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In coal-rich Kentucky, a new green aluminum plant could bring jobs and clean energy

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Sunday, September 15, 2024

When John Holbrook first started working as a pipefitter in the early 1990s, jobs were easy to come by in his corner of northeastern Kentucky. A giant iron and steel mill routinely needed maintenance and repair work, as did the coal “coking” ovens next to it. There was also a hulking coal-fired power plant and a bustling petroleum refinery nearby. Fossil fuels extracted from beneath the region’s rugged Appalachian terrain supplied these industrial sites, which sprung up during the 19th and 20th centuries along the yawning Ohio River and its tributary, Big Sandy. “Work was so plentiful,” Holbrook recalled on a scorching August morning in Ashland, a quiet riverfront city of some 21,000 people. Ashland retains its motto as the place ​“Where Coal Meets Iron,” and railcars still rumble by. But after years of downsizing production, the steel mill’s owner demolished the complex in 2022. A decade ago, the coal plant switched to burning natural gas to generate electricity, which requires less hands-on maintenance. Meanwhile, thousands of jobs vanished from surrounding coalfields as mining became more mechanized, market forces shifted, and clean air policies took hold. Many families have since moved away. The tradespeople who’ve stayed often drive for hours to work on the new construction projects sprouting up in other places, like the massive factories for making and recycling electric-car batteries in western Kentucky and the electricity-powered steel furnace in neighboring West Virginia. If America is undergoing a manufacturing boom, it hasn’t yet reached this hard-hit stretch of the Bluegrass State. But that could soon change. In March, Century Aluminum, the nation’s biggest producer of primary, or virgin, aluminum, announced that it plans to build an enormous plant in the United States — the nation’s first new smelter in 45 years. Jesse Gary, the company’s president and CEO, has pointed to northeastern Kentucky as the project’s preferred location, though he said there were still a ​“myriad of steps” before the company reaches a final decision. The Chicago-based manufacturer is slated to receive up to $500 million in funding from the U.S. Department of Energy to build the facility, which could emit 75 percent less carbon dioxide than traditional smelters, thanks to its use of carbon-free energy and energy-efficient designs. The award is part of a $6.3 billion federal program — funded by the Inflation Reduction Act and the Bipartisan Infrastructure Law — that aims to sharply reduce greenhouse gas emissions from heavy-industry sectors. The Ohio River seen from Ashland, Kentucky, right. John Holbrook at his office in Ashland. Aluminum demand is set to soar globally by up to 80 percent by 2050 as the world produces more solar panels and other clean energy technologies. The makers of the essential material are now under mounting pressure from policymakers and consumers to clean up their operations. In North America alone, aluminum producers will need to cut carbon emissions by 92 percent from 2021 levels to meet net-zero climate goals. Century already owns two aging smelters in western Kentucky. The new ​“green smelter” is expected to create over 5,500 construction jobs and more than 1,000 full-time union jobs. If built in eastern Kentucky, the $5 billion project would mark the region’s largest investment on record. “We just need a crumb or two, just a little giant smelter,” Holbrook said with a laugh when we met at his office near Ashland’s historic main street. A short walk away, stones used in the city’s original iron-making furnaces stand as monuments overlooking the Ohio River. Today, Holbrook heads the Tri-State Building and Construction Trades Council, which represents unions in a cluster of adjoining counties in Kentucky, Ohio, and West Virginia. He’s part of a broad coalition of labor organizers, local officials, environmentalists, and clean energy advocates who are urging Kentucky Governor Andy Beshear, a Democrat, to work with Century to secure the smelter and hammer out a long-term deal to provide clean energy for it. “It’d be a godsend for that area,” said Chad Mills, a pipefitter and the director of the Kentucky State Building and Construction Trades Council. The region ​“needs it more than you can imagine.” The impact of Century’s new smelter would ripple far beyond this rural stretch of verdant peaks and meandering creeks. The planned facility is set to nearly double the amount of primary aluminum that the United States produces — helping to revitalize a domestic industry that has been steadily shrinking for decades owing to spiking power prices and increased competition from China. In 2000, U.S. companies operated 23 aluminum smelters. Today, only four plants are operating, while another two have been indefinitely curtailed. That includes Century’s 55-year-old plant in Hawesville, Kentucky, which has been idle since June 2022. The decline in U.S. production has complicated the country’s efforts to both make and procure lower-carbon aluminum for its supply chains, experts say. Globally, the aluminum sector contributes around 2 percent of total greenhouse gas emissions every year. Nearly 70 percent of those emissions come from generating high volumes of electricity — often derived from fossil fuels — to power smelters almost around the clock. As U.S. primary production dwindles, the country is importing more aluminum made in overseas smelters that are powered by dirtier, less efficient electrical grids. Ironically, an increasing share of that aluminum is being used to make solar panels, electric cars, heat pumps, power cables, and many other clean energy components. The metal is lightweight and inexpensive, and it’s a key ingredient in global efforts to electrify and decarbonize the wider economy. But aluminum is also mind-bogglingly ubiquitous outside the energy sector. The versatile material is found in everything from pots and pans, deodorant, and smartphones to car doors, bridges, and skyscrapers. It’s the second-most-used metal in the world after steel.  Last year, the U.S. produced around 750,000 metric tons of primary aluminum while importing 4.8 million metric tons of it, according to the U.S. Geological Survey.  Meanwhile, the country produced 3.3 million metric tons of ​“secondary” aluminum in 2023. Boosting recycling rates is seen as a necessary step for addressing aluminum’s emissions problem, because the recycling process requires about 95 percent less energy than making aluminum from scratch. But even secondary producers need primary aluminum to ​“sweeten” their batches and achieve the right strength and durability, said Annie Sartor, the aluminum campaign director for Industrious Labs, an advocacy organization. “Primary aluminum is essential, and we have a primary industry that’s been in decline, is very polluting, and is very high-emitting,” Sartor said. Century’s proposed new smelter ​“could be a turning point for this industry,” she added. ​“We all would like to see it get built and thrive.” An employee walks by Century Aluminum’s smelter in Hawesville, Kentucky, in a 2017 photo. The smelter has been idle since 2022. Luke Sharrett for The Washington Post via Getty Images A new green smelter wouldn’t just boost supplies of primary aluminum for making clean energy technologies. The facility, with its voracious electricity appetite, is also expected to accelerate the region’s buildout of clean energy capacity, which has lagged behind that of many other states.  Century expects its planned smelter to produce about 600,000 metric tons of aluminum a year. That means it could need at least a gigawatt’s worth of power to operate annually at full tilt, equal to the yearly demand of roughly 750,000 U.S. homes. By way of comparison, Louisville, Kentucky’s largest city, is home to some 625,000 people. But Kentucky has very little carbon-free capacity available today.  About 0.2 percent of the state’s electricity generation came from solar in 2022, while 6 percent was supplied by hydroelectric dams, mainly in the western part of the state. Coal and gas plants produced most of the rest. Still, after decades of clinging tightly to its coal-rich history, Kentucky is seeing a raft of new utility-scale solar installations under development, including atop former coal mines.  And manufacturers in Kentucky can access the renewable energy being generated in neighboring states as well as regional grid networks like PJM. Swaths of eastern Kentucky are covered by a robust array of high-voltage, long-distance transmission lines operated by Kentucky Power, a subsidiary of the utility giant American Electric Power. Lane Boldman, executive director of the Kentucky Conservation Committee, said that investing in clean energy and upgrading grid infrastructure would offer a chance to employ more of Kentucky’s skilled workers. “It’s exciting, because it actually modernizes our industry and leverages a local workforce that has a great expertise with energy already,” she said when we met in Lexington, near the rolling green hills and long white fences of the area’s horse farms. ​“There are ways you can create economic development that are not so extractive, that just leave the community bare.” Lane Boldman says she became an environmental advocate years ago after seeing how coal strip mining was harming Appalachian communities. Maria Gallucci/Canary Media Northeastern Kentucky isn’t the only location that Century is considering for the smelter. The company is also evaluating sites in the Ohio and Mississippi river basins. The final decision will depend on where there’s a steady supply of affordable power, a Century executive told The Wall Street Journal in early July. (A spokesperson didn’t respond to Canary’s repeated requests for comment.) Century is aiming to secure a power-supply deal to meet a decade’s worth of electricity demand from the new smelter, according to the Journal. The goal is to finalize plans in the next two years and then begin construction, which could take around three years. In the meantime, the U.S. will continue to see a rapid buildout of solar, wind, and other carbon-free power supplies connecting to the grid. Governor Beshear has participated in discussions about the smelter’s power supply, in the hopes of landing Century’s megaproject and all of its ​“good-paying jobs.” His administration ​“continues to work with multiple experts to determine a location in northeastern Kentucky that includes a river port and can support workforce training as well as provide the cleanest, most reliable electric service capacity needed,” Crystal Staley, a spokesperson for the governor’s office, said by email.  