DOI: 10.5061/dryad.djh9w0wcz
title: Technology- and facility-level energy, cost, and environmental performance in U.S. chemicals, cement, iron and steel, food, and non-manufacturing industries

description: This U.S. industrial facilities and technology dataset is a technology-
 and facility-level collection of technological, cost, energy, and
 emissions attributes for six manufacturing and three non-manufacturing
 U.S. industries. The dataset is a JSON array organized by industry. Each
 industry entry (except for mining and agriculture) contains four sections:
 author list, assumptions, emerging technologies, and existing facilities.
 The non-manufacturing industry inventories 18 solutions across
 agriculture, mining and construction sectors and 6 categories, documenting
 qualitative benefits and quantitative energy/emissions reduction
 potentials with low/average/high estimates. The dataset integrates data
 exclusively from publicly available data sources including EPA's
 Greenhouse Gas Reporting Program, U.S. Geological Survey, industry
 reports, peer-reviewed research to provide a unified resource for energy
 systems modeling and analysis. The assumptions section standardizes units
 and conversions and provides fuel and feedstock prices for operating
 expenditure (OPEX) calculations, Chemical Engineering Plant Cost Index
 (CEPCI) values for capital cost (CAPEX) harmonization, and price/inflation
 indices to align values to a common base year. Emerging technologies with
 minimal to no market share in U.S. commercial-scale production facilities
 are characterized across six industries: ammonia (10 processes including
 autothermal reforming, renewable hydrogen-based, biomass gasification,
 methane pyrolysis, and ATR with CCS); cement (26 processes including
 conventional wet/dry kiln variants, low-SCM dry kiln with
 preheater+precalciner, full CCS, and full electrification options);
 ethanol (8 processes including dry mill and wet mill variants, electrified
 process heat via heat pumps, and dry mill BAT with CCS); ethylene and
 propylene (21 processes including electrified steam cracking with
 electricity-cost bands, ethanol-to-ethylene, MTO, and NGL-to-olefins);
 iron and steel (10 processes including H2DRI–EAF, NGDRI–EAF with CCS, and
 molten oxide electrolysis, with varied scrap utilization scenarios); and
 food (9 cross-cutting process-heat decarbonization options such as
 hot-water and steam heat pumps, electric boilers, RNG/biogas boilers, and
 solar thermal steam). The existing facilities section covers: ammonia (36
 facilities across 20 states; SMR 97.2%, coal gasification 2.8%); cement
 (97 facilities across 35 states; conventional dry kiln 90.7%, wet kiln
 9.3%); ethanol (201 facilities; dry mill 95.5%, wet mill 4.5%);
 ethylene/propylene (35 facilities across 6 states; steam cracking 100%);
 iron and steel (102 facilities across 31 states; EAF 86.4%, BF–BOF 7.8%,
 DRI 2.9%, hybrid BF–BOF/EAF 0.9%); and food (production and energy
 intensity by state and five subsectors: animal slaughtering, dairy, fruit
 and vegetable, grain and oilseed milling, and sugar).  The
 dataset offers a broad range of use cases through its standardized JSON
 structure and comprehensive documentation, potentially offering
 interoperability with common analytical tools. Primary uses envisioned for
 this dataset include energy systems optimization modeling, multisectoral
 and integrated assessment modeling of the industrial sector or the broader
 economy (but with higher fidelity of technology characterization),
 technology assessment comparing conventional and emerging production
 routes, spatially resolved production capacity planning analysis, and
 economic analysis of technology deployment costs. The dataset's
 facility-level granularity enables bottom-up modeling approaches while
 maintaining compatibility with top-down sectoral analyses. Technical
 features enhancing reusability include standardized coordinate systems
 (WGS84) for GIS integration, consistent economic units (2018 USD) for
 temporal comparisons, and modular data structure supporting selective
 extraction.
