The pair of 1950s-era coal plants bailed out under Ohio’s House Bill 6 law are likely to remain unprofitable even after a surge in grid operator payments to generators, experts say. 

The PJM Interconnection grid market makes capacity payments to line up power to meet expected demand in the years ahead. Aging, uneconomical coal plants are being retired at a time when data centers and manufacturers are starting to use more electricity, causing future power generation prices to rise.

But even record-high prices in PJM Interconnection’s recent capacity auction won’t cover the hundreds of millions of dollars in subsidies paid by ratepayers to cover Ohio utilities’ costs for the Ohio Valley Electric Corporation’s Kyger Creek and Clifty Creek power plants.

“Even with a super high price, OVEC is still going to be in the red,” said Neil Waggoner, Midwest manager for the Sierra Club’s Beyond Coal campaign.

The ratepayer subsidies are a result of HB 6, the 2019 state law at the heart of the largest corruption scheme in Ohio’s history. Republican legislative leaders have blocked all efforts to repeal the coal subsidies from coming to a floor vote.

This year alone, ratepayers are on track to pay nearly $200 million to prop up the two plants, one of which is in Indiana. By 2030, total ratepayer costs from the bailout could exceed $1 billion, according to RunnerStone, a consultant for the Ohio Manufacturers’ Association.

Starting next summer, the payments for generators to be ready to supply electricity when PJM Interconnection needs it will jump to about nine times the current rate for most of the grid operator’s service region. 

“Put simply, the market pays participants for the promise to produce electricity when called upon by PJM,” said Daniel Lockwood, a spokesperson for the regional grid operator. An auction sets the levels for each year’s capacity payments, and the payments go to generators that bid the clearing price or less.

A spokesperson for the power plants did not directly answer the Energy News Network’s question about whether both cleared the latest PJM auction, although he described the auction results as “positive.”

“The auction results were a positive development for the OVEC plants and are more broadly a signal to the market that additional generation resources are needed in the PJM region,” said Scott Blake, a spokesperson for American Electric Power and Ohio Valley Electric Corp. While the HB 6 rider charges depend on multiple factors, the impact of the 2025/2026 capacity pricing “is expected to be positive for customers,” he said.

AEP is OVEC’s largest shareholder, along with other utility companies in Ohio and other states.

HB 6’s OVEC subsidies currently require Ohio’s residential utility customers to pay between $1.30 and $1.50 per month, depending on whether their utility is owned by AEP, AES Ohio, Duke Energy or FirstEnergy, according to PUCO data from spokesperson Brittany Waugaman. Businesses pay for the rider, too. The HB 6 rider’s net total costs last year were more than $148 million.

Doing the math

While capacity payments will reduce the OVEC plants’ total costs to Ohio ratepayers, the revenue won’t, in itself, make the plants profitable.

Expert testimony from a Michigan case last year found the OVEC plants would need capacity payments averaging about $418/MW-day for several years to become economical. Last month’s record-high price that will take effect next summer was about $270/MW-day.

Economic analyst Devi Glick of Synapse Energy Economics testified in the case on behalf of the Sierra Club.

“To massively oversimplify the economics of the OVEC plants, there are two categories of costs and two categories of revenues,” Glick told Energy News Network. “Costs are on one side of the equation and revenues on the other.”

Based on then-current projections for costs and energy market revenue, Glick calculated what the plants’ capacity revenues would have to be for the equation to balance out.

Several caveats would apply, Waggoner acknowledged, including any differences from last year to this year that could affect projected energy revenues. Nonetheless, he noted, a significant gap would remain.

Glick’s estimate of about $418 as a break-even capacity price for the OVEC plants is realistic and may even be conservative now, said John Seryak, managing partner for RunnerStone.

“PJM is no longer paying for a coal plant’s full power capacity anymore under new rules it created just prior to this capacity auction,” Seryak explained. “That could mean that OVEC needs even higher-priced capacity and energy to be profitable.”

“Future energy market prices, OVEC’s future coal costs, and OVEC’s environmental compliance costs will also be important factors determining the extent of its losses or profitability,” Seryak continued. “All that said, we do not anticipate OVEC operating at a profit without further price increases.”

Meeting energy demand

Blake emphasized the OVEC plants’ role as a “reliable generation resource for our customers and for our region,” adding that the HB 6 rider “ensures that customers in Ohio receive electricity from OVEC for what it costs to produce it and the funds are used to pay down debt with no proceeds going to shareholders.”

That’s not exactly correct, said attorney Kimberly Bojko at Carpenter Lipps, who represents the Ohio Manufacturers’ Association in cases at the Public Utilities Commission of Ohio. “Customers pay the cost to operate and run OVEC and the power produced from OVEC is then sold into the wholesale electric market,” she said. Any revenue offsets the costs of HB 6’s coal subsidy.

The Ohio Manufacturers’ Association also has disputed the use of the HB 6 rider to pay down the OVEC plants’ debt in cases before the PUCO.

“By using ratepayer funds to pay down its debt, AEP Ohio is essentially shifting its bad debt to the Ohio ratepayers,” Seryak said. “It’s akin to if a person forced their neighbor to pay for their mortgage payment.”