Environmental advocates say the aluminum plant represents a chance to reimagine what a major industrial facility can look like: powered by clean energy, equipped with modern pollution controls, and built with local community input from the beginning. Starting sometime this fall, the Sierra Club is planning to host public meetings and distribute flyers in northeastern Kentucky to let residents know about the giant smelter that could potentially be built in their backyards. “It’s an opportunity for us to engage people who might shy away from other aspects of being an environmental activist and say, ​‘Hey, this is something that we can embrace, because it’s going to help us create jobs so that people can stay in their region,’” said Julia Finch, the director of Sierra Club’s Kentucky chapter. ​“This is a chance for us to lead on what a green transition looks like for industry.” Aluminum is the most abundant metal in Earth’s crust. But turning it into a sturdy, usable material is a laborious and dirty process — one that begins with scraping topsoil to extract bauxite, a reddish clay rock that is rich in alumina (also called aluminum oxide). The trickiest part comes next: removing oxygen and other molecules to transform that alumina into aluminum. Until the late 19th century, the methods for accomplishing this were so costly that the tinfoil we now buy at the grocery store was considered a precious metal, like gold, silver, and platinum. Then in 1886, Charles Martin Hall figured out an inexpensive way to smelt aluminum through electrolysis, a technique that uses electrical energy to drive a chemical reaction. Not long after, he helped launch the Pittsburgh Reduction Company, which went on to become the U.S. aluminum behemoth presently known as Alcoa. Around the same time that Hall was tinkering in his woodshed in Oberlin, Ohio, a French inventor named Paul Louis Touissant Héroult was making a similar discovery in Paris. Modern aluminum smelters now use what’s called the Hall-Héroult process — an effective but also energy-intensive and carbon-intensive way of making primary aluminum metal.  Smelting involves dissolving alumina in a molten salt called cryolite, which is heated to over 1,700 degrees Fahrenheit. Large carbon blocks, or ​“anodes,” are lowered down into the highly corrosive bath, and electrical currents run through the entire structure. Aluminum then deposits at the bottom as oxygen combines with carbon in the blocks, creating carbon dioxide as a byproduct.  Today, this electrochemical process contributes about 17 percent of the total CO2 emissions from global aluminum production. It also causes the release of perfluorochemicals (PFCs) — potent and long-lasting greenhouse gases — as well as sulfur dioxide pollution, which can harm people’s respiratory systems and damage trees and crops. In 2021, PFCs accounted for more than half the emissions from Century’s Hawesville smelter and a third of the emissions from its Sebree smelter in Robards, Kentucky, according to the Sierra Club. Newer smelters can dramatically reduce their PFC emissions by using automated control systems, which Century deploys at its smelter in Grundartangi, Iceland. Researchers are also working to slash CO2 by developing carbon-free blocks. The technology involves using chemically inactive, or ​“inert,” metallic alloys in the anodes through which the electrical currents flow. Elysis, a joint venture of Alcoa and the mining giant Rio Tinto, says it is making progress toward the large-scale implementation of its inert anodes and has plans for a demonstration plant in Quebec. The alternative anodes may not be ready in time for a project like Century’s planned green U.S. smelter. Previously, large-scale buyers of aluminum, such as automakers and construction companies, had anticipated that inert anodes would help slash CO2 emissions in the aluminum supply chain in time for companies to meet their 2030 climate goals. But now that’s looking less likely. “There’s a feeling now that it’s just taking longer to develop that technology,” said Lachlan Wright, a manager of the climate intelligence program at RMI, a clean energy think tank. One challenge might simply be the limited production capacity for the new anodes, which can’t yet meet the demands of a large aluminum user. Beyond that, ​“It’s not exactly clear what some of the barriers are there,” Wright added. Still, when it comes to tackling aluminum’s biggest CO2 culprit — all the electricity it takes to run a smelter — the solutions already exist, in the form of renewable energy and other carbon-free sources. “We don’t need a new or emerging technology,” Sartor said. ​“We need huge amounts of existing technology, and it needs to be available in places that work for the industry.” Deep in the heart of Kentucky’s coal country, the scarred and treeless lands of former surface mines are increasingly being repurposed to supply that clean energy.  On another sun-blasted day in early August, I met with Mike Smith in Hazard, a city of some 5,300 people that’s enveloped by the Appalachian Mountains and built along the winding curves of the North Fork Kentucky River. We hopped in his white pickup truck and headed toward his family’s 800-acre property. For years, they leased the land to Pine Branch Mining, which dynamited the mountaintop to reach coal seams buried beneath the surface. ​“I can’t say that I was for it,” Smith told me as we drove past modest homes tucked into creekside hollers and up a bumpy gravel road. Today, he said, ​“the only coal that’s left here is under the river.” After the mine closed a decade ago, the land was reclaimed: smoothed out, packed down, and covered with vegetation to prevent erosion. Now, the property is about to undergo its latest transformation, as the home of the 80-megawatt Bright Mountain Solar facility. Landowner Mike Smith and Louise Sizemore of Edelen Renewables surveyed the former mining site that will soon become the Bright Mountain Solar farm during a visit on August 7. Maria Gallucci/Canary Media Avangrid, the lead developer, plans to begin installing solar panels here next year, according to Edelen Renewables, the project’s local development partner. Edelen is also helping to advance other ​“coal-to-solar” projects in the region, including the 200 MW Martin County Solar Project under construction as well as BrightNight​’s 800 MW Starfire installation. Rivian, the electric-truck maker, has signed on as the anchor customer for the $1 billion Starfire project, which is in the early stages of development.  Building on old mining sites can be more expensive and logistically trickier than, say, putting panels on flat, solid farmland. For one, hauling equipment to the former mines requires driving big, heavy vehicles up narrow mountain roads. Smith’s site is divided into uneven tiers of unpaved land. On our visit, he expertly accelerated his truck up a steep dirt path. When we reached the top, I audibly exhaled with relief. Smith gently laughed. Despite the challenges, there’s an obvious poetry to building clean energy in a place that once yielded fossil fuels. Ideally, it can also bring justice to communities that are still hurting economically and spiritually from the coal industry’s inexorable decline. Bright Mountain and other coal-to-solar developments are projected to generate millions of dollars in local tax revenue over their lifetimes, using land that was left unsuitable for anything other than cattle grazing. “You’ve got to reinvent yourself,” Smith told me as we gazed at the empty expanse of land where the solar project will eventually stand. Dragonflies darted by, and a quail called from somewhere on the property. ​“That’s the only way we can survive.” The next day, I met Adam Edelen, the founder and CEO of Edelen Renewables, at his office in downtown Lexington. Sitting in a wicker rocking chair and sipping a pint glass of sweet tea, Edelen lamented the years of ​“outright hostility” to renewable energy development in the state. However, some Kentucky policymakers are starting to recognize the need to clean up the state’s electricity sector — if not explicitly to tackle climate change, then at least to attract manufacturers like Century Aluminum that want to power their operations with carbon-free energy sources. The Martin County Solar Project spans 900 acres on the old Martiki mine site in Pilgrim, Kentucky. Edelen Renewables “Now, we’re in this headlong rush to make sure we’ve got a diversified energy portfolio to meet the needs of the private sector,” Edelen said. For Century in particular, he added, ​“The issue is that they need cheap power and they need green energy, neither of which Kentucky has a lot of.”  Electricity accounts for about 40 percent of a smelter’s total operating expenses. To remain cost competitive, aluminum producers need to hit a ​“magic benchmark” of around $40 per megawatt-hour, said Wright of RMI. Currently, power-purchase agreements for U.S. renewable energy projects are in the range of $50 to $60 per megawatt-hour — a significant difference for facilities that can consume 1 megawatt-hour of electricity just to produce a single metric ton of aluminum. Provisions in the Inflation Reduction Act could help to narrow that price gap for Century and other primary aluminum makers. The 45X production tax credit is a keystone of the IRA, which President Joe Biden signed into law two years ago. The incentive allows producers of critical materials, solar panels, batteries, and other types of ​“advanced manufacturing” products to receive a federal tax credit for up to 10 percent of their production costs, including electricity. The IRA also set aside another $10 billion for the 48C investment tax credit, an Obama-era program that’s now available to help manufacturers install equipment that reduces emissions by 20 percent. Aluminum producers could use the tax credit to cover the cost of technology that improves their operating efficiency while also slashing CO2 pollution. Edelen Renewables says the 48C tax credit will apply to all the coal-to-solar projects, which the company hopes can supply some of the electricity needed for Century’s green smelter. Under the expanded program, renewable energy projects built in ​“energy communities,” including former coal mine sites, can receive tax credits worth up to 40 percent of project costs, significantly lowering the final cost of electricity associated with the installations. Eastern Kentucky ​“has played such a vital role in powering the country’s economy for the last 100 years,” Edelen said. Coal communities ​“deserve a place in the newer economy, and they’re hungry for that.” Construction on the Martin County Solar Project began in 2023 and is slated to be completed later this year. Edelen Renewables Over in Ashland, John Holbrook said he’s anxiously watching to see if northeastern Kentucky will find its place in the nation’s green industrial transition. If Century selects the region to host its new aluminum smelter, the area’s trade councils and union apprenticeship programs will be more than ready to start training and recruiting workers, he said. But Holbrook and other local labor leaders aren’t holding their breath. Several people I spoke to recalled the elation they felt in 2018 when the company Braidy Industries broke ground near Ashland on a $1.5 billion aluminum rolling mill — and the heartbreak that followed years later when Braidy backtracked on the plant and its promise of hundreds of jobs. Braidy’s former CEO was later accused of misleading the company’s board members, state officials, and journalists about the project’s true financial status. While the Braidy scandal was a unique affair, the fallout still lingers in discussions about Century’s green smelter. ​“I think they’d have to start moving trailers in before we’d feel confident to start saying, ​‘Yeah, this is really happening,’” Holbrook said from behind his wide wooden desk.  Still, he remains ​“cautiously optimistic” about the prospect of Century building its aluminum plant here. ​“It would be region-changing,” he said. ​“And life-changing.”  This story was originally published by Grist with the headline In coal-rich Kentucky, a new green aluminum plant could bring jobs and clean energy on Sep 15, 2024.

