Key points
As the impact of the energy price hike begins to be felt and new commitments to move to net zero carbon are outlined at COP27, Guy Fitzpatrick from Xylem Water Solutions outlines how the process industry can limit water use and cut emissions to make savings now and in the future.
The process industries sector has a starring role to play in building a more sustainable future for everyone.
There is no doubt that organisations from chemical plants to food and beverage manufacturers are being challenged by the dual pressure to do more with less while meeting ever-more-stringent regulations.
Thirsty sectors like mining that depend on a reliable water supply are facing rising total water costs, not only from direct prices but also from treatment costs. Energy-intensive processes like wastewater treatment mean that the total cost of water used in the F&B industry, for example, is roughly 10 times its cost at intake after being cleaned and treated.
As industrial pollution and agricultural runoff add to the strain on our global water systems, concerns for water quality are also growing – with restrictions on discharge into watercourses likely to become even stricter.
But many are rising to the occasion and looking at strategies to save water and cut down on carbon emissions, aware of the value of this precious resource for processing needs – and as an ingredient – to secure their long-term future.
Understanding water sustainability
Taking a more sustainable approach to how water is used in industrial processes offers new opportunities to address the challenges being faced. This commitment to optimising the way water, to reuse where possible and limit the impact of industrial plants in water-scarce areas, is vital to ease the pressure on our eco-systems and to set relevant and achievable goals on our journey to net zero carbon.
As a vital first step, an audit of both energy and water use can help to calculate carbon emissions and set attainable objectives. Establishing baseline energy use, for example, can highlight the impact energy-intensive processes like pumping and aeration have on facilities and help to prioritise improvements. Smart solutions can then provide all-important stepping stones on the path to reducing water usage and cutting back on energy use to provide savings for the future.
Cutting energy use and reducing emissions
We all have a responsibility to turn net zero into reality. And there is a clear financial incentive to do so: though the Energy Prices Bill means firms are less at the mercy of soaring wholesale prices, energy efficiency can have a positive impact on the bottom line.
The most energy-intensive industrial water processes are the heating and cooling applications fundamental to every industry where water is used, and the treatment of water. These two areas contribute significantly to the energy used, the related emissions and, in turn, the true cost of water – but it is here that the latest developments in digital technology can help to drastically reduce energy consumption.
- Lowering energy use for heating and cooling
For many sectors, water cooling processes can be one of the largest consumers of energy – offering ample opportunity for savings. Pump systems are often oversized for the application and therefore use much more energy than needed: intelligent controllers which match performance to demand can offer significant energy savings and eliminate downtime. A motor running at 80% of its maximum speed, for example, uses 48% less energy and slashes carbon emissions.
- Digitising wastewater treatment
Further energy savings can be made to enhance the sustainability of wastewater treatment and management by harnessing the power of decision intelligence.
The latest pumps with fully integrated intelligence can halve electricity-related emissions in wastewater management and contribute to an 80% inventory reduction. Adaptive mixers can further save up to 47% of energy by applying variable thrust to automatically matching output to demand. And aeration systems offer further potential savings: traditionally representing some 30 to 70% of the energy costs in wastewater, turbo blowers can lower this by at least a third along with efficient bubble aeration systems.
Further advances have seen the introduction of plug-and-play wastewater optimisation systems that can be applied to existing assets to address different needs such as meeting nutrient limits or phosphorus compliance, along with energy reduction. By utilising real-time sensor-based algorithms to optimise treatment processes, they can routinely achieve energy reductions of between 25% and 30%.
Minimising water use to conserve critical resources
Water scarcity, and the resilience of water systems, poses a significant threat to the future of human health, our economy and the environment. Many sectors may face future constraints on water usage and disruptions in supply due to water shortages
The reuse of water with chemical-free solutions can help address the challenges we collectively face in protecting critical water resources, while digital solutions can optimise water systems and mean less is needed to operate effectively.
Advanced oxidation process (AOP) systems combine UV plus ozone treatment in some formats to treat and remove hard-to-shift pollutants to produce water that is free from toxins, particularly pollutants that have low biodegradability or high chemical stability. AOP can help to solve the complex problem of management of industrial wastewater as well as supplying clean water, by allowing industries to effectively reuse water from the production process.
Connecting the drops for industry
Water scarcity and the total cost of water, when energy use and the attendant emissions are taken into account, can pose a real risk to the manufacturing process industries. And with customers keen to make more ethical decisions about their supply chain, the way companies manage water has a major influence to the bottom line.
The business case for strategically addressing water challenges is growing stronger – with the cost of mitigating water risks generally much lower than their potential financial impact.
Assessing where improvements can be prioritised to save energy, reduce wasted water, eradicate leakage and improve reliability is a vital first step. Adopting the technologies needed to make changes now can create value for organisations in years to come, guaranteeing sustainability of industry as well as our environment.
For more information, visit www.xylem.com
