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Industrial Decarbonization Roadmap Fact Sheet
The industrial sector is the backbone of America’s economy, producing chemicals, electronics, machinery,
steel, metals, textiles, and many other products that are critical to our society. However, the industrial
sector currently accounts for approximately one third of our nation’s energy-related carbon dioxide (CO2)
emissions. To achieve net zero greenhouse gas (GHG) emissions by 2050, we need to drastically reduce
industry’s collective carbon footprint.
This roadmap identifies four key pathways to reduce industrial emissions through innovation in American
manufacturing. The roadmap emphasizes the urgency of deep decarbonization across the industrial
sector, and presents a staged research, development, and demonstration (RD&D) agenda for industry and
government that will deliver the technologies needed to dramatically reduce emissions.
Five Key Energy Intensive Sectors to Decarbonize
The roadmap focuses on five of the highest CO2-
emitting industries where industrial decarbonization
technologies can have the greatest impact across
the nation. These key sectors—iron and steel;
cement and concrete; food and beverage; chemical
manufacturing; and petroleum refining— represent
approximately 51% of the energy-related CO2
emissions in the U.S. industrial sector and 15% of
U.S. economy-wide total CO2 emissions.
Chemical manufacturing: The U.S.
chemical manufacturing industry is incredibly
diverse and has seen significant growth over
the last decade. To help achieve net-zero goals, the
chemical manufacturing sector can:
Develop low thermal budget process heating
solutions and improve the effectiveness
of thermal energy use to increase energy
efficiency of whole systems
Expand advanced reactions, catalysts,
and reactor systems to improve reaction
performance in addition to reducing carbon
emissions and improving energy efficiency
Electrify processes and use hydrogen,
biomass, or waste as fuel and feedstocks for
manufacturing
Improve materials efficiency and increase
materials circularity
Petroleum refining: Most U.S. refinery
CO2 emissions are from five large
energy-consuming processes: hydrocracking,
atmospheric distillation, catalytic cracking, steam
methane reforming, and regenerative catalytic
reforming. These processes represent the most cost-
effective RD&D opportunities for refineries to reduce
CO2 emissions. To help achieve net-zero goals, the
petroleum refining sector can:
Improve energy efficiency both in processes
and on-site steam and power generation
Industrial Decarbonization Roadmap Fact Sheet Page 1
Lower the carbon footprint of energy sources
and feedstocks by using lower-carbon fossil
energy and introducing low-fossil carbon
sources such as nuclear heat and electricity,
clean electricity, clean hydrogen, or biofuels
Iron and steel: Iron and steel manufacturing
is one of the most energy-intensive industries
worldwide. The use of coal as a feedstock
in production methods, the chemical reduction of
iron oxide, and the sheer volume of iron and steel
produced have made the industry among the highest
in GHG emissions. To help achieve net-zero goals,
the iron and steel sector can:
Transition to low-and no-carbon fuels and
expand industrial electrification
Pilot demonstrations for transformative
technologies such as hydrogen-steel
production, electrolysis of iron ore, and carbon
capture and utilization storage
Improve materials efficiency and increase
materials circularity
Food and beverage: The food and beverage
industry is one of the largest energy
consuming and GHG-emitting industries in
the United States. To help achieve net-zero goals,
the food and beverage sector can:
Improve energy efficiency by advancing the
electrification of process heating, evaporation,
and pasteurization processes
Reduce food waste throughout the supply
chain through methods identified in life cycle
assessments and collaboration between
manufacturers.
Pursue recycling and material efficiency through
alternative packaging and package waste
reduction
Cement: In the U.S. cement industry,
process-related CO2 emissions from
calcination account for about 58% of total
CO2 emissions and energy-related CO2 emissions
accounted for 42% of total emissions. To help
achieve net-zero goals, the cement sector can:
Evolve existing processes to reduce waste,
including circular economy approaches for
concrete construction
Improve materials and energy efficiency with
deployment of breakthrough technologies and
innovative chemistry solutions
Expand use of carbon capture, utilization, and
storage technologies
Increase use low carbon binding materials and
natural supplementary cementitious materials
to lower the carbon-intensity of clinker and solid
materials used to create cement
Four Key Pathways to Industrial Decarbonization
The roadmap identifies four key technological pillars
to significantly reduce emissions for the five most
energy-intensive sectors.
Energy Efficiency: Energy efficiency is a
foundational, crosscutting decarbonization
strategy and is the most cost-effective option
for GHG emission reductions in the near term.