description: # Technology- and facility-level energy, cost, and environmental
 performance in U.S. chemicals, cement, iron and steel, food, and
 non-manufacturing industries This document consolidates per-industry
 READMEs and augments them with field types and examples of the
 US_industrial_facilities_and_technology_dataset.json. # Data description
 This dataset was assembled to enable engineering analysis of energy and
 material flows and technology assessments of various iron and steel
 manufacturing processes. Publicly available facility-level data (EPA
 GHGRP, USGS, EIA, industry reports, peer-reviewed literature) were
 curated, standardized (geocoding, technology classification), and
 harmonized. Process-stage energy/feedstock intensities and direct CO~2~
 factors were cross-validated against mass/energy balances. Capital and
 operating costs were normalized using CEPCI and consistent price
 assumptions. Emerging routes (e.g., hydrogen-based DRI, CCS-enabled,
 electrolytic) were parameterized from literature/pilot studies. The JSON
 supports bottom-up modeling, spatial planning, and benchmarking. No
 proprietary data were used. The industries covered in the dataset include:
 * Iron and steel * Cement * Ammonia * Ethanol * Ethylene and propylene *
 Food (state-level industry characteristics) * Non-manufacturing
 (agriculture, mining, construction; strategies/metadata) # Data provenance
 Sources were curated, standardized, and cross-validated: * U.S. EPA
 Greenhouse Gas Reporting Program (GHGRP) * U.S. Energy Information
 Administration (EIA) * U.S. Geological Survey (USGS) * Industry reports
 and peer-reviewed literature * Mission-specific datasets (e.g., Argonne
 GREET, DOE IEDO studies, Global Energy Monitor trackers) QA/QC included
 geocoding, technology classification, energy/feedstock mass-balance
 checks, and CEPCI/inflation normalization for costs. # File format and
 top-level structure File:
 US_industrial_facilities_and_technology_dataset.json Encoding: UTF-8
 Organization: A list of industry blocks; each block is segmented into: *
 metadata * assumptions * technology_characteristics * existing_facilities
 Notes: * The food block uses existing_industry_by_state (not
 facility-level). * The nonmanufacturing block uses
 emission_reduction_strategies (not facility-level). * “Assumptions”
 provide datasets for CEPCI, fuel/feedstock prices, inflation, units, and
 notes to compute costs and normalize values. Units and boundaries * Energy
 intensity: GJ per metric ton of product (GJ/t). * Feedstock intensity:
 metric ton input per metric ton output (t/t). * Direct/process emissions:
 metric ton CO2 per metric ton product (t CO2/t). “Process” excludes
 combustion unless noted; CCS capture rates may be included. * Capacity:
 typically metric tons per year (t/y). * Costs: * CAPEX: normalized, with
 CEPCI and inflation references. * Fixed O&M: ratio to CAPEX and/or
 fixed amounts per t product. * Variable O&M: fuel and feedstock costs
 computed using Assumptions’ price tables. * Boundaries: Intensities are
 conversion-stage (onsite) unless explicitly noted. Upstream production and
 delivery of fuels/feedstocks are excluded unless stated. Technology
 readiness level (TRL) * TRL follows IEA scale 1–9 (9 = fully commercial).
 * Reported per technology/process stage; references provided per block.
 ### Core field dictionary (common across industries) metadata *
 Description of the industry block, scope, coverage, references, and any
 block-specific notes. assumptions * abbreviations: key abbreviations for
 fuels, feedstocks, and processes. * cepci: Capital cost index values and
 notes (reference year/index). * fuel_price: price tables for fuels (units
 and date/period noted). * feedstock_price: price tables for feedstocks
 (when applicable). * inflation: CPI/PPI or other indices used to normalize
 historical values. * units: canonical units and conversions used across
 the dataset. * notes: boundary, calculation, and normalization notes.
