) to provide global learners with a view of the shifting energy landscape.

    Ilic first taught a version of the class while a professor at Carnegie Mellon University, rolled out a second iteration at MIT just as the pandemic struck, and then revamped the class for its current online presentation. But no matter the course location, Ilic focuses on a central theme: “With the need for decarbonization, which will mean accommodating new energy sources such as solar and wind, we must rethink how we operate power systems,” she says. “This class is about how to pose and solve the kinds of problems we will face during this transformation.”

    Hot global topic

    The edX class has been designed to welcome a broad mix of students. In summer 2021, more than 2,000 signed up from 109 countries, ranging from high school students to retirees. In surveys, some said they were drawn to the class by the opportunity to advance their knowledge of modeling. Many others hoped to learn about the move to decarbonize energy systems.

    “The energy transition is a hot topic everywhere in the world, not just in the U.S.,” says teaching assistant Miroslav Kosanic. “In the class, there were veterans of the oil industry and others working in investment and finance jobs related to energy who wanted to understand the potential impacts of changes in energy systems, as well as students from different fields and professors seeking to update their curricula — all gathered into a community.”

    Kosanic, who is currently a PhD student at MIT in electrical engineering and computer science, had taken this class remotely in the spring semester of 2021, while he was still in college in Serbia. “I knew I was interested in power systems, but this course was eye-opening for me, showing how to apply control theory and to model different components of these systems,” he says. “I finished the course and thought, this is just the beginning, and I’d like to learn a lot more.” Kosanic performed so well online that Ilic recruited him to MIT, as a LIDS researcher and edX course teaching assistant, where he grades homework assignments and moderates a lively learner community forum.

    A platform for problem-solving

    The course starts with fundamental concepts in electric power systems operations and management, and it steadily adds layers of complexity, posing real-world problems along the way. Ilic explains how voltage travels from point to point across transmission lines and how grid managers modulate systems to ensure that enough, but not too much, electricity flows. “To deliver power from one location to the next one, operators must constantly make adjustments to ensure that the receiving end can handle the voltage transmitted, optimizing voltage to avoid overheating the wires,” she says.

    In her early lectures, Ilic notes the fundamental constraints of current grid operations, organized around a hierarchy of regional managers dealing with a handful of very large oil, gas, coal, and nuclear power plants, and occupied primarily with the steady delivery of megawatt-hours to far-flung customers. But historically, this top-down structure doesn’t do a good job of preventing loss of energy due to sub-optimal transmission conditions or due to outages related to extreme weather events.

    These issues promise to grow for grid operators as distributed resources such as solar and wind enter the picture, Ilic tells students. In the United States, under new rules dictated by the Federal Energy Regulatory Commission, utilities must begin to integrate the distributed, intermittent electricity produced by wind farms, solar complexes, and even by homes and cars, which flows at voltages much lower than electricity produced by large power plants.

    Finding ways to optimize existing energy systems and to accommodate low- and zero-carbon energy sources requires powerful new modes of analysis and problem-solving. This is where Ilic’s toolbox comes in: a mathematical modeling strategy and companion software that simplifies the input and output of electrical systems, no matter how large or how small. “In the last part of the course, we take up modeling different solutions to electric service in a way that is technology-agnostic, where it only matters how much a black-box energy source produces, and the rates of production and consumption,” says Ilic.

    This black-box modeling approach, which Ilic pioneered in her research, enables students to see, for instance, “what is happening with their own household consumption, and how it affects the larger system,” says Rupamathi Jaddivada PhD ’20, a co-instructor of the edX class and a postdoc in electrical engineering and computer science. “Without getting lost in details of current or voltage, or how different components work, we think about electric energy systems as dynamical components interacting with each other, at different spatial scales.” This means that with just a basic knowledge of physical laws, high school and undergraduate students can take advantage of the course “and get excited about cleaner and more reliable energy,” adds Ilic.

    What Jaddivada and Ilic describe as “zoom in, zoom out” systems thinking leverages the ubiquity of digital communications and the so-called “internet of things.” Energy devices of all scales can link directly to other devices in a network instead of just to a central operations hub, allowing for real-time adjustments in voltage, for instance, vastly improving the potential for optimizing energy flows.

    “In the course, we discuss how information exchange will be key to integrating new end-to-end energy resources and, because of this interactivity, how we can model better ways of controlling entire energy networks,” says Ilic. “It’s a big lesson of the course to show the value of information and software in enabling us to decarbonize the system and build resilience, rather than just building hardware.”

    By the end of the course, students are invited to pursue independent research projects. Some might model the impact of a new energy source on a local grid or investigate different options for reducing energy loss in transmission lines.

    “It would be nice if they see that we don’t have to rely on hardware or large-scale solutions to bring about improved electric service and a clean and resilient grid, but instead on information technologies such as smart components exchanging data in real time, or microgrids in neighborhoods that sustain themselves even when they lose power,” says Ilic. “I hope students walk away convinced that it does make sense to rethink how we operate our basic power systems and that with systematic, physics-based modeling and IT methods we can enable better, more flexible operation in the future.”

    This article appears in the Autumn 2021 issue of Energy Futures, the magazine of the MIT Energy Initiative More