Decarbonization efforts include:
Strategic energy management approaches to
optimize performance of industrial processes
at the system-level
Systems management and optimization of
thermal heat from manufacturing process
heating, boiler, and combined heat and power
sources
Smart manufacturing and advanced data
analytics to increase energy productivity in
manufacturing processes
Industrial Decarbonization Roadmap Fact Sheet Page 2
Industrial Electrification: Leveraging advancements
in low-carbon electricity from both grid and onsite
renewable generation sources will be critical to
decarbonization efforts. Decarbonization efforts
include:
Electrification of process heat using induction,
radiative heating, or advanced heat pumps
Electrification of high-temperature range
processes such as those found in iron, steel,
and cement making
Replacing thermally-driven processes with
electrochemical ones
Low-Carbon Fuels, Feedstocks, and Energy
Sources (LCFFES): Substituting
low-and no-carbon fuel and feedstocks reduces
combustion associated emissions for industrial
processes. Decarbonization efforts include:
Development of fuel-flexible processes
Integration of hydrogen fuels and feedstocks
into industrial applications
The use of biofuels and bio feedstocks
Carbon Capture, Utilization, and Storage (CCUS):
CCUS refers to the multi-component strategy of
capturing generated CO2 from a point source and
using the captured CO2 to make value added
products or storing it long-term to avoid release.
Decarbonization efforts include:
Post-combustion chemical absorption of CO2
Development and manufacturing optimization
of advanced CO2 capture materials that
improve efficiency and lower cost of capture
Development of processes to utilize captured
CO2 to manufacture new materials
Key Recommendations from the Industrial
Decarbonization Roadmap
Advance early-stage RD&D: Further applied
science necessary for net-zero carbon
emissions by 2050.
Invest in multiple process strategies: Continue
parallel pathways of electrification, efficiency,
low carbon fuels, CCUS, and alternative
approaches.
Scale through demonstrations: Support
demonstration testbeds to accelerate and
de-risk deployment.
Address process heating: Most industrial
emissions come from fuel combustion for heat.
Integrate solutions: Focus on systems impact
of carbon reduction technologies on the
supply chain.
Conduct modeling/systems analyses:
Expand use of lifecycles and techno-economic
analyses.
Industrial Decarbonization Roadmap Fact Sheet Page 3
IndustrialDecarbonizationRoadmapFactSheetTheindustrialsectoristhebackboneofAmerica’seconomy,producingchemicals,electronics,machinery,steel,metals,textiles,andmanyotherproductsthatarecriticaltooursociety.However,theindustrialsectorcurrentlyaccountsforapproximatelyonethirdofournation’senergy-relatedcarbondioxide(CO2)emissions.Toachievenetzerogreenhousegas(GHG)emissionsby2050,weneedtodrasticallyreduceindustry’scollectivecarbonfootprint.ThisroadmapidentifiesfourkeypathwaystoreduceindustrialemissionsthroughinnovationinAmericanmanufacturing.Theroadmapemphasizestheurgencyofdeepdecarbonizationacrosstheindustrialsector,andpresentsastagedresearch,development,anddemonstration(RD&D)agendaforindustryandgovernmentthatwilldeliverthetechnologiesneededtodramaticallyreduceemissions.FiveKeyEnergyIntensiveSectorstoDecarbonizeTheroadmapfocusesonfiveofthehighestCO2-emittingindustrieswhereindustrialdecarbonizationtechnologiescanhavethegreatestimpactacrossthenation.Thesekeysectors—ironandsteel;cementandconcrete;foodandbeverage;chemicalmanufacturing;andpetroleumrefining—representapproximately51%oftheenergy-relatedCO2emissionsintheU.S.industrialsectorand15%ofU.S.economy-widetotalCO2emissions.Chemicalmanufacturing:TheU.S.chemicalmanufacturingindustryisincrediblydiverseandhasseensignificantgrowthoverthelastdecade.Tohelpachievenet-zerogoals,thechemicalmanufacturingsectorcan:•Developlowthermalbudgetprocessheatingsolutionsandimprovetheeffectivenessofthermalenergyusetoincreaseenergyefficiencyofwholesystems•Expandadvancedreactions,catalysts,andreactorsystemstoimprovereactionperformanceinadditiontoreducingcarbonemissionsandimprovingenergyefficiency•Electrifyprocessesandusehydrogen,biomass,orwasteasfuelandfeedstocksformanufacturing•ImprovematerialsefficiencyandincreasematerialscircularityPetroleumrefining:MostU.S.refineryCO2emissionsarefromfivelargeenergy-consumingprocesses:hydrocracking,atmosphericdistillation,catalyticcracking,steammethanereforming,andregenerativecatalyticreforming.Theseprocessesrepresentthemostcost-effectiveRD&DopportunitiesforrefineriestoreduceCO2emissions.Tohelpachievenet-zerogoals,thepetroleumrefiningsectorcan:•Improveenergyefficiencybothinprocessesandon-sitesteamandpowergenerationIndustrialDecarbonizationRoadmapFactSheetPage1•Lowerthecarbonfootprintofenergysourcesandfeedstocksbyusinglower-carbonfossilenergyandintroducinglow-fossilcarbonsourcessuchasnuclearheatandelectricity,cleanelectricity,cleanhydrogen,orbiofuelsIronandsteel:Ironandsteelmanufacturingisoneofthemostenergy-intensiveindustriesworldwide.Theuseofcoalasafeedstockinproductionmethods,thechemicalreductionofironoxide,andthesheervolumeofironandsteelproducedhavemadetheindustryamongthehighestinGHGemissions.Tohelpachievenet-zerogoals,theironandsteelsectorcan:•Transitiontolow-andno-carbonfuelsandexpandindustrialelectrification•Pilotdemonstrationsfortransformativetechnologiessuchashydrogen-steelproduction,electrolysisofironore,andcarboncaptureandutilizationstorage•ImprovematerialsefficiencyandincreasematerialscircularityFoodandbeverage:ThefoodandbeverageindustryisoneofthelargestenergyconsumingandGHG-emittingindustriesintheUnitedStates.Tohelpachievenet-zerogoals,thefoodandbeveragesectorcan:•Improveenergyefficiencybyadvancingtheelectrificationofprocessheating,evaporation,andpasteurizationprocesses•Reducefoodwastethroughoutthesupplychainthroughmethodsidentifiedinlifecycleassessmentsandcollaborationbetweenmanufacturers.•PursuerecyclingandmaterialefficiencythroughalternativepackagingandpackagewastereductionCement:IntheU.S.cementindustry,process-relatedCO2emissionsfromcalcinationaccountforabout58%oftotalCO2emissionsandenergy-relatedCO2emissionsaccountedfor42%oftotalemissions.Tohelpachievenet-zerogoals,thecementsectorcan:•Evolveexistingprocessestoreducewaste,includingcirculareconomyapproachesforconcreteconstruction•Improvematerialsandenergyefficiencywithdeploymentofbreakthroughtechnologiesandinnovativechemistrysolutions•Expanduseofcarboncapture,utilization,andstoragetechnologies•Increaseuselowcarbonbindingmaterialsandnaturalsupplementarycementitiousmaterialstolowerthecarbon-intensityofclinkerandsolidmaterialsusedtocreatecementFourKeyPathwaystoIndustrialDecarbonizationTheroadmapidentifiesfourkeytechnologicalpillarstosignificantlyreduceemissionsforthefivemostenergy-intensivesectors.EnergyEfficiency:Energyefficiencyisafoundational,crosscuttingdecarbonizationstrategyandisthemostcost-effectiveoptionforGHGemissionreductionsinthenearterm.Decarbonizationeffortsinclude:•Strategicenergymanagementapproachestooptimizeperformanceofindustrialprocessesatthesystem-level•Systemsmanagementandoptimizationofthermalheatfrommanufacturingprocessheating,boiler,andcombinedheatandpowersources•SmartmanufacturingandadvanceddataanalyticstoincreaseenergyproductivityinmanufacturingprocessesIndustrialDecarbonizationRoadmapFactSheetPage2IndustrialElectrification:Leveragingadvancementsinlow-carbonelectricityfrombothgridandonsiterenewablegenerationsourceswillbecriticaltodecarbonizationefforts.Decarbonizationeffortsinclude:•Electrificationofprocessheatusinginduction,radiativeheating,oradvancedheatpumps•Electrificationofhigh-temperaturerangeprocessessuchasthosefoundiniron,steel,andcementmaking•Replacingthermally-drivenprocesseswithelectrochemicalonesLow-CarbonFuels,Feedstocks,andEnergySources(LCFFES):Substitutinglow-andno-carbonfuelandfeedstocksreducescombustionassociatedemissionsforindustrialprocesses.Decarbonizationeffortsinclude:•Developmentoffuel-flexibleprocesses•Integrationofhydrogenfuelsandfeedstocksintoindustrialapplications•TheuseofbiofuelsandbiofeedstocksCarbonCapture,Utilization,andStorage(CCUS):CCUSreferstothemulti-componentstrategyofcapturinggeneratedCO2fromapointsourceandusingthecapturedCO2tomakevalueaddedproductsorstoringitlong-termtoavoidrelease.Decarbonizationeffortsinclude:•Post-combustionchemicalabsorptionofCO2•DevelopmentandmanufacturingoptimizationofadvancedCO2capturematerialsthatimproveefficiencyandlowercostofcapture•DevelopmentofprocessestoutilizecapturedCO2tomanufacturenewmaterialsKeyRecommendationsfromtheIndustrialDecarbonizationRoadmap•Advanceearly-stageRD&D:Furtherappliedsciencenecessaryfornet-zerocarbonemissionsby2050.•Investinmultipleprocessstrategies:Continueparallelpathwaysofelectrification,efficiency,lowcarbonfuels,CCUS,andalternativeapproaches.•Scalethroughdemonstrations:Supportdemonstrationtestbedstoaccelerateandde-riskdeployment.•Addressprocessheating:Mostindustrialemissionscomefromfuelcombustionforheat.•Integratesolutions:Focusonsystemsimpactofcarbonreductiontechnologiesonthesupplychain.•Conductmodeling/systemsanalyses:Expanduseoflifecyclesandtechno-economicanalyses.IndustrialDecarbonizationRoadmapFactSheetPage3

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