Seeing the bigger picture

he journey to net zero carbon emissions is one of the most complex, ambitious projects in human history. There is no one technical solution that will break the world’s reliance on fossil fuels. Instead, every link of the value chain must be reviewed.

Only a comprehensive, collaborative approach will enable the world to achieve its goals. For instance, electrification within one industry is an excellent step forward, but if the power is still coming from carbon-intensive sources such as coal, the impact will be limited. Instead, electrification must be paired with low- or zero-carbon electricity generation. The same is true across every industry – a narrow focus is not enough.

Simultaneously, the changes must be financially viable. In a competitive market, expensive changes will see limited adoption, but those that create commercial value while also supporting sustainability objectives will be widely embraced.

Today, almost all industrial processes require electricity, so electricity generation is at the start of most value chains. Historically, electricity generation has involved extremely high levels of carbon emissions, such as from burning coal or natural gas. For electrification to be sustainable, electricity generation processes must reduce carbon emissions significantly.

Fortunately, renewable solutions for electricity generation – such as solar, hydroelectric, and onshore and offshore wind – are taking over. They already account for a significant proportion of total power generation, and their global market share continues to increase every year.

Despite this, few countries have fully phased out carbon-intensive power sources so far. This is in part because renewable power output can fluctuate depending on the weather or other unpredictable conditions. Fluctuation can result in grid instability, so operators use predictable fossil fuel plants to ensure a consistent supply of electricity.

These high-emission facilities will need to be phased out in the decades ahead to reach net zero. Even with the contribution of technologies such as batteries, pumped storage, and other energy storage options, as well as grid stability technology such as synchronous condensers, maintaining a stable, predictable energy supply will be a complicated balancing act.

To overcome these challenges, researchers are already conducting important grid stability experiments. A partnership between ABB and the Fraunhofer Institute for Wind Energy Systems (IWES), for instance, is currently constructing the world’s largest mobile grid simulator. It will begin operating in 2023, enabling researchers to reliably test the performance of new equipment, so that they may better understand the potential issues involved in shifting to renewable wind energy and how to address them.

Further along the value chain, there is also potential for decarbonisation. Many industrial processes still rely on carbon-intensive fossil-fuelled equipment. In many cases, this equipment can easily be replaced with electric alternatives. When powered by electricity from renewable sources, this greatly reduces the carbon emissions associated with a given process. In addition to its sustainability benefits, electrification is often better in terms of overall efficiency, reliability, and safety.

The operators of the Vafos pulp plant in Kragerø, Norway, for example, cut emissions significantly through electrification. The plant produces unbleached pulp for cardboard production, and uses an energy-intensive drying process that involved burning oil.

However, the plant has since switched to electric air heaters. These heaters use a significant amount of power and are paired with ABB’s specialised power controllers to ensure they run as safely, precisely, and efficiently as possible, minimising their impact on the grid. Since 98% of Norway’s electrical production comes from renewable sources, this means that the plant has eliminated 14 000 tpy of carbon dioxide (CO2) emissions. This is equivalent to removing approximately 7000 combustion-engine cars from the roads, and represents one of the community’s contributions to reaching net zero. The facility also benefits from the fact that it no longer needs complex infrastructure for storing and transporting oil.

Many electric options are drop-in replacements, but in some cases, a clean-sheet design delivers better results. This was the case in the Danish port of Esbjerg, which wanted to electrify the heating of homes and businesses. ABB delivered integrated electrical infrastructure for a seawater heat pump.

The electric solution relies on a system of electric motors, drives, and other technology to deliver carbon-free heat to over 100 000 people. In Denmark, over 67% of the grid’s electricity comes from renewable sources, meaning that Esbjerg’s electrification project has significantly reduced carbon emissions.

Figure 1. The Vafos pulp plant in Kragerø, Norway, has eliminated 14 000 tpy of CO2 emissions through electrification.

