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A Massachusetts university is developing technology that aims to use lasers to drastically cut emissions and energy use from Maine’s paper and pulp industry.
Worcester Polytechnic Institute recently received a $2.75 million U.S. Department of Energy grant to help ready the industrial drying technology for commercial use.
“We are all excited about this — this is potentially a groundbreaking technology,” said Jamal Yagoobi, founding director of the institute’s Center for Advanced Research in Drying.
In Maine, the paper and pulp business generates about 1 million metric tons of carbon dioxide emissions each year, roughly half of the state’s industrial emissions. Much of these emissions come from the process of drying mashed, pressed, and rolled wood pulp to yield paper products. The emissions come mainly from three major operations across the state; three additional facilities contribute smaller amounts.
These plants’ emissions will need to be addressed if Maine is to reach its goal of going carbon neutral by 2045. Furthermore, each of these plants is located in an area with an above-average population of low-income residents, according to data assembled by Industrious Labs, an environmental organization focused on the impact of industry. And two are located in areas with a higher-than-average risk of cancer from air toxins, suggesting a correlation between their operations and the incidence of cancer in the area.
At the same, the paper and pulp industry remains economically important to Maine, said Matt Cannon, state conservation and energy director for the Maine chapter of the Sierra Club.
“It’s got real union jobs — the paper industry is still very important to our community,” he said.
Worcester Polytechnic’s drying research center has been working on ways to dry paper, pulp, and other materials using the concentrated energy found in lasers. The lasers Yagoobi’s team is using are not the lasers of the public imagination, like a red beam zapping at alien enemies. Though the lasers are quite strong — they can melt metal, Yagoobi says — they are dispersed over a larger area, spreading out the energy to evenly and gently dry the target material.
Testing on food products has shown that the technology can work. Now, researchers need to learn more about how the laser energy affects different materials to make sure the product quality is not compromised during the drying process.
“For paper, it’s important to make sure the tensile strength is not degrading,” Yagoobi said. “For food products, you want to make sure the color and sensory qualities do not degrade.”
Therefore, before the system is ready for a commercial pilot, the team has to gather a lot more data about how much laser energy is incident on different parts of the surface and how deeply the energy penetrates different materials. Once gathered, this data will be used to determine what system sizes and operating conditions are best for different materials, and to design laser modules for each intended use.
Once these details are worked out, the laser technology can be installed in new commercial-scale drying equipment or existing systems. “This particular technology will be easy to retrofit,” Yagoobi said.
Industrial sources were responsible for about 1.3 billion metric tons of carbon dioxide emissions in the United States in 2023, about 28% of the country’s overall emissions, according to the U.S. Energy Information Administration. Heating processes, often powered by natural gas or other fossil fuels, are responsible for about half of those emissions, said Evan Gillespie, one of the co-founders of Industrious Labs. Many industrial drying processes require high temperatures that have traditionally been hard to reach without fossil fuels, giving the sector a reputation as hard to decarbonize, Gillespie said.
“The key challenge here is: How do you remove natural gas as a heating source inside industrial facilities?” said Richard Hart, industry director at the American Council for an Energy-Efficient Economy. “The scale of what is happening in industry is enormous, and the potential for change is very powerful.”
To make the new technology effective, industry leaders and policymakers will need to commit to reinvesting in old facilities, Gillespie noted. And doing so will be well worth it by strengthening an economically important industry, keeping jobs in place, and creating important environmental benefits, he added.
“There’s often this old story of tensions between climate and jobs,” Gillespie said. “But what we’re trying to do is modernize these facilities and stabilize them so they’ll be around for decades to come.”
Paper and pulp mills produce half of Maine’s industrial CO2 emissions. Could lasers help slash their climate impact? is an article from Energy News Network, a nonprofit news service covering the clean energy transition. If you would like to support us please make a donation.
The operators of the decades-old energy systems that heat and cool buildings in downtown Minneapolis and St. Paul have ambitious plans underway to reduce emissions.
The mostly hidden networks of insulated pipes connected to centralized heating and cooling equipment are known as district energy systems. They’ve long been championed as an energy efficient way to heat and cool campuses or downtowns, especially in cooler climates.
Many, though, are connected to fossil fuel facilities, and the systems’ high efficiency alone won’t be enough to help schools, cities, and companies meet their goals of eliminating greenhouse gas emissions by midcentury or sooner. Climate pledges by these institutional customers are now driving efforts to repower district energy systems with clean energy.
University district energy systems began initiatives to reduce emissions years ago and “now in the last five years we’re seeing a lot of emphasis on this from cities and towns,” said Rob Thornton, president and CEO of the International District Energy Association.
In Minneapolis, Cordia Energy, the private company that operates the largest downtown district energy system, is replacing natural gas boilers with electric models. And in downtown St. Paul, officials are seeking federal funding for a project to recover heat from a wastewater treatment plant and reduce energy use for a system currently powered by electricity and biomass.
“We’re doing decarbonization at the rate that our customer base is asking for and we can economically withstand,” said Jacob Graff, Cordia Energy’s north region president. Customers connected to its downtown Minneapolis system range from stadiums and high rises to apartments and medical facilities.
The concept of district heating has been around for centuries, with its roots in the networks of hot water pipes built in ancient Rome. Some of the first modern steam-based systems were built in New York in the 1880s. Today, the United States has more than 700 district energy systems heating and cooling buildings in downtowns, universities, medical campuses, towns and communities.