Labor and state leaders wants to land the first new U.S. smelter in 45 years. But the deal won’t happen unless Kentucky can furnish lots of clean energy.

When John Holbrook first started working as a pipefitter in the early 1990s, jobs were easy to come by in his corner of northeastern Kentucky.

A giant iron and steel mill routinely needed maintenance and repair work, as did the coal “coking” ovens next to it. There was also a hulking coal-fired power plant and a bustling petroleum refinery nearby. Fossil fuels extracted from beneath the region’s rugged Appalachian terrain supplied these industrial sites, which sprung up during the 19th and 20th centuries along the yawning Ohio River and its tributary, Big Sandy.

“Work was so plentiful,” Holbrook recalled on a scorching August morning in Ashland, a quiet riverfront city of some 21,000 people.

Ashland retains its motto as the place ​“Where Coal Meets Iron,” and railcars still rumble by. But after years of downsizing production, the steel mill’s owner demolished the complex in 2022. A decade ago, the coal plant switched to burning natural gas to generate electricity, which requires less hands-on maintenance. Meanwhile, thousands of jobs vanished from surrounding coalfields as mining became more mechanized, market forces shifted, and clean air policies took hold.

Many families have since moved away. The tradespeople who’ve stayed often drive for hours to work on the new construction projects sprouting up in other places, like the massive factories for making and recycling electric-car batteries in western Kentucky and the electricity-powered steel furnace in neighboring West Virginia. If America is undergoing a manufacturing boom, it hasn’t yet reached this hard-hit stretch of the Bluegrass State.

But that could soon change.

In March, Century Aluminum, the nation’s biggest producer of primary, or virgin, aluminum, announced that it plans to build an enormous plant in the United States — the nation’s first new smelter in 45 years. Jesse Gary, the company’s president and CEO, has pointed to northeastern Kentucky as the project’s preferred location, though he said there were still a ​“myriad of steps” before the company reaches a final decision.

The Chicago-based manufacturer is slated to receive up to $500 million in funding from the U.S. Department of Energy to build the facility, which could emit 75 percent less carbon dioxide than traditional smelters, thanks to its use of carbon-free energy and energy-efficient designs. The award is part of a $6.3 billion federal program — funded by the Inflation Reduction Act and the Bipartisan Infrastructure Law — that aims to sharply reduce greenhouse gas emissions from heavy-industry sectors.

The Ohio River seen from Ashland, Kentucky, right. John Holbrook at his office in Ashland.

Aluminum demand is set to soar globally by up to 80 percent by 2050 as the world produces more solar panels and other clean energy technologies. The makers of the essential material are now under mounting pressure from policymakers and consumers to clean up their operations. In North America alone, aluminum producers will need to cut carbon emissions by 92 percent from 2021 levels to meet net-zero climate goals.

Century already owns two aging smelters in western Kentucky. The new ​“green smelter” is expected to create over 5,500 construction jobs and more than 1,000 full-time union jobs. If built in eastern Kentucky, the $5 billion project would mark the region’s largest investment on record.

