How ProcessBarron Helps You Achieve Your Corporate Goals to Reduce Greenhouse Gas Emissions

Over the last several years, forward-thinking organizations have recognized the benefits of setting goals to reduce greenhouse gas (GHG) emissions. These reduction efforts can help identify opportunities to reduce expenses, encourage innovation, improve employee morale, and help set a standard for how corporations relate to the environment. 

ProcessBarron understands the importance of reducing your corporate carbon footprint, and we have the tools and resources to help your company take significant steps towards reaching these goals!

Industrial Greenhouse Gas Emissions by Sector

Industrial production facilities and electricity production account for almost half of all greenhouse gas emissions. Raw material and finished good production accounted for roughly 23% of all GHG emissions in 2019, including direct emissions through daily operations and indirect emissions associated with electricity use.

Electricity production accounted for 25% of GHG emissions in 2019, of which carbon dioxide (CO2) made up the vast majority. Although greenhouse gas emissions from this sector have decreased by about 12 percent since 1990, industrial activities still make up a significant portion of these emissions. This decrease is largely a result of the shift to lower- and non-emitting sources of electricity generation and an increase in end-use energy efficiency.

Because paper mills, cement plants, power plants, steel mills, and other industrial facilities all play a major role in GHG emissions, changes they make have an outsized impact on future outcomes.  

And ProcessBarron can help. See the industries we serve here! 

Case Study: Optimizing a Historic Dust Collector and Fan System

Several years ago, ProcessBarron received a call from one of our paper mill clients about excessive system resistance and poor particle handling in its No. 4 combination boiler’s ID fan system. This issue resulted in high fan brake horsepower (BHP) and high pollution levels for the paper mill. 

Not only did the company want to find a workable and affordable solution that would achieve the most significant increase in productivity with the least amount of interruption, but the paper mill also had goals to reduce its environmental impact. 

Before reaching out to ProcessBarron, they struggled to find a service provider to meet all these needs and operate within the required parameters. Many companies prefer to avoid the risks associated with significant retrofits and the re-use of existing system components. 

Finding the Solution

During our on-site inspection and analysis of the system, our engineers determined that it wasn’t just the fan or draft system causing issues but also the three mechanical dust collectors that contributed to excessive pressure drop.

As a result, the collectors were doing a notably sub-par job of particle collection, contributing to the plant’s excessive pollution levels and high energy costs.

Our first goal was to find a way to improve the dust collectors by modifying the fan for more efficient production of the required system flow and pressure.

However, the ultimate solution turned out to be a bold stroke of engineering ingenuity. We decided to work with all existing casings, geometry, and footprints in the system but gut the internals of the three dust collectors. Essentially, our team reduced the dust collectors to empty boxes — each just another piece of the ductwork. We used the casing of one of the original collectors to create a single, efficient dust collector. We then installed twenty-four-inch collection tubes to cope with the large air volume required by the system. Our team retrofitted the ID fan with a 74.5-inch optimized heavy-duty radial tip rotor, customized to fit the existing fan housing.

Resulting Cost Savings and Emission Reductions

Our plan included a guarantee to meet specific collection efficiency for the dust collector

and maximum energy consumption for the ID fan.

After our team completed the project, the result exceeded even the highest expectations. Calculations showed that the plant now saves about 1,000 horsepower per year, equating to close to $500,000 annually. From this one project, the plant received a complete ROI in nearly two years.

Your Path to Reducing GHG Emissions and Increasing Productivity

As we showed in our case study example with this paper mill, one project can result in both short and long-term savings for your plant. Not only did the paper mill save half a million annually in energy costs, but they also saw a reduction in maintenance costs now that the plant only has one dust collector to maintain instead of three.

Another way we have helped plants reduce emissions and increase efficiency is through fan upgrades. Electricity costs for industrial equipment can be formidable, but the right fans can save your plant up to hundreds of thousands of dollars each year. We provide airflow testing that provides data that will be valuable for many applications! 

Contact ProcessBarron today to learn more about how we can support your corporate goals to reduce greenhouse gas emissions!