In addition to electrification and sustainable electricity generation, industries must also become more energy efficient. The International Energy Agency (IEA) calls energy efficiency the “first fuel” when it comes to reaching net zero.

From pumps and compressors to fans, conveyors, mixers, and even robots, there are few facilities that function without electric motors. In fact, electric motors

Figure 2. It is critical to reliably test the impact of renewable energy equipment, such as those using wind power, for grid performance.

alone are responsible for 45% of all global electricity consumption.

Adopting more advanced motors further contributes to energy efficiency. Motor efficiency in many countries is rated by the International Efficiency (IE) standard, with IE5 motors currently denoting the best in class. Each increase in IE class, such as from IE4 to IE5, represents a 20% decrease in losses. Despite this, many facilities still use older, less efficient motors that were installed before these regulations came into effect. Switching these motors to more modern models, as well as pairing them with drives, would significantly reduce their energy use.

Motors that can deliver the same output while using less electricity – the goal of efficiency – reduce both operating costs and emissions. Plus, by replacing existing electric motors with modern models equipped with a variable speed drive (VSD), operators can further cut the operating expenses associated with their motors by approximately a quarter.

This is, in part, because VSDs match the motor’s speed and torque to the requirements of the task. Without a drive, motors always run at full speed. Operators control the speed by opposing it mechanically – much like applying the brakes in a car while keeping the other foot on the accelerator. By comparison, a VSD enables precise speed control.

The result of adopting a drive is electricity savings, because any time the motor is not running at full speed, it is using less power. This is particularly significant due to the non-linear relationship between speed and power consumption: a motor running at half speed uses just one-eighth the electricity of one running at full speed. Despite their energy saving potential, just 23% of all industrial motors are currently paired with a drive.

Data-driven digital tools and services also contribute to efficiency. For example, digitally connected motors and drives within equipment can transmit data on variables such as temperature and vibration directly to operators in real time, helping them to identify areas where energy is going to waste.

These same technologies also provide maintenance benefits by automatically alerting operators to risks and prompting them to take proactive action. This helps facilities to avoid costly downtime – and in some cases, maintenance can be performed remotely, saving labour and logistics costs.

In addition to the many steps that can be taken today, there are also technologies in earlier phases of development that will likely contribute to reaching net zero.

One promising innovation is the use of green hydrogen as a low- or zero-carbon fuel. Hydrogen is already in use in existing industrial applications, and there is a real ongoing effort to expand its industrial, infrastructure,

Figure 3. Adding variable speed drives to motors plays a key role in boosting industrial energy efficiency. and transportation applications. As the technology progresses, successfully rolling out hydrogen will depend on creating a new infrastructure for production, storage, distribution, and, ultimately, end use. An example of a pioneer in the green hydrogen industry is Plug Power Inc., a company which develops hydrogen fuel cell systems that replace conventional batteries in vehicles and equipment. The company has recently announced plans to electrify two new hydrogen plants using an Electrical House (eHouse) solution from ABB. These plants will produce a combined 60 tpd of green hydrogen, replacing 170 t of fossil fuels in the logistics and transportation sectors. The pre-tested and prefabricated eHouse substation enables the careful management of the full electrical system, bringing down costs and ensuring reliability. Carbon capture, utilisation, and storage is another development that could contribute to decarbonisation. Capture and storage technology continues to advance at a rapid pace, with recent breakthroughs in hydrocarbon recovery and direct-air CO2 capture. If carbon can be safely captured, it can either be sequestered or current technology can be used to put it to use as alternative fuels or building materials.

Today, fossil fuels still form the backbone of the global industrial economy. Replacing this resource with cleaner, more sustainable, and cost-effective alternatives will undoubtedly be a challenge. However, by reviewing the entire value chain and acting collectively, significant strides can be taken towards achieving net zero. In addition to a big picture approach, this will require collaboration between individuals, businesses, industries, and governments. There is no single action that will resolve the climate crisis – only a combination of many ambitious activities by organisations in many industries will deliver the results that are needed.