Industry in transition: using process heat sustainably and efficiently

CO₂ emissions are set to fall by around 45% by 2030 compared to 2010 (Image source: AdobeStock / Pixelkram)

Industry has enormous potential to contribute to the reduction of CO₂ emissions through modern efficiency measures such as optimized steam systems and the use of innovative steam traps. Improved processes not only reduce environmental pollution but also operating costs.

The Paris Climate Agreement of 2015 sets out a clear direction: Global warming is to be limited to well below 2 °C, preferably 1.5 °C. To achieve this, global greenhouse gas emissions must be drastically reduced - by around 45% by 2030 compared to 2010, with net zero to be achieved by 2050 at the latest. Industry plays a key role here, as it is one of the largest energy consumers and still uses fossil fuels in many cases. Efficiency measures offer great leverage potential for climate protection here.

Defective steam traps are considered a major weak point in the steam system. (Image source: EBE Engineering)

Heat demand in industry: key role for climate strategies

Process heat - usually in the form of steam - is essential for industrial processes, such as heating, cleaning or drying. This heat is often generated using fossil fuels, which results in high CO₂ emissions. According to an analysis by the Niederrhein University of Applied Sciences, companies could save up to 21 billion euros a year by optimizing their systems and significantly reduce their emissions at the same time. Around half of the process heat currently used can be saved economically - depending on the technologies used, process requirements and measures already implemented.

Steam systems under pressure: challenges and losses

Generating steam is energy intensive. Depending on the type of fuel, burning fossil fuels produces considerable amounts of CO₂ - around 0.21 kg CO₂/kWh for natural gas and up to 0.5 kg for coal. Around 2,500 kJ are required for 1 kg of steam at 1,000 kPa, which can lead to hourly emissions of around 151 kg when using natural gas. As many production processes use large quantities of steam, these values are multiplied accordingly.

A significant proportion of the energy used is lost due to leaks and inefficient condensate drains. These deficits not only increase operating costs, but also emissions. Manufacturers estimate that around 10 % of mechanical steam traps fail every year - resulting in significant steam losses.

Companies are increasingly turning to innovative technologies to reduce emissions and improve energy efficiency. These include:

Modernization of steam systems: Switching to more efficient steam traps that reduce steam losses can cut energy costs and minimize emissions. The efficiency gains from advanced steam traps can reduce steam losses by up to 30%.
Recirculation and reuse of condensate: Closed systems in which condensate is returned to the boiler significantly improve overall energy efficiency. Optimized recirculation systems reduce water and energy consumption, which is particularly beneficial in regions with limited water resources.
Use of renewable energies and hybrid solutions: The increasing use of renewable energies such as solar thermal energy and biomass to support steam generation can reduce dependence on fossil fuels. Hybrid solutions combine renewable and conventional energy sources and enable more flexible, environmentally friendly steam generation.
More efficient monitoring and control systems: Modern measurement and control technologies make it possible to detect steam losses due to leaks or defective components at an early stage. Digital monitoring solutions increase system availability and enable proactive maintenance, which leads to significant energy savings.
Improved heat recovery: The recovery and reuse of heat generated during steam generation or other industrial processes is another way of reducing energy consumption. Heat that would otherwise be lost can be used for other processes in the plant or to support the heating system.

Climate protection pays off - also economically

Efficient energy use brings not only ecological but also economic benefits. Modern technologies lower operating costs in the long term and reduce the need for fossil fuels and emission certificates. Government subsidies, tax incentives and regulatory advantages are additional plus points. Companies that focus on sustainable energy use also improve their market position - because customers and business partners are increasingly paying attention to climate-friendly production methods.

A climate-conscious process industry is key to achieving global climate targets. The use of intelligent control technology, effective energy management systems and modern technologies makes companies active co-creators of a climate-friendly future.

Sustainability is also increasingly becoming a competitive factor. Those who reduce emissions today and use resources efficiently will be successful on the market in the long term - and at the same time make an active contribution to climate protection.