 technology_characteristics * capacity: Dict; capacity arrays and
 references by process stage. * Example keys: ironmaking, steelmaking;
 clinker_production; ammonia_production; ethylene_production;
 propylene_production. * capacity: List of capacities (t/y or
 stage-specific basis). * technology: string name of the technology (e.g.,
 H2DRI, Electrified steam cracker). * reference: citations for capacity
 ranges or basis. * capex: Dict; normalized capital cost arrays and
 references by stage. * capex: List of CAPEX values (units noted in
 references). * reference: list of citations and normalization notes. *
 notes: optional text for scope (brownfield vs greenfield, included
 systems). * characteristics: Dict; descriptors of the technology. *
 technology: canonical label (e.g., “EAF-0% scrap-H2DRI”). * technology_id:
 unique identifier (string or integer). * technology_status: “emerging” or
 “commercial”. * Additional tech-specific attributes (e.g.,
 clinker_to_cement_ratio). * direct_emissions: Dict; process emissions and
 capture rates. * process_ghg_emissions: t CO2/t product; may be null if
 not applicable. * carbon_capture_rate (or
 carbon_capture_rate_from_process/combustion in cement): fraction of CO2
 captured (0–1). * reference: citations. - energy_intensity: Dict;
 fuel/electricity use by stage and fuel type. * Keys for stages (e.g.,
 ironmaking, steelmaking; clinker_production; ammonia_production;
 ethylene_production). * For each stage: * electricity_intensity: GJ/t *
 fuel intensities (GJ/t): natural_gas, industrial_coal, metallurgical_coal,
 residual_fuel_oil, distillate_fuel_oil, propane, steam, other (or
 technology-specific fuels like naphtha). * alternative_energy_intensity
 and benchmarks (when present): bandwidth_study_2015, greet, usitc_2025 —
 alternative/reference intensities for comparison (GJ/t). * notes and
 reference: boundary clarifications (e.g., whether feedstock energy is
 counted as fuel). - feedstock_intensity: Dict; material input rates by
 stage. * Keys vary by stage and industry: * Ironmaking: bf_grade_pellets,
 sinter, dri_grade_pellets, electrolysis_grade_ore, limestone, coke, o2,
 etc. (t/t). * Steelmaking: iron_intensity, scrap, charge_carbon,
 injected_carbon, lime, dolime, o2, ng_reductant_or_feedstock, etc. (t/t).
 * Cement: limestone, clay, silica_sand, iron_ore (clinker stage); clinker,
 gypsum, fly_ash, blast_furnace_slag, other_additives (cement grinding)
 (t/t). * Ammonia: natural_gas (feedstock), oxygen (if relevant), etc. (t/t
 NH3). * Ethylene/propylene: feedstock rates (e.g., ethane, naphtha,
 methanol, ethanol) (t/t product basis noted). * reference: citations. -
 fixed_om_cost: Dict; fixed O&M parameters. * ratio_of_capex: List of
 fractions per stage (e.g., 0.03 → 3% of CAPEX annually). * fixed_om_cost
 or fixed_om_cost_in_addition_to_ratio_of_capex: List of fixed $/t values
 in addition to ratio. * notes: modeling guidance for combining components.
 * reference: citations. - variable_om_cost: Dict; variable O&M costs.
 * fuel_and_feedstock_cost: List of computed $/t using Assumptions’ prices
 and energy/feedstock_intensity. * maintenance_operating_and_labor:
 optional $/t values (if provided). * reference: Dict or String explaining
 calculation method and price sources. - trl: Dict; TRL per stage, with
 references. * Keys: stage names (e.g., ironmaking, steelmaking;
 clinker_production; ammonia_production; ethylene_production). * Values:
 TRL integers (1–9). * reference: source (e.g., IEA ETP Clean Energy
 Technology Guide). - existing_facilities * capacity: Dict; capacity by
 stage and references. * Example keys: ironmaking, steelmaking;
 clinker_production; cement_grinding; ammonia_production;
 ethylene_production; propylene_production. * capacity: numeric capacity
 per stage (t/y). * feedstock_type: for ethylene/propylene, notes like
 “Multi-feed (ethane, propane, butane)”. * reference: citations (e.g.,
 trackers, USGS yearbooks). * technology: installed technology (e.g., BF,
 BOF, EAF, SMR, Steam cracking). * capex: Dict; normalized capital values
 and references (when available). * capex: arrays of CAPEX values for
 relevant stages. * reference: citations and normalization notes. *
 characteristics: Dict; facility descriptors. * facility_name, company,
 facility_id (internal), ghgrp_id (EPA), federal_register_id (EIS),
 global_steel_plant_monitor_id (industry tracker), eis_facility_id, naics,
 facility_status (operating, idle), vintage (years since online), address,
 city, county, state, zip_code, latitude, longitude. * technology:
 installed technology route (e.g., BF-BOF). * feedstock: for ethylene
 facilities, feedstock mix (text). * production: Dict; production and
 utilization metrics. * production: annual production (t/y) when available.