“We just need a crumb or two, just a little giant smelter,” Holbrook said with a laugh when we met at his office near Ashland’s historic main street. A short walk away, stones used in the city’s original iron-making furnaces stand as monuments overlooking the Ohio River.

Today, Holbrook heads the Tri-State Building and Construction Trades Council, which represents unions in a cluster of adjoining counties in Kentucky, Ohio, and West Virginia. He’s part of a broad coalition of labor organizers, local officials, environmentalists, and clean energy advocates who are urging Kentucky Governor Andy Beshear, a Democrat, to work with Century to secure the smelter and hammer out a long-term deal to provide clean energy for it.

“It’d be a godsend for that area,” said Chad Mills, a pipefitter and the director of the Kentucky State Building and Construction Trades Council. The region ​“needs it more than you can imagine.”


The impact of Century’s new smelter would ripple far beyond this rural stretch of verdant peaks and meandering creeks.

The planned facility is set to nearly double the amount of primary aluminum that the United States produces — helping to revitalize a domestic industry that has been steadily shrinking for decades owing to spiking power prices and increased competition from China. In 2000, U.S. companies operated 23 aluminum smelters. Today, only four plants are operating, while another two have been indefinitely curtailed. That includes Century’s 55-year-old plant in Hawesville, Kentucky, which has been idle since June 2022.

The decline in U.S. production has complicated the country’s efforts to both make and procure lower-carbon aluminum for its supply chains, experts say.

Globally, the aluminum sector contributes around 2 percent of total greenhouse gas emissions every year. Nearly 70 percent of those emissions come from generating high volumes of electricity — often derived from fossil fuels — to power smelters almost around the clock.

As U.S. primary production dwindles, the country is importing more aluminum made in overseas smelters that are powered by dirtier, less efficient electrical grids. Ironically, an increasing share of that aluminum is being used to make solar panels, electric cars, heat pumps, power cables, and many other clean energy components. The metal is lightweight and inexpensive, and it’s a key ingredient in global efforts to electrify and decarbonize the wider economy.

But aluminum is also mind-bogglingly ubiquitous outside the energy sector. The versatile material is found in everything from pots and pans, deodorant, and smartphones to car doors, bridges, and skyscrapers. It’s the second-most-used metal in the world after steel. 

Last year, the U.S. produced around 750,000 metric tons of primary aluminum while importing 4.8 million metric tons of it, according to the U.S. Geological Survey. 

Meanwhile, the country produced 3.3 million metric tons of ​“secondary” aluminum in 2023. Boosting recycling rates is seen as a necessary step for addressing aluminum’s emissions problem, because the recycling process requires about 95 percent less energy than making aluminum from scratch. But even secondary producers need primary aluminum to ​“sweeten” their batches and achieve the right strength and durability, said Annie Sartor, the aluminum campaign director for Industrious Labs, an advocacy organization.

“Primary aluminum is essential, and we have a primary industry that’s been in decline, is very polluting, and is very high-emitting,” Sartor said. Century’s proposed new smelter ​“could be a turning point for this industry,” she added. ​“We all would like to see it get built and thrive.”

An employee walks by Century Aluminum’s smelter in Hawesville, Kentucky, in a 2017 photo. The smelter has been idle since 2022. Luke Sharrett for The Washington Post via Getty Images

A new green smelter wouldn’t just boost supplies of primary aluminum for making clean energy technologies. The facility, with its voracious electricity appetite, is also expected to accelerate the region’s buildout of clean energy capacity, which has lagged behind that of many other states. 

Century expects its planned smelter to produce about 600,000 metric tons of aluminum a year. That means it could need at least a gigawatt’s worth of power to operate annually at full tilt, equal to the yearly demand of roughly 750,000 U.S. homes. By way of comparison, Louisville, Kentucky’s largest city, is home to some 625,000 people.

But Kentucky has very little carbon-free capacity available today. 

About 0.2 percent of the state’s electricity generation came from solar in 2022, while 6 percent was supplied by hydroelectric dams, mainly in the western part of the state. Coal and gas plants produced most of the rest. Still, after decades of clinging tightly to its coal-rich history, Kentucky is seeing a raft of new utility-scale solar installations under development, including atop former coal mines. 

And manufacturers in Kentucky can access the renewable energy being generated in neighboring states as well as regional grid networks like PJM. Swaths of eastern Kentucky are covered by a robust array of high-voltage, long-distance transmission lines operated by Kentucky Power, a subsidiary of the utility giant American Electric Power.

Lane Boldman, executive director of the Kentucky Conservation Committee, said that investing in clean energy and upgrading grid infrastructure would offer a chance to employ more of Kentucky’s skilled workers.

“It’s exciting, because it actually modernizes our industry and leverages a local workforce that has a great expertise with energy already,” she said when we met in Lexington, near the rolling green hills and long white fences of the area’s horse farms. ​“There are ways you can create economic development that are not so extractive, that just leave the community bare.”

Lane Boldman says she became an environmental advocate years ago after seeing how coal strip mining was harming Appalachian communities. Maria Gallucci/Canary Media

Northeastern Kentucky isn’t the only location that Century is considering for the smelter. The company is also evaluating sites in the Ohio and Mississippi river basins. The final decision will depend on where there’s a steady supply of affordable power, a Century executive told The Wall Street Journal in early July. (A spokesperson didn’t respond to Canary’s repeated requests for comment.)

Century is aiming to secure a power-supply deal to meet a decade’s worth of electricity demand from the new smelter, according to the Journal. The goal is to finalize plans in the next two years and then begin construction, which could take around three years. In the meantime, the U.S. will continue to see a rapid buildout of solar, wind, and other carbon-free power supplies connecting to the grid.

Governor Beshear has participated in discussions about the smelter’s power supply, in the hopes of landing Century’s megaproject and all of its ​“good-paying jobs.” His administration ​“continues to work with multiple experts to determine a location in northeastern Kentucky that includes a river port and can support workforce training as well as provide the cleanest, most reliable electric service capacity needed,” Crystal Staley, a spokesperson for the governor’s office, said by email. 

Environmental advocates say the aluminum plant represents a chance to reimagine what a major industrial facility can look like: powered by clean energy, equipped with modern pollution controls, and built with local community input from the beginning. Starting sometime this fall, the Sierra Club is planning to host public meetings and distribute flyers in northeastern Kentucky to let residents know about the giant smelter that could potentially be built in their backyards.

“It’s an opportunity for us to engage people who might shy away from other aspects of being an environmental activist and say, ​‘Hey, this is something that we can embrace, because it’s going to help us create jobs so that people can stay in their region,’” said Julia Finch, the director of Sierra Club’s Kentucky chapter. ​“This is a chance for us to lead on what a green transition looks like for industry.”


Aluminum is the most abundant metal in Earth’s crust. But turning it into a sturdy, usable material is a laborious and dirty process — one that begins with scraping topsoil to extract bauxite, a reddish clay rock that is rich in alumina (also called aluminum oxide). The trickiest part comes next: removing oxygen and other molecules to transform that alumina into aluminum. Until the late 19th century, the methods for accomplishing this were so costly that the tinfoil we now buy at the grocery store was considered a precious metal, like gold, silver, and platinum.

Then in 1886, Charles Martin Hall figured out an inexpensive way to smelt aluminum through electrolysis, a technique that uses electrical energy to drive a chemical reaction. Not long after, he helped launch the Pittsburgh Reduction Company, which went on to become the U.S. aluminum behemoth presently known as Alcoa.