“Customers pay for more than just OVEC’s debt, though,” Seryak added. “Customers also pay for losses in the energy market OVEC incurs. When this occurs, it means the electric grid does not need OVEC for reliability. Instead, OVEC is burning coal pointlessly at a loss and charging it to Ohio’s ratepayers.”

Ohio coal plant subsidies still a bad deal for ratepayers despite growing generation demand, experts say is an article from Energy News Network, a nonprofit news service covering the clean energy transition. If you would like to support us please make a donation.

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California has given America a glimpse at what running one of the world’s largest economies on renewable energy might look like.

The state recently hit a milestone: 100 days this year with 100% carbon-free, renewable electricity for at least a part of each day, as tracked by Stanford University engineering Professor Mark Z. Jacobson.

The state notched the milestone while — so far — avoiding blackouts and emergency power reductions this year, even with the hottest July on record.

That progress is largely due to the substantial public and private investments in renewable energy — particularly batteries storing solar power to use when the sun isn’t shining, according to energy experts.

“California has made unprecedented investments in our power grid in recent years — and we’re seeing them pay off in real time,” Gov. Gavin Newsom said in a statement to CalMatters. “Not only is our grid more reliable and resilient, it’s also increasingly running on 100% clean electricity.”

The state faces a huge challenge in coming years: A series of mandates will require carbon-free energy while also putting more electric cars on roads and electric appliances in homes. California, under state law, must run on 60% renewable energy by 2030, ramping up to 100% by 2045.

Signs of progress are emerging. From January to mid-July of this year, zero-carbon, renewable energy exceeded demand in California for 945 hours during 146 days — equivalent to a month-and-a-half of 100% fossil-fuel-free electricity, according to the California Energy Commission, the state agency tasked with carrying out the clean energy mandates.

But California still has a long way to go to stop burning fossil fuels for electricity. Natural gas, which emits greenhouse gases and air pollutants, remains its single largest source of electricity.

Just over half of power generated for Californians in 2022 came from solar, wind, other renewables and nuclear power, while 36% came from natural gas plants.

Reliability of the power grid is a top concern as the state switches to solar and wind energy. Unpredictable events like wildfires and winter storms also cause outages, while hot summer months, with air conditioners whirring, strain the supply.

In August of 2020 California experienced its first non-wildfire blackouts in nearly 20 years, and in late August and September of 2022, a severe heatwave forced regulators to ask consumers to voluntarily reduce power for 10 days.

Since September 2022 — when California teetered on the edge of those blackouts and the governor pleaded for conservation — nearly 11,600 new megawatts of clean energy have been added to the state’s grid, said Elliot Mainzer, chief executive of the California Independent System Operator, which manages the grid. (That’s enough to power around 9 to 12 million homes although it’s not available all at one time.)

California also now has more than 10,000 megawatts of battery capacity, making it the largest supply outside of China. Battery power from large commercial facilities proved its worth during last month’s heat wave, Mainzer said.

Batteries “were a major difference-maker,” Mainzer said. “The batteries charged during the day, when solar energy is abundant, and then they put that energy back onto the grid in the afternoon and evening, when solar production is rolling off the system.”

California relies heavily on four-hour duration lithium-ion batteries, which come in large, centralized facilities and hybrid facilities paired with solar energy projects. More homes also are installing batteries with their rooftop solar installations, but they supply a small amount of power.

Planning and practicing various emergency scenarios has also helped immensely, Mainzer said.

“Our grid operators are now increasingly experienced at managing these extreme heat events,” Mainzer said. “Our forecasters also did an excellent job of reviewing the next day’s conditions so that the market could respond effectively.”

‘The table is set’ for clean energy

California may need to more than double its energy generation capacity by 2045 to meet the 100% clean energy target while adding electric cars, appliances and other technologies, said Siva Gunda, who sits on the California Energy Commission. 

To do that, California aims to build about 6,000 to 8,000 megawatts of new energy resources each year. The state hit a record last year, adding more than 6,000 megawatts, Gunda said. Each megawatt is enough to serve between 750 and 1,000 homes. 

“The table is set,” Gunda said. “The pieces are there for success, and it’s about executing it, together with a common vision and collaboration.”

The commission is closely monitoring a new concern: Artificial intelligence technology, which uses large data centers that consume power. “We’re carefully watching where the loads are going to grow,” Gunda said.

Stanford’s Jacobson said running on 100% renewable energy is becoming more common.

Over the July 28 weekend, California marked the 100th nonconsecutive day within a 144-day stretch in which 100% of electricity came from renewable sources for periods ranging from five minutes to more than 10 hours, he said.

On April 8, a solar eclipse reduced solar power generation and increased demand on the grid, which was met by batteries. On May 5, wind, hydroelectric and solar energy reached more than 160% of demand for a significant portion of the day.

California continues to waffle about ending its reliance on natural gas and nuclear power.

Fearing emergency rolling blackouts like the one in 2020, Newsom and the Legislature in 2022 allowed some natural gas plants that were supposed to go offline to keep operating. 

And the Diablo Canyon nuclear power plant will continue operating while Pacific Gas & Electric pursues federal permission to stay open past 2025. Nuclear power is considered renewable and carbon-free but it creates radioactive waste.

