In this lesson, we will continue the discussion about energy but will turn to the manufacturing (or “industrial”) sector. The U.S manufacturing sector uses a significant amount of energy, emits a large portion of greenhouse gases (GHG) and is a major economic contributor in terms of jobs and GDP. Globally, growing populations and rising middle classes throughout the developing world, will mean new consumers demanding all the products we take for granted in the U.S. That means more natural resources to fuel factories and energy sources to power them. In light of that fact, it is important to understand where the manufacturing sector stands in terms of its own transition from energy efficiency to onsite renewables. How manufacturers consume energy and how policy-makers incentive energy efficiency and use of renewables is of critical importance globally as we seek to build a more sustainable energy future and economic system.
Upon completion of this lesson, you will be able to:
Read | Lesson 7 content and all assigned readings |
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Participate | Graded Discussion |
Complete | Essay |
If you have questions, please feel free to post them to the Questions about EGEE 401 Discussion forum in Canvas. While you are there, feel free to post your own responses if you, too, are able to help a classmate.
Ever since the onset of the industrial revolution, manufacturing capacity and output in the US has been nurtured due to its critical importance both in terms of producing what US consumers demand, but also in terms of the key components and products needed to maintain national security. Underpinning that growth has been the relatively easy access to the vast natural resources reserves in the US including abundant fossil fuels to power manufacturing facilities.
While the overall percentage of the workforce employed in manufacturing has fallen considerably in the past fifty years, the industrial sector still accounts for approximately 11% of US GDP and hovers around 9% of the workforce (NAM: 2022 US Manufacturing Facts [1]). Despite this smaller economic footprint in the US, the industrial sector emits 23% of total US GHG emissions (EPA) and accounts for 33% of total U.S. energy consumption (EIA). Thus, when looking at the energy transition in the US, as with the transportation sector, improving manufacturing processes and materials use is imperative (EIA: Use of Energy Explained [2]).
Industrial processes use energy in a variety of ways including those similar to commercial and residential facilities: heating and cooling, lighting and office-related needs. But manufacturing also requires energy to turn motors and power industrial equipment, generate steam for process heating and even use fossil fuel derivatives for feedstocks (e.g., chemicals, plastics). Natural gas and petroleum account for the majority of energy use with renewables seeing a slight increase in the past 20 years. One area where manufacturing has made significant gains is in energy efficiency. In fact, data from the most recent Manufacturing Energy Consumption Survey from the US EIA (2018) revealed that “from 1998 to 2018, manufacturing energy intensity decreased by 26%. During this same period, manufacturing gross output increased by 12%, indicating continued energy efficiency gains.”
Not surprisingly, accompanying the efficiency gains have been a general trend of declining GHG emissions from US manufacturers in terms of both direct emissions (produced at the facility) and indirect emissions (produced offsite but associated with the facility’s use of electricity). The EPA reports that “total U.S. greenhouse gas emissions from industry, including electricity, have declined by 14% since 1990.” Even with all the positive momentum in this sector toward greater energy efficiency and a lower carbon footprint, there is still ample opportunity for improvement due to the variety of ways the industrial sector consumes energy and the vast amount of resources required as feedstock and inputs to production.
This Project Drawdown site provides a "Sector Summary of Industry [3]."
This EPA site documents "Sources of Greenhouse Gas Emissions [4]."
After reviewing the EPA overview of GHG emissions in the US industrial sectors, turn back again to Project Drawdown to explore energy use in the industrial sector. Scan the "Solutions in this Sector" examples at the bottom of the page and compare with the four general reduction opportunities the EPA identifies. How might the solution categories in Project Drawdown help address any of the four opportunities identified by EPA? What other reduction opportunities could EPA have identified? What about additional solutions Project Drawdown could highlight? No doubt there are many ways to reduce energy use in the extremely complex system that constitutes the US industrial sector. Considering the improvements that have already occurred and the many opportunities that remain, US manufacturing is positioned to play a complementary role to overarching energy and climate goals.
Due to the overall importance of manufacturing to the US economy, the federal government devotes a significant amount of resources toward ensuring the strength of the sector but also toward continued improvement of its energy efficiency and use of clean energy (through incentives, tax credits, grants, etc.). Importantly though, manufactured components are needed to build wind turbines, solar panels, battery storage devices, variable speed motors and other finished products that collectively contribute to the energy transition. Using lighter materials and recycled materials in the manufacturing process also means final products that are themselves potentially more energy efficient and sustainable from a resource standpoint. Thus, as the US and other countries incentivize the development of the products and technologies that result in more renewables and more energy efficient products, the efficiency and sustainability of the manufacturing process itself can convey multiple co-benefits to society.
This US Department of Energy document shares “Energy-Saving Opportunities for Manufacturing Enterprises [5].”