Around the same time that Hall was tinkering in his woodshed in Oberlin, Ohio, a French inventor named Paul Louis Touissant Héroult was making a similar discovery in Paris. Modern aluminum smelters now use what’s called the Hall-Héroult process — an effective but also energy-intensive and carbon-intensive way of making primary aluminum metal. 

Smelting involves dissolving alumina in a molten salt called cryolite, which is heated to over 1,700 degrees Fahrenheit. Large carbon blocks, or ​“anodes,” are lowered down into the highly corrosive bath, and electrical currents run through the entire structure. Aluminum then deposits at the bottom as oxygen combines with carbon in the blocks, creating carbon dioxide as a byproduct. 

Today, this electrochemical process contributes about 17 percent of the total CO2 emissions from global aluminum production. It also causes the release of perfluorochemicals (PFCs) — potent and long-lasting greenhouse gases — as well as sulfur dioxide pollution, which can harm people’s respiratory systems and damage trees and crops. In 2021, PFCs accounted for more than half the emissions from Century’s Hawesville smelter and a third of the emissions from its Sebree smelter in Robards, Kentucky, according to the Sierra Club.

Newer smelters can dramatically reduce their PFC emissions by using automated control systems, which Century deploys at its smelter in Grundartangi, Iceland. Researchers are also working to slash CO2 by developing carbon-free blocks. The technology involves using chemically inactive, or ​“inert,” metallic alloys in the anodes through which the electrical currents flow. Elysis, a joint venture of Alcoa and the mining giant Rio Tinto, says it is making progress toward the large-scale implementation of its inert anodes and has plans for a demonstration plant in Quebec.

The alternative anodes may not be ready in time for a project like Century’s planned green U.S. smelter. Previously, large-scale buyers of aluminum, such as automakers and construction companies, had anticipated that inert anodes would help slash CO2 emissions in the aluminum supply chain in time for companies to meet their 2030 climate goals. But now that’s looking less likely.

“There’s a feeling now that it’s just taking longer to develop that technology,” said Lachlan Wright, a manager of the climate intelligence program at RMI, a clean energy think tank. One challenge might simply be the limited production capacity for the new anodes, which can’t yet meet the demands of a large aluminum user. Beyond that, ​“It’s not exactly clear what some of the barriers are there,” Wright added.

Still, when it comes to tackling aluminum’s biggest CO2 culprit — all the electricity it takes to run a smelter — the solutions already exist, in the form of renewable energy and other carbon-free sources.

“We don’t need a new or emerging technology,” Sartor said. ​“We need huge amounts of existing technology, and it needs to be available in places that work for the industry.”


Deep in the heart of Kentucky’s coal country, the scarred and treeless lands of former surface mines are increasingly being repurposed to supply that clean energy. 

On another sun-blasted day in early August, I met with Mike Smith in Hazard, a city of some 5,300 people that’s enveloped by the Appalachian Mountains and built along the winding curves of the North Fork Kentucky River.

We hopped in his white pickup truck and headed toward his family’s 800-acre property. For years, they leased the land to Pine Branch Mining, which dynamited the mountaintop to reach coal seams buried beneath the surface. ​“I can’t say that I was for it,” Smith told me as we drove past modest homes tucked into creekside hollers and up a bumpy gravel road. Today, he said, ​“the only coal that’s left here is under the river.”

After the mine closed a decade ago, the land was reclaimed: smoothed out, packed down, and covered with vegetation to prevent erosion. Now, the property is about to undergo its latest transformation, as the home of the 80-megawatt Bright Mountain Solar facility.

Landowner Mike Smith and Louise Sizemore of Edelen Renewables surveyed the former mining site that will soon become the Bright Mountain Solar farm during a visit on August 7. Maria Gallucci/Canary Media

Avangrid, the lead developer, plans to begin installing solar panels here next year, according to Edelen Renewables, the project’s local development partner. Edelen is also helping to advance other ​“coal-to-solar” projects in the region, including the 200 MW Martin County Solar Project under construction as well as BrightNight​’s 800 MW Starfire installation. Rivian, the electric-truck maker, has signed on as the anchor customer for the $1 billion Starfire project, which is in the early stages of development. 

Building on old mining sites can be more expensive and logistically trickier than, say, putting panels on flat, solid farmland. For one, hauling equipment to the former mines requires driving big, heavy vehicles up narrow mountain roads. Smith’s site is divided into uneven tiers of unpaved land. On our visit, he expertly accelerated his truck up a steep dirt path. When we reached the top, I audibly exhaled with relief. Smith gently laughed.

Despite the challenges, there’s an obvious poetry to building clean energy in a place that once yielded fossil fuels. Ideally, it can also bring justice to communities that are still hurting economically and spiritually from the coal industry’s inexorable decline. Bright Mountain and other coal-to-solar developments are projected to generate millions of dollars in local tax revenue over their lifetimes, using land that was left unsuitable for anything other than cattle grazing.

“You’ve got to reinvent yourself,” Smith told me as we gazed at the empty expanse of land where the solar project will eventually stand. Dragonflies darted by, and a quail called from somewhere on the property. ​“That’s the only way we can survive.”

The next day, I met Adam Edelen, the founder and CEO of Edelen Renewables, at his office in downtown Lexington. Sitting in a wicker rocking chair and sipping a pint glass of sweet tea, Edelen lamented the years of ​“outright hostility” to renewable energy development in the state. However, some Kentucky policymakers are starting to recognize the need to clean up the state’s electricity sector — if not explicitly to tackle climate change, then at least to attract manufacturers like Century Aluminum that want to power their operations with carbon-free energy sources.

The Martin County Solar Project spans 900 acres on the old Martiki mine site in Pilgrim, Kentucky. Edelen Renewables

“Now, we’re in this headlong rush to make sure we’ve got a diversified energy portfolio to meet the needs of the private sector,” Edelen said. For Century in particular, he added, ​“The issue is that they need cheap power and they need green energy, neither of which Kentucky has a lot of.” 

Electricity accounts for about 40 percent of a smelter’s total operating expenses. To remain cost competitive, aluminum producers need to hit a ​“magic benchmark” of around $40 per megawatt-hour, said Wright of RMI. Currently, power-purchase agreements for U.S. renewable energy projects are in the range of $50 to $60 per megawatt-hour — a significant difference for facilities that can consume 1 megawatt-hour of electricity just to produce a single metric ton of aluminum.

Provisions in the Inflation Reduction Act could help to narrow that price gap for Century and other primary aluminum makers.

The 45X production tax credit is a keystone of the IRA, which President Joe Biden signed into law two years ago. The incentive allows producers of critical materials, solar panels, batteries, and other types of ​“advanced manufacturing” products to receive a federal tax credit for up to 10 percent of their production costs, including electricity.

The IRA also set aside another $10 billion for the 48C investment tax credit, an Obama-era program that’s now available to help manufacturers install equipment that reduces emissions by 20 percent. Aluminum producers could use the tax credit to cover the cost of technology that improves their operating efficiency while also slashing CO2 pollution.

Edelen Renewables says the 48C tax credit will apply to all the coal-to-solar projects, which the company hopes can supply some of the electricity needed for Century’s green smelter. Under the expanded program, renewable energy projects built in ​“energy communities,” including former coal mine sites, can receive tax credits worth up to 40 percent of project costs, significantly lowering the final cost of electricity associated with the installations.

