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All manufacturing and process industries are focused on sustainable operations. Optimized use of energy not only leads to cost savings but also trims emissions, hence contributing to a greener and a more sustainable scenario.

Digital Solutions today offer a variety of possibilities to effectively manage Energy & Emissions. While Real-Time Monitoring captures live trends and preserves digital records of plant performance. Engineers can use such data to deliberate improvement measures for a sustainable future.

Closed-loop optimization tools such as Advanced Process Control (APC) and Real-Time Optimization (RTO) have been used for decades to reduce Energy consumption and trim Emissions, while pursuing other economic objectives as well. Several open-loop optimization techniques aided with simulations or data models can also be used for process optimization to save Energy. While the former is effective in the control room, the latter can be applied to optimize energy by enabling a comprehensive production planning with due consideration of Energy and Emissions related Key Performance Indicators (KPIs).

Closed-loop optimization tools such as Advanced Process Control (APC) and Real-Time Optimization (RTO) have been used for decades to reduce Energy consumption and trim Emissions, while pursuing other economic objectives as well. Several open-loop optimization techniques aided with simulations or data models can also be used for process optimization to save Energy. While the former is effective in the control room, the latter can be applied to optimize energy by enabling a comprehensive production planning with due consideration of Energy and Emissions related Key Performance Indicators (KPIs).

However, an integrated solution which looks at all elements of a process plant is seldom implemented. While an APC might be ensuring optimization of one plant, the other process units might be neglected. Asset management tools and Energy KPIs may well be effective but the trade-off on production is easy to overlook.

It is imperative to evaluate a holistic scenario before implementing an Energy & Emissions saving solution. All aspects of production and logistics must be thoroughly analyzed to achieve a profitable and sustainable outcome.

Real-Time Energy Tracking System

A Manufacturing Execution System (MES) can be used to track energy flows across all process units at a site. The system essentially consists of a process historian with all energy related tags and a dashboarding mechanism to effectively display them. To construct the dashboards and display the right KPIs, an audit to identify all the Energy flow indicators and digitally tag them. A boundary level mass balance will help identify losses and thus chalk out action plans to trim such losses.

To understand better, let us use the example of a process industry. This industry uses Rankine Cycle, i.e. a giant Turbine drives the Electricity Generator and all other power requirements are obtained from the back pressure outlet of the Turbine.

A significant amount of steam generated is used in the process itself, and rest are available for all heating or power needs.

Hence, the plant uses a combination of motors and steam turbines to drive its equipment. Such plants will have steam headers at multiple levels with a mix of:

• Process consumption
• Heating utilities
• Turbines

All the steam headers will have vents for pressure control and let down from higher levels. Such steam venting can be eliminated by prudent process control.

The first step is to quantify the venting rate and let down rate by a steam balance and include that to display vent rates on the real-time dashboards. Insightful decisions such as:

• Using the vent steam for a heating requirement
• Switching between motors and turbines
• Turbine performance and maintenance requirements may be then deliberated leading to reduced energy consumption.

Proper maintenance of motors by minimizing unnecessary reactive power draw and identifying issues like misalignment or worn bearings can lead to energy reduction. Real-time measurements of power-factor across all equipment can enable effective preventive maintenance.

Fuel consumption can be significantly reduced through tighter process control by minimizing flaring, maintaining optimal oxygen levels, pre-heating gaseous fuels, and enhancing flue gas recovery. These measures not only improve energy efficiency but also reduce waste, lower costs, and contribute to a more sustainable and optimized energy management approach.

Digital Emissions Monitoring

Predictive Emissions Monitoring System (PEMS) has proven effective in monitoring emissions thereby enabling process industries to comply with regulatory standards. PEMS has been accepted as a reliable emissions monitoring and reporting technique by all major environmental regulatory bodies across the globe.

Unlike the traditional Continuous Emissions Monitoring System (CEMS), PEMS is a software application. While CEMS measures the actual emissions, PEMS “predicts” the emission levels.

PEMS reports a change in emission when a variation in process inputs such as heat rate, ambient conditions and air for combustion is measured. PEMS uses models to co-relate process parameters to the emission levels and works in real-time. These models are periodically checked for process fidelity, as required for compliance.

PEMS is more reliable and cost effective than CEMS. Since PEMS only requires basic digital infrastructure, it is realized that PEMS saves 50% of initial capital and 90% of operational expenditure.

How InOpTra can help

In an era where sustainability and operational efficiency are paramount, digital monitoring systems have emerged as game-changers. By enabling real-time insights into energy usage and emissions, these intelligent platforms empower industries to make data-driven decisions that drive compliance, optimize performance, and reduce environmental impact.

At InOpTra, we understand the transformative power of digital solutions. Our expertise in integrating advanced monitoring technologies helps businesses not only meet regulatory standards but also build a future-ready foundation for responsible energy management. Embracing these innovations isn’t just a strategic advantage—it’s a step toward a cleaner, smarter, and more sustainable world.