A systematic technique for cost-effective CO₂ emission reduction in process plants

There has been growing interests to reduce the environmental impact caused by greenhouse gas emissions from process plants through various energy conservation strategies. CO₂ emissions are closely linked to energy generation, conversion, transmission and utilisation. Various studies on the design of energy-efficient processes, optimal mix of renewable energy and hybrid power system are driven to reduce reliance on fossil fuel as well as CO₂ emissions reduction. This paper presents a systematic technique in the form of graphical visualisation tool for cost-effective CO₂ emission reduction strategies in industry. The methodology is performed in four steps. The first step involves calculating the energy consumption of a process plant. This is followed by identification of potential strategies to reduce CO₂ emissions using the CO₂ management hierarchy as a guide. In the third step, the development of “Investment” versus “CO₂ Reduction” (ICO₂) plot is constructed to measure the optimal CO₂ emission reductions achieved from the implementation of possible CO₂ reduction strategies. The Systematic Hierarchical Approach for Resilient Process Screening (Wan Alwi and Manan in AIChE J 11:3981–3988, 2006) method is used in the fourth step via substitution or partial implementation of the various CO₂ reduction options in order to meet the cost-effective emission reduction within the desired investment limit or payback period (PP). An illustrative case study on a palm oil refinery plant has been used to demonstrate the implementation of the method in reduction of CO₂ emissions. The developed graphical tool provides an insight-based approach for systematic CO₂ emission reduction in the palm oil refinery considering both heat and power energy sources. Result shows that 31.2 % reduction in CO₂ emissions can be achieved with an investment of USD 38,212 and PP of 10 months based on the present energy prices in Malaysia.