Eastern Kentucky ​“has played such a vital role in powering the country’s economy for the last 100 years,” Edelen said. Coal communities ​“deserve a place in the newer economy, and they’re hungry for that.”

Construction on the Martin County Solar Project began in 2023 and is slated to be completed later this year. Edelen Renewables

Over in Ashland, John Holbrook said he’s anxiously watching to see if northeastern Kentucky will find its place in the nation’s green industrial transition. If Century selects the region to host its new aluminum smelter, the area’s trade councils and union apprenticeship programs will be more than ready to start training and recruiting workers, he said.

But Holbrook and other local labor leaders aren’t holding their breath. Several people I spoke to recalled the elation they felt in 2018 when the company Braidy Industries broke ground near Ashland on a $1.5 billion aluminum rolling mill — and the heartbreak that followed years later when Braidy backtracked on the plant and its promise of hundreds of jobs. Braidy’s former CEO was later accused of misleading the company’s board members, state officials, and journalists about the project’s true financial status.

While the Braidy scandal was a unique affair, the fallout still lingers in discussions about Century’s green smelter. ​“I think they’d have to start moving trailers in before we’d feel confident to start saying, ​‘Yeah, this is really happening,’” Holbrook said from behind his wide wooden desk. 

Still, he remains ​“cautiously optimistic” about the prospect of Century building its aluminum plant here. ​“It would be region-changing,” he said. ​“And life-changing.” 

This story was originally published by Grist with the headline In coal-rich Kentucky, a new green aluminum plant could bring jobs and clean energy on Sep 15, 2024.

Read the full story here.
Photos courtesy of

How Mississippians Can Intervene in Natural Gas Pipeline Proposal

Mississippi residents can comment on a proposal for a natural gas pipeline that would span nearly the full width of the state

Mississippians have until Tuesday to intervene in a proposal for a natural gas pipeline that would span nearly the full width of the state.The pipeline, called the “Mississippi Crossing Project,” would start in Greenville, cross through Humphreys, Holmes, Attala, Leake, Neshoba, Newton, Lauderdale and Clarke counties and end near Butler, Alabama, stretching nearly 208 miles.Tennessee Gas Pipeline Co., a subsidiary of Kinder Morgan, sent an application for the project to the Federal Energy Regulatory Commission on June 30. The company hopes the pipeline, which would transfer up to 12 billion cubic feet of natural gas per day, will address a rising energy demand by increasing its transportation capacity.Kinder Morgan says on its website that, should it receive approval, construction would begin at the end of 2027 and the pipeline would begin service in November 2028. The company says the project would cost $1.7 billion and create 750 temporary jobs as well as 15 permanent positions.The project would also include new compressor stations in Humphreys, Attala and Lauderdale counties, although exact locations haven’t been set.Singleton Schreiber, a national law firm that focuses on environmental justice, is looking to spread awareness of the public’s ability to participate in the approval process, whether or not they support the proposal.“We’re just trying to raise awareness to make sure that people know this is happening,” said Laura Singleton, an attorney with the firm. “They’re going to have to dig and construct new pipelines, so it’s going to pass through sensitive ecosystems like wetlands, private property, farmland, things like that. So you can have issues that come up like soil degradation, water contamination, and then after the pipeline is built you could potentially have leaks, spills.”Singleton added while such issues with pipelines are rare, when “things go bad, they go pretty bad.”To comment, protest, or file a motion to intervene, the public can go to FERC’s website (new users have to create an account, and then use the docket number “CP25-514-000”). The exact deadline is 4 p.m. on Aug. 5. More instructions can also be found here.In addition to FERC, the proposal will also face review from the U.S. Army Corps of Engineers, U.S. Fish and Wildlife Service, National Park Service and the state environmental agencies in Mississippi and Alabama.Mississippians have seen multiple incidents related to gas leaks in recent years. In March, three workers were injured after accidentally rupturing an Atmos Energy pipeline doing routine maintenance in Lee County, leaving thousands without service. Then last year, the National Transportation Safety Board found that Atmos discovered gas leaks over a month prior to two explosions in Jackson, one of which claimed the life of an 82-year-old woman.This story was originally published by Mississippi Today and distributed through a partnership with The Associated Press.Copyright 2025 The Associated Press. All rights reserved. This material may not be published, broadcast, rewritten or redistributed.Photos You Should See - June 2025

BPA faces suit over energy market decision that opponents say would raise rates

The lawsuit comes after governors, lawmakers, utility regulators and renewable energy proponents in the region unsuccessfully pressed the BPA to reconsider its plans.

Five energy and conservation nonprofits are suing the Bonneville Power Administration over its decision to join a new energy trading market, claiming it will raise electricity and transmission costs in Oregon and across the region. The lawsuit, filed Thursday in the 9th U.S. Circuit Court of Appeals, alleges that BPA’s move violates the Northwest Power Act and the National Environmental Policy Act and will also weaken energy grid reliability and reduce access to clean energy. BPA, the Northwest’s largest transmission grid operator, in May announced it would join the Arkansas-based Southwest Power Pool day-ahead market known as “Markets Plus” instead of joining California’s day-ahead market. The Southwest market is smaller with fewer electrical generation resources, experts say. Prior to that decision, Pacific Northwest governors, lawmakers, utility regulators and renewable energy proponents had pressed the BPA for months to reconsider its plans, which the agency initially announced in March.The nonprofits involved in the legal challenge are the Oregon Citizens’ Utility Board, a watchdog organization that advocates for utility customers; national environmental group the Sierra Club; the Montana Environmental Information Center, which promotes clean energy; the Idaho Conservation League, a natural landscape conservation group; and the NW Energy Coalition, which promotes affordable energy policies. The groups, represented by San Francisco-based environmental law nonprofit Earthjustice, want the court to vacate BPA’s decision, require the agency to prepare an environmental impact statement and rescind the financial commitments already made to the Southwest energy market.The BPA’s spokesperson Nick Quinata declined to comment on the pending litigation. Previously, the agency said the Southwest day-ahead market is superior to the California one because it would allow BPA to remain more independent due to its market design and governance structure. BPA, part of the U.S. Department of Energy, markets hydropower from 31 federal dams in the Columbia River Basin and supplies a third of the Northwest’s electricity, most of it to publicly owned rural utilities and electric cooperatives. It also owns and operates 15,000 miles – 75% – of the Northwest’s high-voltage transmission lines. Nearly every electric utility in Oregon benefits from either the clean hydroelectricity or the transmission lines controlled by BPA. BPA’s decision sets the stage for having two energy markets across the West.The lawsuit says that will likely lead to rising prices and blackouts during periods of high electricity demand because of the complexity of transmitting power across boundaries between different utilities and the agreements required for such transfers. Oregon’s two largest utilities, investor-owned Portland General Electric and Pacific Power, have both signed agreements to join California’s day-ahead market instead. They, too, have argued that once BPA leaves the Western market, the available energy they can purchase would diminish and become more expensive, leading to higher prices for customers across the region.Regional electricity providers also may have to construct additional power generation facilities, increase operation of existing facilities or both, to make up for BPA’s participation in a smaller and less efficient energy market, the suit contends. It could also increase reliance on generation resources powered by fossil fuels such as coal or natural gas plants because clean energy isn’t as widely available in the smaller Southwest market, the suit says. The Northwest Power Act, passed by Congress in the 1980s, requires BPA to provide low-cost power to the region while encouraging renewable energy, conservation and protection of fish and wildlife.BPA violated those duties when it chose the Southwest market option, according to the lawsuit. The groups also allege BPA’s market choice could harm fish and wildlife in the Columbia basin because it could alter the operation of the federal hydroelectric dams from which Bonneville markets power. The lawsuit claims BPA failed to comply with federal environmental law by not conducting any environmental impact analysis on impacts to fish and wildlife before making its decision. The Citizens’ Utility Board, a party to the lawsuit, said it hoped the BPA reverses course – otherwise its decision will splinter the West’s electricity markets, costing utility customers billions of dollars at a time when many are already dealing with skyrocketing bills.The board, as well as other critics of BPA’s decision, have pointed to an initiative developing an independent governance structure for California’s day-ahead market.“Oregon is facing overlapping energy challenges: rising utility bills, rising electricity demand from data centers, and stalling progress on meeting clean energy requirements. The last thing we need is for one of our region’s largest clean energy suppliers to reduce ties with the Pacific Northwest,” said the group’s spokesperson Charlotte Shuff. — Gosia Wozniacka covers environmental justice, climate change, the clean energy transition and other environmental issues. Reach her at gwozniacka@oregonian.com or 971-421-3154.If you purchase a product or register for an account through a link on our site, we may receive compensation. By using this site, you consent to our User Agreement and agree that your clicks, interactions, and personal information may be collected, recorded, and/or stored by us and social media and other third-party partners in accordance with our Privacy Policy.