State officials and private investors aim to create an entirely new industry — giant floating ocean wind platforms — to produce 13% of California’s power, enough to power 25 million homes, by 2045. The massive projects will cost billions of dollars. 

Some Democratic legislators are hoping to make it easier to build wind and solar projects, since sometimes local obstacles and permitting take years. They are negotiating an end-of-session package of proposed laws that could streamline construction, CalMatters reported earlier this month. California’s legislative session ends Aug. 31.

Jacobson said the cost of large-scale solar power projects has “dropped substantially” in recent decades largely because of “economies of scale — just the huge growth of solar on a worldwide scale.”

“There’s no miracle technology that was developed,” he said. “It’s just subtle improvements in existing technologies and deployment, deployment, deployment.”

California hits milestones toward 100% clean energy — but has a long way to go is an article from Energy News Network, a nonprofit news service covering the clean energy transition. If you would like to support us please make a donation.

Editor’s note: Miles Braxton’s company is Okovate Sustainable Energy. A previous version of this post misspelled the company’s name.

Agrivoltaics — co-locating solar arrays with farming operations — is generating enthusiasm among both farmers and clean energy advocates as a way to promote sustainability in agriculture. 

When implemented correctly, agrivoltaics provides a vital dual income stream for farmers — in solar energy generation, but also as a means of providing an optimal growing environment for compatible crops and herds. The added revenue may allow more farmers to retain their land for themselves and future generations. 

While pilot projects around the country are identifying best practices, not all have been successful, and practitioners say that advancing the technology will require an equitable approach that centers farmers’ needs first.

A discussion during the recent Solar Farm Summit in Rosemont, Illinois, directly addressed the issue, featuring a majority-Black panel of practitioners and service providers. Three major themes emerged during the discussion: maximizing compatibility of solar arrays with existing land use, demonstrating the financial benefits of agrivoltaics, and addressing how solar power can help BIPOC farmers hold on to their land.

“I think one thing that, through our work in this technical assistance, has become very, very clear [is] that people don’t just want to build an agrivoltaics project for the sake of building an agrivoltaics project,” said Jordan Macknick of the National Renewable Energy Laboratory (NREL), who also served as moderator for the discussion. “How does agrivoltaics enable you to take that next step and focus on things like succession planning or farmer training?”

Benefits for farmers

Miles Braxton started his company, Okovate Sustainable Energy, to work exclusively on “farmer-focused” solar development.

Braxton said after several years of developing community solar projects, he “really saw the inefficiencies” of taking farmland out of production for solar projects. “That’s a problem that is just going to keep piling on top of itself until it gets to the point where we can’t develop anything.

“We target crop farmers who are growing a very specific suite of crops that we know works well with our design,” Braxton said.

Cetta Barnhart, owner of Seed Time Harvest Farms in Florida, also cultivates her own plot of fruits and vegetables, and cited her background in food and wellness in promoting the compatibility of solar and agriculture to benefit the bottom line for farmers.

“This is more hands-on of what a farmer can really do in their current practices. If they’re raising cattle, there’s a way that they implement solar with that. If they are having bare land, the pollinator is another way that they can benefit from that,” she said. “So how these solar projects are developed and created for real farmers is still a big conversation to be had.“ 

Ena Jones, owner of Roots & Vine Produce and Café, and president of Community Partners for Black Farmers, cited her dual role as a working farmer and an advocate as an advantage in promoting the potential compatibility of agrivoltaics and cultivation — especially for Black farmers.

“We advocate and we also lobby for farmers at the state level for the state of Illinois and the state of Georgia. And I’m here to kind of segue to help farmers understand … how different solar opportunities can help them with production on their farms, and be an asset to the production on their farms. And also, to help solar developers understand farm[ing],” Jones said.

Noting that solar projects can help cut energy costs, Jones said “Energy use is one of the farmer’s [major] expenses outside of diesel, and of course seed. So, if they can reduce that cost dramatically, even by a third, that would impact their bottom line in revenue extensively. It is very important, especially for BIPOC farmers, to be ushered into this technology so that they won’t be left behind in the process.”

Making connections

Agrivoltaics can be a valuable tool to reduce overall costs, expand potential revenue – or both – as a means of promoting optimal use of farmland. A both-and approach can work to address what is often an inherent tension between the best use of large, flat plots of land for large solar arrays – parcels that also frequently comprise some of the richest soil for cultivation. 

For example, the 180 MW Madison Fields project in Ohio represents a test ground for large-scale agrivoltaics – farming on 1,900 acres between the rows of a utility-scale solar array. One of the project’s focuses is determining which crops and herds are the best prospects to coexist with large-scale solar developments.

“People have a lot of questions with regard to energy development going forward in this state … Finding a balance where you can do a number of things on the same ground — in this case energy production as well as agricultural production — is obviously huge,” Dale Arnold, director of energy policy for the Ohio Farm Bureau told the Energy News Network in July.

Macknick highlighted another project where NREL and Clean Energy to Communities (C2C), along with the Black Farmers Collaborative, worked on a proof of concept project which incorporated solar panels on a demonstration farm cultivated by Barnhart that features citrus trees, leafy greens, and other produce.

