Decarbonising the chemical industry: a critical step in our sustainability journey
The International Energy Agency has reported that energy-related CO2 emissions reached a record level of 37.4 billion tonnes in 2023. The chemical and petrochemical sector alone is responsible for around 2.2% of global greenhouse gas emissions, derived both directly from chemical processes and indirectly from the energy used in production. As a result, decarbonising the sector is essential if we want to achieve global climate targets and ensure the industry’s long-term sustainability.
This article examines the implications of decarbonisation, its particular importance in the chemical industry and what makes a successful deployment strategy.
What is decarbonisation?
A daunting word for much of the industrial sector, decarbonisation refers to reducing industrial carbon emissions by transitioning to low-carbon energy, improving energy efficiency across production lines and introducing innovative technologies. It is not a straightforward process and certainly not quick. But it is no longer up for debate if we are serious about tackling climate change, improving the resilience of our industries and achieving net zero emissions targets in the little time we have left.
Stepping up decarbonisation efforts in the chemical industry
The chemical industry is undeniably a huge CO2 emitter due to its dependence on fossil fuels for energy and raw materials. Decarbonisation should be seen as both a priority and a responsibility if we want to reduce the sector's environmental impact and achieve global sustainability goals. It requires significant changes in energy use and production processes and the adoption of new technologies.
Which industries are most affected?
Decarbonisation efforts impact several sectors of the chemical industry, including:
- Fine chemicals: High-value chemicals used in pharmaceuticals, agrochemicals and speciality chemicals.
- Cosmetics: Ingredients and compounds used in personal care products.
- Plastics and polymers: Materials that are important for packaging, automotive parts and many other applications.
- Petrochemicals: Chemicals derived from crude oil and natural gas that are integral to industrial applications.
Implications of decarbonisation
Complex but necessary changes to industrial processes
The decarbonisation of the chemical industry will require significant changes to existing industrial processes:
Adopting clean technologies
A number of technological measures are essential if we are serious about lowering emissions. These include the introduction of electric heating and preventative maintenance, as well as carbon capture and storage (CCS) and other advanced data-driven technologies to optimise operations. Other measures that have a key role to play in decarbonising the chemical industry include:
- Process electrification: Switching from fossil fuels to electricity, especially if sourced from renewable sources, is an important step towards reducing emissions. This can be applied to various processes, such as steam generation or high-temperature heating.
- Green hydrogen: Replacing grey hydrogen with green hydrogen produced by electrolysis using renewable energy can significantly reduce emissions in processes such as ammonia production or refining.
- Redesigning production lines: Adapting production lines to incorporate energy-efficient technologies and processes can significantly reduce emissions. This requires rethinking the way chemicals are produced, processed and distributed.
Energy efficiency and process improvements
Improving process efficiency to use energy in a more optimal way is another key strategy. This may also involve:
- Energy management and predictive maintenance systems: Systems for real-time monitoring and controlling energy consumption can help identify issues and reduce inefficiencies, as well as prevent unexpected breakdowns or downtime.
- Process automation: Automating processes to optimise performance and reduce energy consumption can lead to significant energy and emissions savings.
Use of alternative raw materials and recycling
Switching to sustainable raw materials and recycling can further lower emissions:
- Bio-based raw materials: Using renewable biological sources instead of fossil fuels for raw materials can reduce the carbon footprint of chemical products.
- Chemical recycling: Recovering and reusing chemical substances to reduce waste and raw material consumption is an essential part of a circular economy.
- Circular economy: Designing products to be durable and recyclable will help to minimise waste and reduce a company’s environmental impact.
Associated investments and costs
There are no shortcuts. Transitioning to a low-carbon chemical industry requires significant financial investment. However, these initial outlays will eventually lead to tangible long-term benefits:
- High upfront costs: Investment in new technologies and facilities may be considerable and time-consuming.