States, enviro groups fight Trump plan to keep dirty power plants going

In late spring, the Department of Energy ordered two aging and costly fossil-fueled power plants that were on the verge of shutting down to stay open. The agency claimed that the moves were necessary to prevent the power grid from collapsing — and that it has the power to force the plants to stay open even if the…

In late spring, the Department of Energy ordered two aging and costly fossil-fueled power plants that were on the verge of shutting down to stay open. The agency claimed that the moves were necessary to prevent the power grid from collapsing — and that it has the power to force the plants to stay open even if the utilities, state regulators, and grid operators managing them say that no such emergency exists. But state regulators, regional grid operators, environmental groups, and consumer groups are pushing back on the notion that the grids in question even need these interventions — and are challenging the legality of the DOE’s stay-open orders. The DOE claimed that the threat of large-scale grid blackouts forced its hand. But state utility regulators, environmental groups, consumer advocates, and energy experts say that careful analysis from the plant’s owners, state regulators, regional grid operators, and grid reliability experts had determined both plants could be safely closed. These groups argue that clean energy, not fossil fuels, are the true solution to the country’s grid challenges — even if the ​“big, beautiful” bill signed by Trump last week will make those resources more expensive to build. Some of the environmental organizations challenging DOE’s orders have pledged to take their case to federal court if necessary. “We need to get more electrons on the grid. We need those to be clean, reliable, and affordable,” said Robert Routh, Pennsylvania climate and energy policy director for the Natural Resources Defense Council, one of the groups demanding that DOE reconsider its orders. Keeping J.H. Campbell and Eddystone open ​“results in the exact opposite. It’s costly, harmful, unnecessary, and unlawful.” Taking on the DOE’s grid emergency claims The groups challenging the DOE’s J.H. Campbell and Eddystone stay-open orders point out that the agency is using a power originally designed to protect the grid against unanticipated emergencies, including during wartime, but without proving that such an emergency is underway. “This authority that the Department of Energy is acting under — Section 202(c) of the Federal Power Act — is a very tailored emergency authority,” said Caroline Reiser, NRDC senior attorney for climate and energy. ​“Congress intentionally wrote it only to be usable in specific, narrow, short-term emergencies. This is not that.” For decades, the DOE has used its Section 202(c) power sparingly, and only in response to requests from utilities or grid operators to waive federal air pollution regulations or other requirements in moments when the grid faces imminent threats like widespread power outages, Reiser said. But DOE’s orders for Eddystone and J.H. Campbell were not spurred by requests from state regulators or regional grid operators. In fact, the orders caught those parties by surprise. They also came mere days before the plants were set to close down and after years of effort to ensure their closure wouldn’t threaten grid reliability. J.H. Campbell was scheduled to close in May under a plan that has been in the works since 2021 as part of a broader agreement between utility Consumers Energy and state regulators, and which was approved by the Midcontinent Independent System Operator (MISO), the entity that manages grid reliability across Michigan and 14 other states. “The plant is really old, unreliable, extremely polluting, and extremely expensive,” Reiser said. ​“Nobody is saying that this plant is needed or is going to be beneficial for any reliability purposes.” To justify its stay-open order, DOE cited reports from the North American Electric Reliability Corp. (NERC), a nonprofit regulatory authority that includes utilities and grid operators in the U.S. and Canada. NERC found MISO is at higher risk of summertime reliability problems than other U.S. grid regions, but environmental groups argue in their rehearing request that DOE has ​“misrepresented the reports on which it relies,” and that Consumers Energy, Michigan regulators, and MISO have collectively shown closing the plant won’t endanger grid reliability. Eddystone, which had operated only infrequently over the past few years, also went through a rigorous process with mid-Atlantic grid operator PJM Interconnection to ensure its closure wouldn’t harm grid reliability. The DOE’s reason for keeping that plant open is based on a report from PJM that states the grid operator might need to ask utility customers to use less power if it faces extreme conditions this summer — an even scantier justification than what the agency cited in its J.H. Campbell order, Reiser said. As long as the DOE continues to take the position that it can issue emergency stay-open orders to any power plant it decides to, these established methods for managing plant closures and fairly allocating costs will be thrown into disarray, she said. “We have a system of competitive energy markets in the United States that is successful in keeping the lights on and maintaining reliability the vast, vast majority of the time,” Reiser said. ​“The Department of Energy stepping in and using a command-and-control system interferes with those markets.”

Designing a new way to optimize complex coordinated systems

Using diagrams to represent interactions in multipart systems can provide a faster way to design software improvements.