“I had already looked into doing solar on my property and was just looking at it to have solar as the backup,” Barnhart said. “But when we started talking as a team and then we found out about the agrivoltaics portion [and] how that can be incorporated into farming, it really brought forth a bigger and better opportunity to not just benefit by having it but also sharing that with other farmers,” Barnhart told NREL in 2023.

Mike DellaGala of Solar Collective said taking a farmer-centered approach can also be beneficial to product and service providers.

“I think a lot of the conversation … has been the difference between farmers and developers, and how we are or [are] not communicating and getting projects over the finish line or not. And I think… if you’re farmer-first or farmer-centric, I think that’s the way to success for everybody… allowing [farmers] to dictate a lot of the project details has been really successful for us. And it makes our job easier, frankly,” DellaGala said.

A farmer-centric and collaborative approach is especially vital in ensuring equitable access to the benefits of agrivoltaics for BIPOC farmers, Barnhart said.

“I stand in the gap somewhat between having conversations with [BIPOC] farmers and having conversations with project developers because you need someone in the middle. I’m a community advocate. I hope there are more of us in the room than not. They have to be in place in order to bridge the conversation as to how this really works well in real-life time,” Barnhart said.

Braxton cited the need to rein in the power of utilities, which he says frequently raise roadblocks to community-level projects to protect their own interests. 

“Utilities have too much power. They have too much money to lobby. They don’t want you to sell power back to your community because [of the impact to] their own rates that they can control. So that’s a risk. The root of those problems is that here in the U.S. … we have 50 little countries [states] that make up their own policies and do their own thing… I think there needs to be a policy to incentivize solar to be developed innovatively. I don’t think policy makers at the state level understand the importance of that,” Braxton said.

Jones noted that policy change will likely be driven by farmer demand, which by extension benefits the larger community.

“In my opinion, once the farmers understand [how solar can] help them on their farms, I can’t say this enough, they will force politicians to comply. The money will be there; the funding will be there. But the engagement needs to happen. It desperately needs to happen,” she said.

Land retention for BIPOC farmers

Loss of land –through racism and other factors, has long been a contentious topic among BIPOC farmers – and Black farmers in particular. According to a 2022 study, discriminatory federal policies contributed to Black farmers losing roughly $326 billion worth of acreage during the 20th century. In July, the Biden-Harris administration announced a distribution of $2 billion to thousands of Black and other minority farmers, created through the Inflation Reduction Act as a means to begin to address this inequity.

Agrivoltaics may not intuitively track as a relevant strategy for land retention; but Barnhart touted its value, especially for Black farmers. 

“[Black farmers] have lost a lot of land because we just couldn’t afford to keep it… We didn’t just lose land because it was confiscated… What solar does is add an income stream or a reduction in your expenses so that there’s more you can do on your farm and create an opportunity for the next generation. 

“It gives us a reason to keep the land going, and it gives us, in our community, resiliency we are experiencing through our climate change storms. For the families that can have that piece of land, that builds a resiliency to protect them in their neighborhoods, protect their own backyard, and protect the future generations, give the future generations something they can look forward to that makes sense to them. Then we build into something that takes care of our wealth building opportunities, our succession planning, and our look into the future to make a change,” Barnhart said.

How a ‘farmer-first’ approach could lead to more successful agrivoltaics projects is an article from Energy News Network, a nonprofit news service covering the clean energy transition. If you would like to support us please make a donation.

Construction is underway in St. Paul, Minnesota, on a major affordable housing development that will combine solar, geothermal and all-electric appliances to create one of the region’s largest net-zero communities.

Twin Cities Habitat for Humanity broke ground in June on a four-block, 147-unit project on the site of a former golf course that’s being redeveloped by the city and its port authority, which made the decision to forgo gas hookups. 

Affordable housing and Habitat for Humanity builds in particular have become a front line in the fight over the future of gas. The organization has faced criticism in other communities for accepting fossil fuel industry money and partnering with utilities on “net-zero” homes that include gas appliances. It’s also built several all-electric projects using advanced sustainable construction methods and materials.

The scale of the Twin Cities project is what makes it exciting, according to St. Paul’s chief resilience officer Russ Stark. 

“We’ve had plenty of motivated folks build their own all-electric homes, but they’re one-offs,” he said. “There haven’t been many, if any, at scale.”

Stark added that the project, known as The Heights, was made possible by the federal Inflation Reduction Act. 

“I think it’s fair to say that those pieces couldn’t have all come together without either a much bigger public investment or the Inflation Reduction Act, which ended up being that big public investment,” he said.

A vision emerges

Port Authority President and CEO Todd Hurley said his organization bought the property in 2019 from the Steamfitters Pipefitters Local 455, which maintained it as a golf course until 2017. When no private buyers expressed interest in the property, the Port Authority bought it for $10 million.

Hurley said the Port Authority saw potential for light industrial development and had the experience necessary to deal with mercury pollution from a fungicide the golf course staff sprayed to kill weeds.

“We are a land developer, a brownfield land developer, and one of our missions is to add jobs and tax base around the creation of light industrial jobs,” Hurley said.