What might the future state of manufacturing look like with continued improvements in energy use? In the video below, the US Department of Energy outlines some of the benefits to the economy and the energy transition of clean manufacturing techniques. Importantly, this video drives home the point that cleaner manufacturing processes improve energy efficiency and sustainability, but also new materials and methods used in the process itself result in manufactured components that improve the overall sustainability of many types of final products. Lastly, increased efficiency, productivity and sustainability of the industrial sector can significantly enhance the overall competitiveness of US manufacturing.
Most of us have a basic understanding of manufacturing. It's how we convert raw materials, components, and parts into finished goods that meet our essential needs and make our lives easier. But what about clean energy manufacturing? Think of it as taking manufacturing to the next level.
Some clean energy manufacturers use innovative technologies to improve manufacturing products or processes by reducing energy use in waste. Others use cutting-edge advanced manufacturing techniques like 3D printing to save time and energy or to build other clean energy technologies like wind turbines and solar panels. Clean energy and advanced manufacturing have the potential to boost the US manufacturing industry and open pathways to increased American competitiveness.
So, what does clean energy manufacturing look like? Well, one example is advanced fiber reinforced polymer composites. These innovative materials combine strong fibers with tough plastics so that the end product is stronger but lighter than steel. American manufacturers already use advanced composites and products such as aircraft and satellites, but as manufacturing processes for making advanced composites become faster and more efficient. Lower costs will unleash these materials and other industries - including clean energy industries. For example, advanced composites could help manufacturers make lightweight vehicles with record-breaking fuel economy. Lighter and longer wind turbine blades and strong high-pressure tanks for natural gas fueled cars.
Let's look at their potential benefits for vehicles. Advanced composites could reduce the weight of a vehicle's body and chassis by as much as 50 percent and improve fuel efficiency by about 25 percent without compromising performance or safety. This could help save thousands in fuel costs over the lifetime of an average vehicle. Another example of clean energy manufacturing is advanced battery technology for plug-in electric vehicles. Most plug-in electric vehicles today use lithium-ion batteries, which already offer an excellent power-to-weight ratio, high-energy efficiency, and long life. But through advanced manufacturing, new advancements in lithium-ion battery production has led to significant cost reductions. This makes for cheaper batteries and more plug-in electric vehicles on the streets.
Advanced manufacturing means more than just making high-tech products. It also includes using new leading-edge machines and processes to streamline productivity, saving time, energy and money. One example is 3D printing or additive manufacturing. With this breakthrough process, product development no longer begins on a draftsman table, instead additive manufacturing creates 3D objects directly from a computer model reducing wasted materials and saving energy. So how does it work? 3D printing produces an object from scratch by adding material and successive layers, similar to how an inkjet printer deposits tiny dots of ink to make a 2D image. 3D printers can create nearly any object imaginable by depositing materials right where they are needed. This fast-developing new technique will likely make a huge impact in manufacturing as it gives industry new design flexibility, reduces energy use, and shortens time to market. A variety of industries are exploring 3D printing, including clean energy, automotive, electronics, aviation, pharmaceuticals, and food. So, as you can see, clean energy manufacturing is changing the way we do business. From the kinds of products we build to the ways we build them, and it's making America more competitive. Clean energy manufacturing, recharging and revolutionizing American manufacturing.
In this lesson, we explored energy use in the industrial sector and the general trends overtime in its improved energy efficiency and lower GHG emissions. However, there is still ample opportunity for improvements in multiple types of manufacturing processes across all industrial sectors. Considering how dependent the US economy is on spending on consumer products, improving the sustainability of high demand/widely used goods can result in big wins for energy and the environment. There are also many incentives at the federal and state levels for improved industrial energy efficiency. Improving the energy use profile of manufacturing while also utilizing new materials in the manufacturing process itself, can yield multiple co-benefits for society at large. To pull these concepts together, we’re going to engage in a creative activity.
To successfully complete this assignment, you will write an essay which reflects the ideas and concepts presented in this lesson, specifically answering the questions provided below.
You will need to pick one manufactured item from your home (piece of furniture, an electronic device, bathroom fixture, etc.) and research the typical manufacturing process for that item and how facilities that produce that item (or its component parts) typically use energy.
In your submission of 325 (plus or minus 10%) word or less, please answer the following questions:
Hint: the US Department of Energy, EPA and EnergyStar all have good resources to understand basic manufacturing processes, related energy use as well as incentives and best practices.
Links
[1] https://nam.org/state-manufacturing-data/2022-united-states-manufacturing-facts/
[2] https://www.eia.gov/energyexplained/use-of-energy/industry.php#:~:text=The%20United%20States%20is%20a,of%20total%20U.S.%20energy%20consumption
[3] https://drawdown.org/sectors/industry
[4] https://www.epa.gov/ghgemissions/sources-greenhouse-gas-emissions#industry
[5] https://www.nrel.gov/docs/fy11osti/50365.pdf