Preliminary overview of innovative industrial-materials processes

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Abstract
In evaluating the potential for industrial energy conservation, 45 candidate processes were identified. The chemical and the iron and steel industries presented the most well-developed candidates, whereas those processes identified in the pulp and paper and textiles industries were the most speculative. Examples of the candidate processes identified include direct steelmaking and ore-to-powder systems, which potentially require 30 to 40% less energy, respectively, than conventional steelmaking systems; membrane separations and freeze crystallization, which offer up to 90% reductions in energy use when compared with distillation; the cold processing of cement, which offers a 50% reduction in energy requirements; and the dry forming of paper, which offers a 25% reduction in the energy needed for papermaking. A review of all the industries revealed that the revolutionary alternatives often use similar concepts in avoiding current process inefficiencies. These concepts include using chemical, physical, or biological processes to replace thermally intensive processes; using specific forms of energy to minimize wasteful thermal diffusion; using chemical, biological, or ultrasonic processes to replace physical reduction; combining multiple processing steps into a single reactor; using a dry processing to eliminate energy needed for evaporation; and using sterilization or biotechnology to reduce the need for refrigeration.

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