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 CO₂ 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
  Facility-level access (FLIGHT): https://ghgdata.epa.gov/ghgp/main.do
• U.S. Energy Information Administration (EIA)
  Fuel prices and industrial energy data: https://www.eia.gov/
• U.S. Geological Survey (USGS)
  Mineral/industry statistics: https://www.usgs.gov/
• Industry reports and peer-reviewed literature
  Technology specifications, costs, and performance parameters