Industrial decarbonisation

Assess industrial decarbonisation measures

Use measured site data to identify, quantify and rank energy and emissions measures. No site-wide saving percentage is assumed.

Open the screening calculator Read reporting requirements

Select measures from evidence

Use this list to define the workstreams for a site survey. Each measure requires a separate site assessment.

Practice	Saving basis	Payback	Evidence needed
Heat-loss elimination (insulate bare valves, flanges, fittings, tanks)	No site-wide default	Site-specific	Calculate from measured surface area, temperature, operating hours and insulation specification
Steam-system programme (traps, leaks, blowdown, condensate, combustion control)	No site-wide default	Site-specific	Use a steam-system balance and the US Department of Energy steam assessment tools
Waste-heat recovery (economizers, preheating, heat exchange)	No site-wide default	Site-specific	Match a measured heat source to a simultaneous heat sink and assess the full system boundary
Compressed-air leak programme + controls	No site-wide default	Site-specific	Measure leakage or model it from system volume, pressure decay and compressor performance
Variable-speed drives on pumps & fans	No site-wide default	Site-specific	Use the actual hydraulic or air-system curve, duty profile, motor data and control method
LED lighting + controls	No site-wide default	Site-specific	Use a fitting inventory, measured power, control strategy and operating hours
Water-efficiency programme (metering, leaks, reuse, washdown discipline)	No site-wide default	Site-specific	Prepare a site water balance and assess each loss or reuse route separately
Fuel switching / alternative fuels (biomass, heat pump, electrification)	No site-wide default	project	Compare useful heat on the same boundary using current contracts, efficiency, capacity and reporting factors

For exposed hot surfaces, do not apply a site-wide percentage. Use the heat-loss calculator with measured geometry, temperature and operating hours.

Use the results correctly

Record the baseline, measurement boundary, operating period, capital cost, expected saving and verification method for each proposed measure. Keep regulatory obligations separate from voluntary investment assumptions.

Model carbon exposure

Apply a dated carbon-price input to a defined emissions boundary.

Prepare reporting evidence

Keep the calculation, source, boundary and approval record together.

Check German requirements

Review EnEfG duties and verify current EEW funding conditions before applying.

Inzonex removable modular insulation on industrial equipment

Equipment heat loss

Measure exposed hot surfaces

Use measured surface area, temperature and operating hours to calculate heat loss from boilers, kilns, heat exchangers, valves and pipework. Inzonex supplies removable modular insulation for equipment that requires maintenance access.

Design target: surface temperature at or below 45 °C, subject to the application and design review
Claimed heat-loss reduction: up to 96%, subject to the measured boundary and insulation specification
Removable construction for inspection and maintenance access
Calculation record available for the selected equipment and operating conditions

View modular insulation Prepare a heat-loss study

Do not add a calculated reduction to an emissions report until the reporting boundary, factor, implementation date and verification method have been approved.

Questions

What are the main practices to reduce industrial emissions?

Start with measured energy flows. Common workstreams include exposed-surface heat loss, steam traps and leaks, combustion control, waste-heat recovery, compressed air, variable-speed drives, lighting, water and fuel switching. The order depends on the site's measured losses, operating constraints and costs.

How much can a typical plant save in total?

There is no reliable percentage that applies to every plant. Use meter data, operating hours and equipment measurements to establish a baseline. The calculator provides a screening scenario only and does not replace an energy audit.

Which practice should come first?

Start with the largest verified loss that can be corrected without disrupting safe operation. Record the baseline, implementation cost, expected saving, measurement method and operational constraints before ranking measures.

Why do emissions regulations make these practices urgent?

Energy and emissions data can affect carbon-cost exposure, import reporting and corporate reporting. The applicable duty depends on the jurisdiction, activity, company size and reporting period. Check the relevant rule before treating a measure as a compliance action.