The Port Authority worked with the city’s planning department on a master plan that included housing, and it solicited developers to build a mix of market-rate, affordable and low-income units. The housing parcels were eventually sold for $20 million to a private developer, Sherman Associates, which partnered with Habitat and JO Companies, a Black-owned affordable and multi-family housing developer.

“Early on, we identified a very high goal of (becoming) a net zero community,” Hurley said. “Everything we have been working on has been steering towards getting to net zero.”

Twin Cities Habitat President and former St. Paul mayor Chris Coleman said the project met his organization’s strategic plan, which calls for building bigger developments instead of its traditional practice of infilling smaller lots with single-family homes and duplexes. The project will be the largest the organization has ever built in the Twin Cities.

Coleman said the Heights offered an opportunity to fill a need in one of St. Paul’s most diverse and economically challenged neighborhoods and “be part of the biggest investment in the East Side in over 100 years.”

The requirement for all-electric homes merged with Habitat’s goal of constructing more efficient and sustainable homes to drive down utility costs for homeowners, he said. Habitat built solar-ready homes and sees the solar shingles on its homes in The Heights as a potential avenue to producing onsite clean energy.

Zeroing in on net zero

Mike Robertson, a Habitat program manager working on the project, said the organization worked with teams from the Minneapolis-based Center for Energy and Environment on energy modeling.

“The Heights is the first time that we’ve dived into doing an all-electric at scale,” Roberston said. “We have confidence that these houses will perform how they were modeled.”

Habitat plans to build the development to meet the Zero Energy Ready Home Program standards developed by the U.S. Department of Energy. Habitat will use Xcel Energy’s utility rebate and efficiency programs to achieve the highest efficiency and go above and beyond Habitat’s typical home standards.

The improved construction only adds a few thousand dollars to the overall costs and unlocks federal government incentives to help pay for upgrades, he said.

The nonprofit will receive free or reduced-cost products from Andersen Windows & Doors and other manufacturers. GAF Energy LLC, a solar roofing company, will donate solar shingles for over 40 homes and roofing materials. On-site solar will help bring down energy bills for homeowners, he said.

Chad Dipman, Habitat land development director, said the solar shingles should cover between half and 60% of the electricity the homes need. Habitat plans to use Xcel Energy incentive programs to help pay for additional solar shingles needed beyond those donated. 

Habitat will install electric resistance heating technology into air handlers to serve as backup heat for extremely cold days. Dipman said that the air source heat pumps will also provide air conditioning, a feature not available in most Habitat properties in Minnesota.  

Phil Anderson, new homes manager at the Center for Energy and Environment, has worked with Habitat on the project. He said the key to reducing the cost of heating and cooling electric homes is a well-insulated, tight envelope and high-performance windows. Habitat will build on its experience with constructing tight homes over the past decade, he said.

“Overall, the houses that we’ve been part of over the last almost ten years have been very tight homes,” Anderson said. “There’s just not a lot of air escaping.”

Habitat’s national office selected The Heights as this year’s Jimmy & Rosalynn Carter Work Project, named after the former president and his wife, two of Habitat’s most famous supporters. The work project begins September 29^th and will receive as visitors Garth Brooks and Trisha Yearwood, who now host the Carters’ program.

Robertson said thousands of volunteers from around the country and the world will help put up the homes. The Heights project “raises a lot of awareness for Habitat and specifically for this development and the decarbonization efforts that we’re putting into it,” he said.

The Heights’s two other housing developers continue raising capital for their projects and hope to break ground by next summer. Habitat believes the project will meet its 2030 completion deadline.

A St. Paul, Minnesota Habitat for Humanity project will offer affordable housing without fossil fuels is an article from Energy News Network, a nonprofit news service covering the clean energy transition. If you would like to support us please make a donation.

DALTON, Ga. — Growing up in Cartersville, Georgia, Lisa Nash saw what happens to communities when factory jobs disappear. It was the 1980s and corporations were offshoring production to reduce costs and raise profits. The jobs that remained in this northwest corner of the state were typically lower-paying ones that didn’t offer the same ladder to the middle class.

“My parents and grandparents were in manufacturing, and they were the ones saying, ​‘Don’t do it,’” Nash recalled.

Nash disregarded their advice, embarking instead on a long career in manufacturing — first in textiles, followed by stints in aviation, automotive, and steel. Now she’s helping to bring higher-tech, higher-paying factory work back to the corridor between Atlanta and Chattanooga. 

Nash is the general manager of the Qcells solar panel factory in Dalton, a town of 34,000 located 50 miles up I-75 from her hometown. It opened in January 2019, after the Trump administration imposed a fresh round of tariffs on Chinese-made panels. The Korean conglomerate Hanwha owns Qcells, and initially planned to hire several hundred people at the site, Nash told me on a recent visit to the factory. By the end of 2019, it employed more than 800. 

Then, in 2020, Georgia helped elect President Joe Biden and sent two Democrats to the Senate, clinching a thin majority. Senators Jon Ossoff and Raphael Warnock got to work crafting detailed policies to promote domestic manufacturing of clean energy technologies, which China had dominated for years; they wanted solar panels and batteries made in America — specifically Georgia — instead of in China, a geopolitical rival.