Cordia Energy’s Minneapolis system opened in 1972 to serve the 57-story IDS Center, still the tallest building in Minneapolis. Today, the steam and chilled water system manages seven plants that heat and cool the IDS and more than 100 other buildings, including U.S. Bank Stadium, Target Center, and the convention center.
Hennepin County owns and operates a much smaller district energy system, connected to a downtown trash incinerator, that primarily serves county buildings and Minneapolis City Hall.
District Energy St. Paul began in the early 1980s after then-Mayor George Latimer hired Swedish engineer Hans Nyman to replace the aging steam system with a hot-water central heating system. Latimer wanted to create a national model of district energy and he largely succeeded. District Energy St. Paul has the largest hot water system in the country, with more than 200 buildings.
Together, the two systems serve some of the state’s biggest buildings, which have emerged as the largest source of greenhouse gas emissions in both cities. In Minneapolis, 65% of the emissions are from commercial, multifamily and industrial buildings. St. Paul’s data is similar.
Cordia plans to reduce emissions from its Minneapolis system by 30% by 2030 before reaching net zero by 2050. Xcel Energy’s green tariff program will offset around half the electricity Cordia uses this year, and it wants to buy more credits if they become available.
The company is replacing older engine-driven chillers with electric models at the former Dayton’s department store, where it has operations. Chillers modulate the temperature inside buildings and can be powered by electricity or natural gas. Geothermal is another potential solution being studied.
A potential geothermal project “hasn’t cleared the economic hurdles yet,” Graff said. “I think we’ll eventually get there.”
Minneapolis customers are not alone in seeking to reduce emissions from district energy systems, Graff said. San Francisco will be Cordia’s first system to decarbonize using hydropower from a dam the company owns in Yosemite National Park.
Downtown St. Paul’s district heating system is owned and operated by a company called District Energy, which recently worked with the city and the regional planning agency on a $152 million U.S. EPA grant application to tap heat from a regional wastewater plant for the city’s system. It would include a project with Xcel Energy to pay for an electric boiler and hot water storage.
District Energy president and CEO Ken Smith said half the system already has been decarbonized through biomass, solar thermal and renewable energy credits. An analysis showed that recovering heat from the Metro Wastewater Treatment Plant, which manages 170 million gallons of water daily, could produce 60 megawatts of thermal energy, and heat pumps could lift the temperature up to the system average.
If District Energy receives the Climate Pollution Reduction Grant, the system would go live in 2028 and allow District Energy to provide 92% of energy from carbon-free or carbon-neutral sources, far ahead of its goal of net zero by 2050.
“This certainly would be able to accelerate that by 30 years,” Smith said. “From everything we’ve seen, there’s nothing like this, certainly not in the United States, and I don’t believe there’s anything like it at this scale in Canada, either.”
St. Paul Resilience Officer Russ Stark said District Energy’s emissions represent a small portion of the total greenhouse gases in the city. Still, around 50,000 tons of carbon would be eliminated annually, and that’s “very impactful,” he said.
The wastewater project would allow District Energy St. Paul to expand to more buildings, decarbonizing them in the process, Stark said. Adding clients “is not a simple process but we’ve been talking a lot about that being an exciting part of the project,” he said. “I don’t know how many major city downtowns there are where there’s an opportunity to largely decarbonize most of the downtown in the way that we can.”
A one-size-fits-all solution for decarbonizing district energy systems doesn’t exist, as most are unique based on customers and geography. Not all can be inexpensively retrofitted for electricity, and the ongoing office and commercial real estate fallout from the Covid-19 pandemic adds risk to financing projects.
Thornton, of the district energy association, said electricity pricing can escalate quickly, especially in summer, creating uncertainty in the market. New technology may require more space, different controls and significant staff training. Federal policy remains unclear about what parts of a district energy system would qualify for tax incentives, he said.
Graff ticks off many challenges in decarbonizing Cordia’s Minneapolis operations. Geothermal works well on campuses and in low-slung neighborhoods where the problem of sending steam to the 50th floor of a skyscraper does not exist, Graff said.
There’s not a simple clean power source like natural gas that has the energy density to create and push steam through a network, he said. To illustrate the point during a tour of Cordia’s downtown plant, he pointed to a pipe with a modest circumference and said the natural gas flowing through it provided the heating for much of the system.
Electrification may be a goal of heating and cooling, but offsetting it with clean power is daunting. Cordia would have to install heat pumps capable of drawing more than 400 megawatts from a clean energy source, which would be no small feat, Graff said.
Hydrogen sounds promising but has no track record yet for supplying an entire downtown district energy system, Graff said. Biomass has potential, too, but sourcing enough it to service a sprawling district energy system reliably remains difficult.
Battery storage, microgrids and other technologies could all play a role, but each brings issues ranging from cost to a lack of testing in a district energy environment, at least at the size of the downtown Minneapolis system.
“We have the economy of Minneapolis in our hands, and regional economics depend on downtown Minneapolis,” Graff said “We need a reliable infrastructure that people can count on that can be delivered economically, and it’s our responsibility to do that.”
In Twin Cities and beyond, district energy systems see pressure to cut carbon emissions is an article from Energy News Network, a nonprofit news service covering the clean energy transition. If you would like to support us please make a donation.
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