Reducing carbon intensity scores (CI Scores) has become a top priority for many facilities. A carbon intensity score measures how much carbon dioxide (CO₂) is emitted to produce a specific unit of something. Think of it as the “carbon footprint” per unit. The lower the score, the less carbon emissions created in making that item. This score helps companies understand and improve their environmental impact by finding ways to produce the same products with fewer emissions.
One way many companies are aiming to improve their CI score is by increasing the efficiency of their process equipment. This article will explore reducing CI scores and how industrial facilities can implement changes to optimize performance and reduce emissions.
Boilers: The Heart of Efficient Thermal Energy
Boilers are often one of the largest consumers of fuel in industrial facilities. As a general rule, industrial boilers consume about 37 percent of all energy (excluding electricity) at industrial facilities.The exact percentage varies widely depending on the facility’s type, size, and the intensity of the processes relying on steam or hot water.
In sectors like ethanol production, food processing, and chemical manufacturing, boiler fuel consumption tends to be at the higher end of this range. This makes improving boiler efficiency one of the most effective ways to lower CI scores in industrial facilities.
Key Strategies for Optimizing Boiler Efficiency:
To improve boiler efficiency and reduce fuel usage, consider these key strategies:
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Install an Economizer: Economizers capture waste heat from exhaust gases and use that heat elsewhere in the facility. This is commonly used to preheat the boilers feedwater and can significantly reducing fuel use.
- Tune the Burner Regularly: Regular tuning ensures the right amount of air mixes with the fuel, optimizing combustion and avoiding energy loss from excess air or incomplete burning.
- Improve Insulation: Insulating boiler room valves, pipes, and other components minimizes heat loss, reducing fuel requirements and enhancing boiler room safety.
- Clean Fireside Surfaces: Removing soot and deposits from the boiler’s fireside surfaces increases heat transfer efficiency, keeping fuel use down.
- Return Condensate: Reusing condensate from the steam process cuts down on energy needed to heat fresh water, lowering fuel demand.
Implementing this low hanging fruit will help reduce your CI score. For more efficiency gains, check out our article: 15 Ways To Increase Boiler Efficiency.
Air Compressors: Reducing Energy Waste in Compressed Air Systems
Air compressors are another energy-intensive piece of equipment commonly found in industrial facilities, and their efficiency plays a significant role in CI scores. Air compressors power pneumatic tools, conveyance systems, and other machinery crucial to production.
Key Strategies for Improving Air Compressor Efficiency:
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Rasmussen Mechanical technician using Ultrasonic Leak Detection.
Eliminate Leaks: Studies estimate that as much as 20-30% of compressors total output is lost through leaks in aging systems. By identifying and fixing leaks, facilities can significantly reduce energy waste and emissions.
- Use Variable Speed Drives (VSDs): Air compressors with VSDs adjust their speed based on demand, preventing excess energy use when less air is required. This smart technology can reduce energy consumption by 35% or more.
- Optimize System Pressure: Many facilities operate at unnecessarily high pressures, wasting energy. The higher the pressure the more energy that is used. By optimizing system pressure, facilities can minimize energy use and extend the life of their compressors.
Efficient air compressors not only reduce CI scores but also contribute to long-term cost savings, making them an invaluable investment for sustainable operations.
HVAC Systems: Controlling Facility Climate with Less Carbon Impact
Industrial HVAC systems are essential for maintaining optimal temperature and air quality, particularly in large facilities that produce food and fuel products. However, HVAC systems are notorious for their high energy consumption, which can increase carbon intensity.
Key Strategies for HVAC Efficiency:
- Implement Energy Recovery Ventilation (ERV): ERV systems capture waste heat and use it to pre-condition incoming air, reducing the HVAC system’s workload. This technology can cut energy consumption by up to 20%.
- Upgrade to High-Efficiency HVAC Units: Modern HVAC systems are designed to use less energy, even in high-demand environments. Replacing aging HVAC units with ENERGY STAR-certified equipment can improve efficiency by up to 30%.
- Automated Control Systems: Smart building control systems can adjust temperature and ventilation settings based on occupancy and time of day, minimizing unnecessary energy use.
Implement Energy Recovery Ventilation (ERV):By investing in efficient HVAC systems, industrial facilities can reduce their CI scores and meet sustainability targets more effectively.
What Else Can Be Done?
Beyond optimizing mechanical equipment, facilities can implement several strategies to reduce carbon intensity, including:
- Supplementing Grid Electricity: Replacing or supplementing grid electricity with things like hydroelectric, biomass or solar can reduce carbon emissions associated with energy use. CHP systems, also known as cogeneration, produce electricity and capture waste heat for additional energy needs. CHP systems are highly efficient and can be tailored to meet a facility’s specific energy needs, reducing grid electricity reliance.
- Optimize Process Efficiency: Streamlining production processes, reducing material waste, and implementing lean manufacturing techniques can lower the overall consumption. This reduces emissions per unit produced.
- Improve Insulation and Building Envelope: Proper insulation of buildings, pipes, and tanks helps reduce energy losses. Additionally sealing leaks in windows, doors, and walls can lower a facility’s carbon footprint.
- Enhance Water Use Efficiency : Reducing, reusing, and recycling water in industrial processes can be an effective strategy. This often decreases the energy required for water heating, pumping, and treatment, leading to lower carbon emissions.
Conclusion: Improving Carbon Intensity Scores with Efficient Mechanical Equipment
Reducing carbon intensity scores has become essential for industrial facilities aiming to meet sustainability targets, cut emissions, and stay competitive. By focusing on the efficiency of boilers, air compressors, and HVAC systems—facilities can make substantial progress in lowering their carbon intensity scores. Each piece of optimized equipment directly reduces the carbon footprint of production, lowering fuel consumption, minimizing energy waste, and reducing overall emissions.
In industries like ethanol and food processing, these reductions in carbon intensity scores have a significant impact, as these sectors are high-energy consumers. Implementing key strategies—such as installing economizers on boilers, eliminating air leaks in compressor systems, and upgrading to energy-efficient HVAC units—improves CI scores. Not to mention, also brings long-term operational savings. Going further, facilities can explore additional carbon reduction measures, such as switching to renewable energy, enhancing water efficiency, and optimizing process workflows.
By integrating these best practices, companies can create a greener production environment, reduce their carbon intensity scores, and build a more sustainable future. As carbon intensity scores become more crucial for regulatory compliance, focusing on mechanical efficiency is a smart step for any industrial operation.