Those measures made it into the Inflation Reduction Act, which passed in August 2022 — two years ago this week. The legislation created the nation’s first comprehensive policies to support domestic clean energy manufacturing. Qcells broke ground on a second facility in Dalton in February 2023. Completed that August, the expansion added two football fields’ worth of manufacturing space with four new production lines — which produce 1.5 times more solar panels than the original three lines, thanks to technological advances. Now the whole complex employs 2,000 people full time and makes 5.1 gigawatts of solar panels a year, more than any other site in the U.S.

Politicians have been promising for decades to retrain American workers and revive long-lost manufacturing, with little to show for it. Now, though, the U.S. has entered a new era on trade: Leaders of both parties have rejected the long-standing free-trade consensus and its penchant for offshoring jobs. Biden married that reshoring impulse with a desire to boost clean energy production, to both stimulate the economy and fight climate change. 

This grand experiment remains in its infancy, and the success of the clean energy manufacturing revolution is by no means guaranteed. Cheap imports could outcompete even newly subsidized American products. 

And if Republicans win the presidency and retake Congress, they’ve threatened to stop subsidizing low-carbon energy resources and instead double down on fossil fuel production. House Republicans — including Dalton’s representative, Marjorie Taylor Greene — have voted repeatedly and unsuccessfully to repeal the domestic manufacturing incentives in the IRA. (Greene’s press office did not respond to multiple requests for comment.)

“Donald Trump and his Republican allies promised to gut the Inflation Reduction Act if he’s reelected, so there’s a lot at stake here,” Representative Nikema Williams, who leads the Georgia Democrats, told me.

Since the IRA passed, Georgia has received $23 billion in clean energy factory investment, much of it flowing to northwest Georgia. I wanted to see what impact this is having on communities formerly hit hard by industrial decline, so I followed the money trail to Dalton earlier this summer. 

I found a population that seems to like having advanced solar manufacturing in their backyard. Dalton’s solar jobs are boosting wages, invigorating the historic town center, and employing local high school graduates. Those benefits are starting to spread to nearby communities, where new solar factories are springing to life. In November, voters will weigh two very different visions of America’s energy future on the ballot, but Dalton is already reaping the rewards from slotting solar into its storied history of industrial production.

From carpets to solar

Both CSX and Norfolk Southern run Class I rail lines through Dalton, a testament to its industrial legacy, and freight trains bellow day and night.

That legacy harks back to 1900, according to local historians, when Catherine Evans Whitener sold a hand-tufted bedspread from her front porch for $2.50. The cottage industry took off in this land of forested ridges and stream-crossed valleys, and over time, local factories consolidated into global carpeting giants Shaw Industries and Mohawk Industries.

“The carpet industry was born here,” Carl Campbell, executive director of economic development at the Greater Dalton Chamber of Commerce, told me when I visited the Chamber. The New Georgia Encyclopedia states that 80 percent of America’s tufted carpet production happens within 100 miles of Dalton.

The conference room where we spoke sported large-format aerial photographs of the major factories nearby: the largest Shaw site, 650,000 square feet; and the new Engineered Floors colossus, 2.8 million square feet. 

“You feel like there’s enough carpet in that building to cover the whole world,” said Campbell, who grew up in Dalton. 

Dalton employment numbers peaked at 80,200 in 2006, per the Chattanooga Times Free Press. But the Great Recession crushed the homebuilding industry, cratering demand for Dalton’s carpeting products. 

Dalton ​“was a ghost town in 2011, nothing going on because everybody was hurting,” Campbell added. From June 2011 to June 2012, Dalton notched the dubious distinction of most jobs lost of all 372 metro areas surveyed by the Bureau of Labor Statistics. By that point, one-quarter of Dalton’s pre-recession jobs had vanished, and unemployment surged to 12.3 percent. 

Since then, the industry has recovered somewhat. Engineered Floors, Mohawk, and Shaw still dominate local employment, with some 14,000 jobs among them, Campbell said. Those companies have had to adapt to evolving consumer tastes, shifting from wall-to-wall carpets to hardwood and other flooring materials. They’ve also automated aspects of production, reducing the number of workers needed.

In the wake of the Great Recession, local leaders sought to diversify Dalton’s industry. The county acquired an undeveloped lot south of town, and Campbell later pushed to clear and level the site, so it was shovel-ready for some future tenant. When Trump’s solar tariffs kicked in, Campbell’s counterparts at Georgia’s Department of Economic Development sent Qcells his way. 

Qcells showed up in February 2018, looking to spin up its first American solar-panel factory in less than a year. ​“Suddenly, we had exactly what they needed,” Campbell said.

Thus Dalton managed to bring in new industry to balance out its base of carpets and flooring. Qcells originally promised to invest $130 million and hire 525 people within five years, Campbell said. 

“They did it in three months,” he added. ​“In terms of an economic development project, they check all the boxes: Everything they said they would do, they did it faster than they said they would do it.”

Domestic solar manufacturing, by humans and robots

When I asked folks around town what they thought of Qcells, they kept mentioning the dozens of air-conditioning units arrayed on the factory roof, like a field of doghouses, easily visible from I-75. I later learned that Qcells brought in helicopters to install those units, which made for a bit of small-town spectacle. Still, it struck me as a surprising detail to dwell on for a business that somehow turns the sun’s rays into cheap, emissions-free electricity. 

