Industrial process heating furnace operations consume considerable energy in the U.S. manufacturing sector, making it crucial to identify energy efficient strategies due to the growing need to minimize energy usage and emissions. It is important to identify the potential impact of these factors to enable process engineers to operate process heating systems at the maximum possible efficiency. This study examines and identifies the key impact factors that influence the efficiency of process heating systems using MEASUR (v1.4.0), the DOE software tools such as the insulation effectiveness, the burner stoichiometry, cooling medium, thermal storage, and atmospheric gases. Data from a two-fuel-fired heat treatment furnace and an electric arc furnace (EAF) for steelmaking were employed to establish the baseline heat balance models in MEASUR. The fractional factorial design experiment was developed with two-level parameter values and energy efficiency strategies for the heat input into industrial furnaces. The three most significant parameters for the heat input for a fuel-fired industrial furnace, Industrial Furnace A, are excess air percentage or the oxygen percentage in flue gas (OF), average surface temperature (ST), and combustion air temperature (CT). Similarly, for an electric industrial furnace, Industrial Furnace B, the parameters are charge temperature (CHT), average surface temperature (ST), and time open (TO). A comparative analysis was carried out for the fuel-fired and equivalent electric resistance furnaces to identify the prospect of electrification of industrial furnaces relying upon fossil fuels. The study aims to assist industries and designers in making informed decisions regarding industrial furnace upgrades, process optimization, and maintenance investments, resulting in substantial energy and cost savings, and a reduced environmental impact.

This study presents the electrification plan of a school bus (SB) fleet and examines its potential in vehicle-to-grid (V2G) applications. The data collected includes the efficiency of a 120 kW EV charger, energy consumption of a 40-foot electric school bus (ESB), and a diesel bus operating on the same route. The energy consumption data of the ESB and diesel school bus (DSB) were processed to derive the yearly average distance-specific energy consumption of 0.37 mile/kWh (0.60 km/kWh) grid electricity and 5.55 MPG (2.36 km/L), respectively. The energy consumption ratio of the ESB over the DSB is 14.92 kWh/gallon (3.94 kWh/L) diesel. Based on the CO₂ intensity, 1.956 lb/kWh (0.887 kg/kWh) of electricity produced in WV and that of diesel fuel, the distance-specific CO₂ emissions of the ESB were 5.38 lb/mile (1.52 kg/km), which are higher than the 4.08 lb/mile (1.15 kg/km) from the diesel bus operating on the same route. This study also presents the V2G potential of the proposed electrical school bus fleet. Based on the estimated grid-to-vehicle battery (G2VB) efficiency of 92% and vehicle battery-to-grid (VB2G) efficiency of 92%, the grid–vehicle battery–grid (G2VB2G) efficiency is 84.64%. The application of V2G technology is associated with a loss of electricity. Based on the 20% to 80% battery charge, and the estimated 92% VB2G efficiency, the proposed ESB fleet has the potential to provide 14,929 kWh electricity, 55.2% of the ESB fleet battery capacity. The increased cost associated with the implementation of the proposed V2G is about USD 7.5 million, a 400% increase compared to the charger satisfying the operation of ESBs when V2G is not used. The V2G application also is expected to increase the charging cycles, which raises concerns about battery degradation and its replacement during SB service lifetime. Accordingly, more research work is needed to address the increased cost and grid capacity demand, and battery degradation associated with V2G applications.