Higher production and lower emissions – net zero strategy for a chemical plant

The chemical plant planned to double its production capacity while striving for significant reductions in CO₂ emissions and energy consumption. The first strategy developed by another auditing firm did not meet the client’s requirements – it lacked practical, actionable guidelines that could reduce energy losses without interfering with production processes.

The key challenge was developing a roadmap for emissions reduction and energy optimization that would simultaneously increase plant efficiency and achieve zero-emission targets.

One of the client’s motivations to start the path to net zero came from the automotive sector, where many stakeholders place high importance on reducing the environmental impact of business operations. Circularity is a crucial aspect of the client’s activities, reflected in the industry they operate in – recycling batteries, catalysts, and critical materials.

The plant aimed to reduce consumption of thermal energy contained in steam and condensate. With a strong commitment to environmental protection embedded in its DNA, the company sought to minimize emissions, planning to achieve net zero by 2035.

The client team had previously attempted to develop an emissions reduction strategy with another auditing firm. Unfortunately, its strategic goals were not met. Through our collaboration with EFESO, the client came to us, and we met their expectations within 4 months.

We developed a CO₂ reduction roadmap aligned with the client’s key objectives and fully achievable. The plant was preparing for a planned production doubling in 2024–2025. Our roadmap enabled increased production capacity while simultaneously reducing emissions and energy consumption. Importantly, the strategy did not interfere with production processes, which was critical for the plant.

The engineering team’s expertise identified several points with energy losses that could cover heat demand in the main process. Key actions at the plant included heat recovery from air compressors and wastewater.

The plant in China was using higher parameters in some areas, such as elevated steam temperatures, which led to increased costs and losses. Both the client team and the previously engaged auditing firm had overlooked solutions that would allow the client to reduce greenhouse gas emissions by 70% if they follow the guidelines we developed.

Preparing a net zero strategy requires not only an audit but also a practical action roadmap tailored to the plant’s specifics and development plans. Through close collaboration with the client, it was possible to identify areas for energy recovery and determine an action sequence that minimizes costs and maximizes efficiency. The implemented solutions allow the plant to increase production while significantly reducing emissions and energy consumption, creating a solid foundation to achieve full net zero.

The client’s plant is part of a global chemical industry group. This company, with 45 production plants, is a leader in battery and critical materials recycling. The Jiangmen plant, located in southern China, has been operating since 2006.