Once I crossed Qcells’ sizzling parking lot and stepped indoors, it started to make sense. Georgia gets hot, and carpet factories get hot, but the vast floors of the twin solar factories are quite literally cool places to work. 

The climate control is not unique to assembling solar panels, but it is required for the sensitive, precisely calibrated product. The air conditioners are but one sign that high-tech manufacturing has arrived, and that it makes for pretty comfortable work.

I met my two tour guides, Wayne Lock and Alan Rodriguez, in the factory lobby, and they quickly confirmed the physical appeal of Qcells jobs. Lock, now a quality engineer at Qcells, previously worked in carpet manufacturing; he had to wear special heat-resistant gear to handle carpeting materials that would otherwise deliver third-degree burns. Rodriguez, an engineering supervisor at Qcells, used to apply the coating material underneath carpets.

“You’re sandwiched between the steamer and the oven, so it gets quite hot,” Rodriguez told me. Attending to those machines exposed him to temperatures that could exceed 100 degrees Fahrenheit.

Even more than Qcells’ air conditioning, though, people I spoke to kept bringing up the pay.

By offering more for zero-skill, entry-level positions than the other factories in town, Qcells started attracting workers and pushed up wages across Dalton, Campbell said: ​“Competition brings everybody, so everybody’s had to kind of equalize to keep employees.” 

Now Qcells hourly wages for non-experienced hires start at $17.50 to $22 — that amounts to $36,400 to $45,760 a year for full-time work. Workers with experience in robotics and manufacturing can take home much more than that. Employees can raise their pay through a variety of on-the-job training, most of which involves handling and troubleshooting the in-house fleet of robots.

Lock, Rodriguez, and I walked into the newest factory, past meeting rooms with names like Naboo and Mandalore, Star Wars locales where quirky robots coexist with all manner of creatures. As we strolled across the floor, squat wheeled autonomous vehicles rolled past us down pathways marked by tape on the smooth floor, ferrying bales of materials or hauling out hulking boxes of finished panels.

“We try to stay out of their way, and if we don’t, they yell at us,” said Lock. ​“It’s fun.”

As we stood talking, I noticed that one such robo-buggy was waiting for us to move. Barely discernible over the background drone of machines, a female voice intoned, ​“Robot is moving. Please look out.” When humans hold up more time-sensitive deliveries, Lock explained, the voice switches to male and gets louder. 

Other robots remain fixed in place, carrying out repetitive precision tasks. I stared, mesmerized, at one machine that split wafer-thin silicon cells in half, first scoring them with a laser, then slicing them with a concentrated jet of water. A taller machine grabbed nearly 8-foot metal frames and sliced them through the air like a master swordsman in a Kurosawa film, to slot them around glassed-in silicon panels. 

Throughout the process, cameras scan cells and use artificial intelligence to shunt defective items off the line for manual correction. 

In the 2019-era factory next door, humans carry out many of these tasks. Lock, though, didn’t see the robots as competitors — he said they were taking on more physically demanding jobs so the humans could step into higher-skilled roles tending to robots.

“The ergonomics are better for you,” he said, and the new lines are more productive. 

Hiring local, spending local

When Qcells was first staffing up, it relied on Quick Start, a Georgia state program that funds worker training for new factories before they open — a major draw for executives deciding where to locate their factories.

Qcells still recruits to meet ongoing staffing needs, and it has been paying special attention to high schoolers who are graduating and looking for employment. Nash speaks passionately about Qcells’ recruitment efforts; she’s seen the civic fallout from decades when local families encouraged kids to avoid manufacturing.

“Small communities cannot thrive with kids graduating and leaving those communities to live elsewhere, to get high-paying technical jobs,” Nash said. ​“That’s what’s happening across the country. Bringing manufacturing back, and bringing highly automated manufacturing, is offering job opportunities where now these students are staying here.”

Some 56 percent of Dalton-area students enroll in postsecondary education within 16 months of graduating high school, said Stephani Womack, director of education and workforce development for the Greater Dalton Chamber of Commerce. For the remainder, the chamber wants to make sure family-supporting jobs are available.

For two weeks in June, Womack helped run Project Purpose, a crash course in how to start and navigate careers that pay living wages. Recent high school graduates prepped for interviews, shopped for professional clothes, and toured housing options and downtown hotspots — the kinds of places they could frequent once they join the workforce. 

But the centerpiece of the program amounted to professional speed dating, as Dalton’s major employers offered tours and entry-level jobs. Last year, Dalton’s first time running Project Purpose, seven young adults completed the program, and Qcells hired one of them. This time, 18 finished, and Qcells hired 12 of them to start on July 1.

“Next year, we hope to double that, or more,” Nash said. 

Several participants came in knowing about Qcells, betting that the intensive crash course would increase their odds of landing good roles there, Womack told me over a table at Garmony House, a downtown coffee shop that draws lines for its statuesque strawberry cupcakes and coffee-glazed cinnamon rolls.

“Qcells is providing a diverse set of options for our students who need to go to work but want to stay in our community,” Womack said. ​“They see a climate-controlled facility with entry-level opportunities — that’s exciting for them. … Manufacturing isn’t what it used to be.”