 * capacity_utilization or capacity_utilization_rate: fraction (0–1). *
 reference: citations (e.g., USGS average utilization). * technology: stage
 technology (e.g., BOF). * energy_intensity: Dict; stage energy intensities
 (GJ/t product) and references. * Stage keys (ironmaking, steelmaking;
 clinker_production; ammonia_production; ethylene_production). * Fuel keys
 (electricity, natural_gas, industrial_coal, residual_fuel_oil,
 distillate_fuel_oil, propane, steam, other). *
 alternative_energy_breakdown may include: * fuel_types: list of fuels used
 onsite. * fuel_values: fractions (0–1) of total fuel energy by type. *
 natural_gas_ratio: fraction (0–1). * reference: source (e.g., FIED). *
 notes: boundary clarifications (e.g., whether dilution steam is excluded
 from hydrocarbon feed). - feedstock_intensity: Dict; stage material
 intensities (t/t), references. * Ironmaking examples: bf_grade_pellets,
 sinter, coke, limestone, o2. * Steelmaking examples: iron_intensity,
 scrap, charge_carbon, injected_carbon, lime, dolime, o2,
 ng_reductant_or_feedstock. * Cement examples: clinker/gypsum/additives for
 cement grinding; limestone/clay/sand/iron_ore for clinker. * Ethylene
 examples: feedstock_intensity {ethane: 1.2, naphtha: 0} depending on
 facility feedstock. - fixed_om_cost and variable_om_cost: Dicts (when
 available); same structure and meaning as in technology_characteristics. -
 direct_emissions: Dict; process emissions and capture. *
 process_ghg_emissions: t CO2/t stage output (e.g., BF ironmaking = 0.64 t
 CO2/t iron). *
 greenhouse_gasrp_reported_carbon_dioxide_emissions_non_biogenic_metric_tons: facility-level annual value (cement examples). * reference: citations. - trl: Dict; TRL per stage (typically TRL 9 for commercial technologies), with references. # Industry-specific schema and content notes Iron and steel * Stages: ironmaking (BF, DRI/H2DRI) and steelmaking (BOF, EAF); combined routes may appear (ironmaking_steelmaking). Cement * Stages: raw_material_preparation, clinker_production, cement_grinding. Ammonia * Stage: ammonia_production (SMR, ATR, and variants). Ethanol * Technologies: dry mill and wet mill, with BAT variants. Ethylene and propylene * Technologies: steam cracking (NGL, naphtha, gas oils), electrified furnaces, hydrogen-fired furnaces, ethanol dehydration to ethylene, methanol-to-olefins (MTO). Food * Structure differs: existing_industry_by_state instead of facility-level records. - characteristics: NAICS_code, industry_by_state_id, state, state_and_subsector_name, technology (e.g., “Conventional Grain and Oilseed Milling Processing”). - production: production (t/y) for given year and technology - energy_intensity: end_use_breakdown (e.g., conventional_boiler_use electricity/natural_gas shares), references (DOE IEDO). - Emerging technologies: Hot Water Heat Pump entries with capacity_emerging_technology, capex_emerging_technology, characteristics (technology_id, status), direct_emissions (GHG reduction potential), TRL, references. Nonmanufacturing * Sections: nonmanufacturing_metadata, emission_reduction_strategies (for agriculture, mining, construction). * Focus: strategies and metadata; no facility-level capacity/production entries. # Examples of variable names and content (by type) * capacity (Dict) * Structure: {stage_name: {capacity: [values], technology: "name", reference: [citations]}} * Types: Integer/Float arrays; technology string; reference list of strings. * Content: Minimum/average/maximum capacities per stage; example ranges drawn from industry trackers. * capex (Dict) * Structure: {stage_name: {capex: [values], reference: [citations], notes: "optional"}} * Types: Float arrays; reference list. * Content: Normalized capital costs in M (units noted in references); adjusted via CEPCI/inflation. * characteristics (Dict) * Emerging technologies: {technology, technology_id, technology_status, optional attributes (e.g., clinker_to_cement_ratio)}. * Existing facilities: {facility_name, company, facility_id, ghgrp_id, federal_register_id, global_steel_plant_monitor_id, eis_facility_id, technology, feedstock, address, city, county, state, zip_code, latitude, longitude, naics, vintage, facility_status}. * direct_emissions (Dict) * Structure: {stage_name: {process_ghg_emissions: Float|Null, carbon_capture_rate: Float (0–1) or CCS split for cement, reference: String}} * Content: Process CO2 per t product, CCS fractions, and facility-level non-biogenic annual emissions (cement). * energy_intensity (Dict) * Structure: {stage_name: {electricity: [GJ/t], natural_gas: [GJ/t], industrial_coal: [GJ/t], residual_fuel_oil: [GJ/t], distillate_fuel_oil: [GJ/t], propane: [GJ/t], steam: [GJ/t], other: [GJ/t]}, reference: String, notes: String} * Optional benchmarking keys: alternative_energy_intensity (bandwidth_study_2015, greet, usitc_2025). * Content: Conversion-stage energy use; per-fuel breakdown with references and boundary notes. * feedstock_intensity (Dict) * Structure: {stage_name: {material_key: Float (t/t), ...}, technology: String, reference: String} * Content: Material consumption per t output; industry-specific keys (ore/pellets/scrap for steel; limestone/clinker/gypsum/additives for cement; NG/methanol/ethanol/naphtha for chemicals). * fixed_om_cost (Dict) * Structure: {stage_name: {ratio_of_capex: [Float|Null], fixed_om_cost_in_addition_to_ratio_of_capex or fixed_om_cost: [Float], reference: [String], notes: String}} * Content: Annual fixed O&M modeled as % of CAPEX plus fixed $/t components. * variable_om_cost (Dict) * Structure: {stage_name: {fuel_and_feedstock_cost: [Float], maintenance_operating_and_labor: [Float|Null], reference: Dict|String}} * Content: Computed $/t using Assumptions prices and energy/feedstock intensities; references note price basis. * production (Dict) * Structure: {stage_name: {production: Float|Integer, capacity_utilization: Float, reference: String, technology: String}} * Content: Annual production, utilization rates, and references (e.g., USGS averages). * trl (Dict) * Structure: {stage_name: Integer, reference: String} * Content: TRL by stage (IEA scale). * alternative_energy_breakdown (Dict, existing facilities) * Structure: {fuel_types: [String], fuel_values: [Float fractions], natural_gas_ratio: Float, reference: String, notes: String} * Content: Plant fuel mix shares for cross-checking intensity breakdowns. ## Code/software Any text editor or viewer can open the primary JSON file: * Text editors: Notepad, Notepad++, Visual Studio Code, etc. Recommendation: Use Python, Julia, or R to extract, validate, and analyze the data programmatically. ## Access information Data was derived from the following sources: * U.S. EPA Greenhouse Gas Reporting Program (GHGRP) Program page: [https://www.epa.gov/ghgreporting](https://www.epa.gov/ghgreporting) Facility-level access (FLIGHT): [https://ghgdata.epa.gov/ghgp/main.do](https://ghgdata.epa.gov/ghgp/main.do) * U.S. Energy Information Administration (EIA) Fuel prices and industrial energy data: [https://www.eia.gov/](https://www.eia.gov/) * U.S. Geological Survey (USGS) Mineral/industry statistics: [https://www.usgs.gov/](https://www.usgs.gov/) * Industry reports and peer-reviewed literature Technology specifications, costs, and performance parameters