ABB: How to Drive Energy Efficiency in Hard-to-Abate Sectors
The industrial sector is responsible for about 29% of global greenhouse gas (GHG) emissions and is under a spotlight to limit its environmental impact.
The European Commission's Clean Industrial deal is a strategic effort to enhance both competitiveness and sustainability within the region.
However, the journey towards significant decarbonisation is fraught with challenges, especially as many promising technologies are still in their infancy.
A whitepaper from ABB and Fraunhofer IPA looks at decarbonising actions these industries can take today.
Chris Poynter, President of ABB Motion’s System Drives division, says: “Industrial decarbonisation is not just an environmental necessity—it’s a strategic business opportunity.
"The ABB and Fraunhofer IPA report highlights solutions available today, as well as technology developments that are key to accelerate the energy transition.
"With initiatives like the EU Clean Industrial Deal and the Decarbonization Investment Bank, industries have a unique opportunity to innovate, cut costs and lead in sustainable growth.
"By adopting electrification, energy-efficient motors and drives and new technologies, they can reduce emissions while increasing their competitiveness.”
Iron and steel
Iron and steel are foundational to decarbonisation, serving as crucial components of clean energy infrastructure.
These materials are essential in the manufacture of turbine towers, pipelines, new vehicles and construction projects aimed at moving away from fossil fuels.
Together, iron and steel production accounts for 5% of global GHG emissions, with 81% of the energy used in these processes going towards fired heaters like blast furnaces.
The ABB whitepaper advocates for a shift towards electric arc furnaces, which melt scrap steel and require less coke, thereby substantially reducing emissions.
In addition, iron can be processed at lower temperatures using direct reduction techniques, such as employing hydrogen—another technique outlined in the paper for cutting emissions.
Dr. Markus Kröll, Head of Business Division Circular Economy and Carbon-Neutral Production at Fraunhofer IPA, says: “Our analysis identifies the highest emitting processes within each industrial sector, and then pinpoints technologies that can mitigate them.
“It focuses particularly on key solutions: the electrification of processes, heat, carbon capture and hydrogen.
“There is no silver bullet for decarbonisation, but there are readily available solutions. This report should make it easier for business leaders to determine the best path forward.”
Cement
The production of cement, especially the calcination of limestone into clinker, is another significant source of emissions.
The CO₂ released during clinker production is an inevitable byproduct of the chemical reactions involved.
The ABB whitepaper explores strategies to lessen clinker usage by supplementing it with materials such as gypsum, natural volcanic materials and industrial byproducts.
Although the current alternatives for traditional clinker offer only moderate CO₂ emission reductions, emerging solutions could lead to more substantial savings.
These include cements derived from the carbonation of calcium silicates which have the potential to actively sequester CO₂.
With current techniques like CCUS (Carbon Capture, Utilisation and Storage) not yet commercially viable, new methods are essential for meaningful progress.
Chemical
The chemical sector relies heavily on fossil fuels, both as a source of energy and as feedstocks.
Direct emissions from chemical processes and fuel combustion contribute to 42% of the industry’s total GHG footprint.
Emissions related to electricity use make up about 35% of the total CO₂ emissions, with a significant percentage coming from processes utilising electric drivetrains.
Incorporating IE5 motors, which offer up to 40% lower energy losses compared to conventional induction motors, would substantially increase energy efficiency.
Additionally, introducing variable-speed drives could reduce electricity usage by up to 25% when compared to fixed-speed drives, presenting another viable option for emission reduction in the chemical industry.
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