For younger people to stay in town and build a life, Dalton needs more housing, and now it’s getting its first large apartment complex in over two decades, Campbell said. In total, 900 apartment units are slated to come online from last August through this November — not enough to catch up on a long-running housing deficit, but a step in the right direction.

That renewed real estate activity is reflected in downtown Dalton’s bustling core. 

Locals pack the booths at the Oakwood Cafe, perhaps the only place in America that sells a platter of egg, sausage, toast, and grits for just $3.65. Multiple microbreweries beckon, as does a plush cocktail bar, the Gallant Goat, which stocks fresh mint by the fistful to garnish its drinks. Down the road, diners can sample ceviche of shrimp shipped in from coastal Mexico, succulent chicken wings, and high-end Southern cuisine. 

This spring, the plush Carpentry Hotel opened across from the Oakwood Cafe, decked out with vibrant textile art to commemorate the town’s carpeting heritage.

“That’s been big for us, getting that hotel in downtown. That’s indicative of a robust local economy that people are coming to participate in,” local real estate agent Beau Patton told me as the late afternoon sun streamed into the Gallant Goat. Patton works with Qcells employees who want to buy homes in the area. He sees the factory’s decision to locate there as ​“very mutually beneficial” for Qcells and Whitfield County: ​“What you hope is Whitfield County grows with it, and it grows with Whitfield County.” 

From Dalton to towns across Georgia

Dalton got in early on the national clean-energy factory revival, and has already seen its solar factory push up wages, enable high school graduates to stay and start careers, and inject money into a reinvigorated downtown. Many more communities in Georgia are following close behind with their own cleantech factories, seeking a similar economic jolt.

“There is a palpable and intense sense of excitement across the state about how these manufacturing and infrastructure policies are supercharging Georgia’s economic development,” said Senator Jon Ossoff, the Georgia Democrat who authored the IRA manufacturing incentives that Qcells is tapping into. ​“And I would add, it’s not just the primary industrial facilities; it’s all of the secondary and tertiary suppliers and vendors and service companies and the financial services firms needed to support them.”

Qcells is building an even bigger factory compound down in Cartersville, which won a conditional $1.45 billion loan guarantee from the Department of Energy on August 8. This facility will take advantage of Inflation Reduction Act tax credits to onshore more steps of the solar supply chain: slicing silicon wafers, carving them into solar cells, and assembling finished modules with even newer robots than the ones I saw in Dalton. Until now, those high-value precursors to solar panels were shipped in from overseas. Workers in Dalton complete just the last step: assembling modules. Cartersville promises to bring the dream of American-made solar a bit closer to reality.

To achieve that dream, the industry has a few other challenges to confront. For one, 97 percent of the glass that encloses solar panels comes from China. Besides the geopolitical implications of that dependence, glass is so fragile and heavy that its shipping costs make domestic production enticing both economically and environmentally. 

“We need domestic glass to have an efficient supply chain,” said Suvi Sharma, founder and CEO of solar recycling startup Solarcycle. His company is breaking ground on a combination solar-panel recycling facility and solar-glass factory in Cedartown, some 70 miles southwest of Dalton. Sharma expects to invest $344 million in the community and hire 600 full-time employees.

Compared with Dalton and Cartersville, ​“Cedartown is more off the beaten path — this would be the first large-scale factory going up there,” said Sharma. After years in which the population declined and young people looked elsewhere for jobs, ​“this enables them to keep people and bring in more people. There’s a cascading impact.”

Solarcycle will use its rail spur to ship in low-iron silica from a mine in Georgia, plus soda ash and limestone. Over time, it will supplement those raw ingredients with increasing amounts of glass the company will pull from decommissioned solar panels, including those made by Qcells. The goal is to produce enough glass for 5 gigawatts of panels per year; Solarcycle will ship the glass to nearby customers. At that point, workers in northwest Georgia will have a hand in all the major steps of solar-module production except the processing of raw polysilicon. Hanwha recently became the largest shareholder in REC Silicon to secure access to domestic polysilicon from the Pacific Northwest. 

Georgia also nabbed a hefty chunk of the electric-vehicle factory buildout catalyzed by IRA incentives. Hyundai is dropping nearly $1 billion on its ​“Metaplant” near the deepwater port of Savannah and building an adjacent $4.3 billion battery plant with LG. Kia erected a new EV9 SUV manufacturing line at its plant in West Point, about halfway down Georgia’s border with Alabama. The first EV9 rolled off the line in June — less than two years after the IRA was signed into law.

Dalton, then, is a leading indicator of the industrial invigoration that clean energy factories are bringing to cities and towns across Georgia. People broadly appreciate it — if not for the role in combating climate change or countering China’s industrial might, then for high starting wages, comfortable working conditions, and opportunities for advancement. 

But for this nascent factory boom to endure, the policies that triggered it need to stay in effect. The people of Georgia played a decisive role in spurring this manufacturing revival; this November, they’ll have an outsize role in deciding if it continues.

How Dalton, Georgia, went from Carpet Capital to Solartown, USA is an article from Energy News Network, a nonprofit news service covering the clean energy transition. If you would like to support us please make a donation.