- Long-term cost savings: Improved energy efficiency and a reduced reliance on fossil fuels will result in significant financial savings over time. For example, energy management systems, process automation and contingency plans can help identify patterns and anomalies to predict how and when a system is likely to fail. This will then make it possible to intervene in a timely manner. Without this, system failures will be much more costly and may even be irreversible.
Long-term environmental and economic benefits
Decarbonisation offers numerous environmental and economic benefits:
- Reduced greenhouse gas emissions: Reducing CO2 emissions will have a direct impact on climate change.
- Improved corporate reputation: Companies that proactively reduce their carbon footprint often enjoy a better public image and market position.
- Regulatory compliance: Compliance with environmental regulations will prevent any legal issues and help avoid possible sanctions. This, in turn, will ensure that operations run smoothly and that there are no issues with market access.
Finding the right partner: Equans decarbonisation projects in the chemical industry
As an established leader in energy transition initiatives, Equans has been actively involved in various decarbonisation projects in the chemical industry, leveraging its decades of experience and international partnership network to offer innovative solutions and operational expertise. Equans works side by side with companies to modernise their plants and processes and provides tailored deployment strategies that improve both environmental and financial performance.
To improve production efficiency and sustainability, L'Oréal worked with Equans to build a demineralised water plant. This complex project included the installation of tanks, pipework, instrumentation, automation systems and intricate carvings[1] . By implementing these solutions, L'Oréal was able to significantly improve water consumption during production, thereby meeting its overall environmental goals.
Equans worked with Pierre Fabre to install a robotic palletising island, an innovative solution designed to increase industrial output. The project involved the extension of a pallet conveyor system and the installation of a destacker to allow six production lines to be palletised efficiently. The installation was carried out during a two-week production shutdown and only doubled the site's productivity but also rationalised logistics flows to achieve an output of 16 cartons per minute.
In a groundbreaking initiative, Equans worked with Sanofi to build a new CO2-based refrigeration production plant. This project was the first installation of a high-capacity CO2 refrigerant in the pharmaceutical industry. Equans also took over the technical maintenance of Sanofi's industrial processes and facilities. The results were impressive, reducing CO2-equivalent emissions by 4,500 tonnes annually and reducing energy consumption by a factor of 15, further demonstrating the tangible benefits of decarbonisation in the industry.
Becton Dickinson case study: a New "Energy Hub" for the plant
To modernise and improve sustainability, Becton Dickinson set out to overhaul its fragmented production and distribution chain. The aim was to rationalise processes, reduce maintenance and improve performance while adopting a low-carbon approach.
Equans France designed and built a 300 m2 'energy hub' to centralise the production of thermal fluids and electrical energy, which acts as a strategic energy source for the site and distributes energy efficiently throughout the facility. This hub includes three 1.2 MW air-cooled chillers, two of which are equipped with energy-efficient magnetic bearings, and a 1.3 MW water-cooled GF Quantum chiller, Now, a gas-fired 5.8 MW boiler room and a 50 m pipe rack distribute thermal energy to 50 ventilation systems on site.
Refrigeration and electrical experts worked together on the design to tailor the system to Becton Dickinson's needs. This user-oriented approach successfully optimised both production and performance. The project was completed within a tight 18-month schedule thanks to a single project coordinator, securing smooth communication and execution throughout the project’s timeline.
Decarbonisation: a path to improved performance and profitability
Decarbonising the chemical industry is complex but necessary if we want to meet our global climate targets. Through a combination of energy-efficiency measures, the introduction of clean technologies, process optimisation and switching to alternative raw materials, the industry can significantly reduce its carbon footprint while unlocking opportunities for growth and innovation. But it isn’t easy to go it alone. Companies like Equans have an important role to play in this transformation, providing expertise and bespoke solutions to support the chemical industry’s decarbonisation initiatives, ensuring that they not only reduce their environmental impact but also drive up performance and secure the industry’s long-term profitability.
