The industrial sector in the United States is responsible for approximately one-third of the nation’s carbon dioxide emissions. This level surpasses the combined emissions of passenger vehicles, trucks, and airplanes. Decarbonizing such a significant source of greenhouse gases represents a critical challenge for combating climate change, yet it also presents a pivotal opportunity for innovation. Researchers at Stanford Engineering have developed new technology to transform the industrial landscape by using electricity instead of fossil fuels to power thermochemical reactors.
Published in Joule on August 19, Stanford’s new reactor design uses magnetic induction to generate the high heat necessary for various industrial processes. Compared to conventional fossil fuel-powered reactors, this electrified version is smaller, cheaper, and more efficient. According to Jonathan Fan, an associate professor of electrical engineering at Stanford and senior author of the paper, the technology is a leap forward in reactor performance, optimized to push it to physical limits using green electricity.
Traditional thermochemical reactors function by burning fossil fuels to heat a fluid, which then circulates through pipes to power industrial processes. This method, however, is inherently inefficient due to heat loss throughout the system and the bulky infrastructure required to transfer heat. Stanford’s reactor, by contrast, generates heat directly through induction, eliminating the need for cumbersome pipes and reducing opportunities for energy loss.
The technology behind induction heating is akin to that used in modern induction stovetops. An oscillating magnetic field is generated by running an alternating current through a coil wrapped around a material, such as steel. This field induces an electric current in the steel, which converts the current into heat due to the material’s imperfect conductivity. In Stanford’s reactor, this method allows the heating of a lattice structure inside the reactor, simplifying the process and boosting energy efficiency.
One of the major innovations in this system is the use of high-frequency currents and poor-conducting ceramic materials, which allow for more precise heat control. The reactor’s internal lattice structure further enhances efficiency by lowering electrical conductivity and allowing for better heat transfer to catalysts used in industrial reactions. This design makes the reactor smaller and more efficient than traditional reactors while achieving the same high temperatures needed for chemical processes.
The reverse water gas shift reaction demonstrated the new reactor’s effectiveness, which converts captured carbon dioxide into usable gases for sustainable fuels. Impressively, the reactor achieved over 85% efficiency in its proof-of-concept phase. This indicates that nearly all electrical energy was converted into usable heat, showcasing the technology’s potential for real-world applications.
This reactor could help decarbonize industries ranging from cement manufacturing to carbon capture. Fan and his colleagues are actively working with partners in the oil and gas sectors to adapt the technology to industrial needs. They are also exploring the reactor’s potential for further scaling up and improving efficiency as they develop more system-wide sustainable solutions.
Stanford’s new reactor design underscores the transformative potential of electrification for decarbonizing industrial processes. “We’re not just trying to replace what we have; we’re creating even better performance,” Fan explained. The research team aims to shrink, simplify, and decarbonize industrial reactors by combining electrification with advanced materials and design innovations.
As the global push for sustainability continues, innovations like Stanford’s reactor provide a glimpse of what the future might hold for industries traditionally reliant on fossil fuels. The shift toward greener and more efficient industrial processes will accelerate by making these technologies more affordable and scalable. Fan aptly notes, “Industrial decarbonization is going to require new, systems-level approaches, and I think we’re just getting started.”
The success of Stanford Engineering’s research indicates that electrification could be the key to tackling some of the most challenging sources of emissions. While the journey toward widespread adoption of this technology will require collaboration across sectors, this advancement in reactor design is a vital first step. The potential for electrified reactors to transform industries, reduce emissions, and redefine infrastructure is a critical development in our global efforts toward sustainability. As industries transition, the ripple effects could fundamentally reshape how we approach energy consumption and production in the 21st century.