Coordinating complicated interactive systems, whether it’s the different modes of transportation in a city or the various components that must work together to make an effective and efficient robot, is an increasingly important subject for software designers to tackle. Now, researchers at MIT have developed an entirely new way of approaching these complex problems, using simple diagrams as a tool to reveal better approaches to software optimization in deep-learning models.They say the new method makes addressing these complex tasks so simple that it can be reduced to a drawing that would fit on the back of a napkin.The new approach is described in the journal Transactions of Machine Learning Research, in a paper by incoming doctoral student Vincent Abbott and Professor Gioele Zardini of MIT’s Laboratory for Information and Decision Systems (LIDS).“We designed a new language to talk about these new systems,” Zardini says. This new diagram-based “language” is heavily based on something called category theory, he explains.It all has to do with designing the underlying architecture of computer algorithms — the programs that will actually end up sensing and controlling the various different parts of the system that’s being optimized. “The components are different pieces of an algorithm, and they have to talk to each other, exchange information, but also account for energy usage, memory consumption, and so on.” Such optimizations are notoriously difficult because each change in one part of the system can in turn cause changes in other parts, which can further affect other parts, and so on.The researchers decided to focus on the particular class of deep-learning algorithms, which are currently a hot topic of research. Deep learning is the basis of the large artificial intelligence models, including large language models such as ChatGPT and image-generation models such as Midjourney. These models manipulate data by a “deep” series of matrix multiplications interspersed with other operations. The numbers within matrices are parameters, and are updated during long training runs, allowing for complex patterns to be found. Models consist of billions of parameters, making computation expensive, and hence improved resource usage and optimization invaluable.Diagrams can represent details of the parallelized operations that deep-learning models consist of, revealing the relationships between algorithms and the parallelized graphics processing unit (GPU) hardware they run on, supplied by companies such as NVIDIA. “I’m very excited about this,” says Zardini, because “we seem to have found a language that very nicely describes deep learning algorithms, explicitly representing all the important things, which is the operators you use,” for example the energy consumption, the memory allocation, and any other parameter that you’re trying to optimize for.Much of the progress within deep learning has stemmed from resource efficiency optimizations. The latest DeepSeek model showed that a small team can compete with top models from OpenAI and other major labs by focusing on resource efficiency and the relationship between software and hardware. Typically, in deriving these optimizations, he says, “people need a lot of trial and error to discover new architectures.” For example, a widely used optimization program called FlashAttention took more than four years to develop, he says. But with the new framework they developed, “we can really approach this problem in a more formal way.” And all of this is represented visually in a precisely defined graphical language.But the methods that have been used to find these improvements “are very limited,” he says. “I think this shows that there’s a major gap, in that we don’t have a formal systematic method of relating an algorithm to either its optimal execution, or even really understanding how many resources it will take to run.” But now, with the new diagram-based method they devised, such a system exists.Category theory, which underlies this approach, is a way of mathematically describing the different components of a system and how they interact in a generalized, abstract manner. Different perspectives can be related. For example, mathematical formulas can be related to algorithms that implement them and use resources, or descriptions of systems can be related to robust “monoidal string diagrams.” These visualizations allow you to directly play around and experiment with how the different parts connect and interact. What they developed, he says, amounts to “string diagrams on steroids,” which incorporates many more graphical conventions and many more properties.“Category theory can be thought of as the mathematics of abstraction and composition,” Abbott says. “Any compositional system can be described using category theory, and the relationship between compositional systems can then also be studied.” Algebraic rules that are typically associated with functions can also be represented as diagrams, he says. “Then, a lot of the visual tricks we can do with diagrams, we can relate to algebraic tricks and functions. So, it creates this correspondence between these different systems.”As a result, he says, “this solves a very important problem, which is that we have these deep-learning algorithms, but they’re not clearly understood as mathematical models.” But by representing them as diagrams, it becomes possible to approach them formally and systematically, he says.One thing this enables is a clear visual understanding of the way parallel real-world processes can be represented by parallel processing in multicore computer GPUs. “In this way,” Abbott says, “diagrams can both represent a function, and then reveal how to optimally execute it on a GPU.”The “attention” algorithm is used by deep-learning algorithms that require general, contextual information, and is a key phase of the serialized blocks that constitute large language models such as ChatGPT. FlashAttention is an optimization that took years to develop, but resulted in a sixfold improvement in the speed of attention algorithms.Applying their method to the well-established FlashAttention algorithm, Zardini says that “here we are able to derive it, literally, on a napkin.” He then adds, “OK, maybe it’s a large napkin.” But to drive home the point about how much their new approach can simplify dealing with these complex algorithms, they titled their formal research paper on the work “FlashAttention on a Napkin.”This method, Abbott says, “allows for optimization to be really quickly derived, in contrast to prevailing methods.” While they initially applied this approach to the already existing FlashAttention algorithm, thus verifying its effectiveness, “we hope to now use this language to automate the detection of improvements,” says Zardini, who in addition to being a principal investigator in LIDS, is the Rudge and Nancy Allen Assistant Professor of Civil and Environmental Engineering, and an affiliate faculty with the Institute for Data, Systems, and Society.The plan is that ultimately, he says, they will develop the software to the point that “the researcher uploads their code, and with the new algorithm you automatically detect what can be improved, what can be optimized, and you return an optimized version of the algorithm to the user.”In addition to automating algorithm optimization, Zardini notes that a robust analysis of how deep-learning algorithms relate to hardware resource usage allows for systematic co-design of hardware and software. This line of work integrates with Zardini’s focus on categorical co-design, which uses the tools of category theory to simultaneously optimize various components of engineered systems.Abbott says that “this whole field of optimized deep learning models, I believe, is quite critically unaddressed, and that’s why these diagrams are so exciting. They open the doors to a systematic approach to this problem.”“I’m very impressed by the quality of this research. ... The new approach to diagramming deep-learning algorithms used by this paper could be a very significant step,” says Jeremy Howard, founder and CEO of Answers.ai, who was not associated with this work. “This paper is the first time I’ve seen such a notation used to deeply analyze the performance of a deep-learning algorithm on real-world hardware. ... The next step will be to see whether real-world performance gains can be achieved.”“This is a beautifully executed piece of theoretical research, which also aims for high accessibility to uninitiated readers — a trait rarely seen in papers of this kind,” says Petar Velickovic, a senior research scientist at Google DeepMind and a lecturer at Cambridge University, who was not associated with this work. These researchers, he says, “are clearly excellent communicators, and I cannot wait to see what they come up with next!”The new diagram-based language, having been posted online, has already attracted great attention and interest from software developers. A reviewer from Abbott’s prior paper introducing the diagrams noted that “The proposed neural circuit diagrams look great from an artistic standpoint (as far as I am able to judge this).” “It’s technical research, but it’s also flashy!” Zardini says.

The UK Says at an Energy Summit That Green Power Will Boost Security, as the US Differs

Britain has announced a major investment in wind power as it hosts an international summit on energy security

LONDON (AP) — Britain announced a major investment in wind power Thursday as it hosted an international summit on energy security — with Europe and the United States at odds over whether to cut their reliance on fossil fuels.U.K. Prime Minister Keir Starmer said the government will invest 300 million pounds ($400 million) in boosting Britain’s capacity to manufacture components for the offshore wind industry, a move it hopes will encourage private investment in the U.K.’s renewable energy sector.“As long as energy can be weaponized against us, our countries and our citizens are vulnerable and exposed,” U.K. Energy Secretary Ed Miliband told delegates.He said “low-carbon power” was a route to energy security as well as a way to slow climate change.Britain now gets more than half its electricity from renewable sources such as wind and solar power, and the rest from natural gas and nuclear energy. It aims to generate all the U.K.’s energy from renewable sources by 2030.Tommy Joyce, U.S. acting assistant secretary of energy for international affairs, told participants they should be “honest about the world’s growing energy needs, not focused on net-zero politics.”He called policies that push for clean power over fossil fuels "harmful and dangerous," and claimed building wind turbines requires "concessions to or coercion from China" because it supplies necessary rare minerals.Hosted by the British government and the International Energy Agency, the two-day summit brings together government ministers from 60 countries, senior European Union officials, energy sector CEOs, heads of international organizations and nonprofits to assess risks to the global energy system and figure out solutions. Associated Press writer Jennifer McDermott contributed to this story. ___The Associated Press’ climate and environmental coverage receives financial support from multiple private foundations. AP is solely responsible for all content. Find AP’s standards for working with philanthropies, a list of supporters and funded coverage areas at AP.org.Copyright 2025 The Associated Press. All rights reserved. This material may not be published, broadcast, rewritten or redistributed.Photos You Should See - Feb. 2025

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