Eco-Friendly Housekeeping Assists Sustainability Goals

Facility monitoring, LED lighting and low-impact cleaners help reduce carbon footprint at chemical process industries (CPI) facilities

It is not always possible to refine a process to help reduce a facility’s carbon footprint; however, embracing some newer trends in more sustainable housekeeping practices presents an opportunity to become more environmentally conscious without impacting production. Here, we look at three developments in eco-friendly facility upkeep — facility monitoring, energy efficient LED lighting and low-impact cleaning solutions — that can provide a nudge in the green direction, while also ensuring safety, which is always the highest priority in the chemical process industries (CPI).

Monitoring and sustainability

Thanks to more advanced sensors and monitoring technologies, there is a growing trend toward using facility and process monitoring to bolster sustainability initiatives directed at improving efficiency and reducing emissions, while also enhancing safety.

Facility monitoring using sensors tied to data acquisition systems allows users to easily access useful data and use the insights to make better decisions regarding sustainability practices, such as reducing emissions, improving process efficiency, lowering CO₂ footprints and lowering utility or other operational costs.

“Many processors are interested in monitoring electrical, water and gas utilities to capture as much savings as possible, while also being environmentally responsible,” says Rick Canfield, product engineer at AutomationDirect (Cumming, Ga.; automationdirect.com).

Don Fregelette, vice president of chemical industry marketing at Emerson (Shakopee, Minn.; emerson.com), adds: “There is also a growing trend in the industry to require more monitoring points as corporate initiatives in areas such as energy reduction, decarbonization, safety and controlling more complex unit operations require a better understanding of the process.”

According to Fregelette, today’s chemical processors are embracing energy solutions that are aimed at improving combustion efficiency and regulatory compliance, including the following:

• Controlling air-to-fuel ratio, monitoring fluegas composition, monitoring oxygen in fluegas and continuous emissions monitoring solutions (CEMS)

• Improving safety monitoring with device diagnostics for more predictive safety monitoring and using remote proof-testing capabilities to extend the time in between required comprehensive proof tests

• Improving operational efficiency, improving plant mass balance and controlling more complex process conditions

Kris Worfe, Endress+Hauser USA (Greenwood, Ind.; us.endress.com) industry marketing manager for the chemical sector, adds: “Monitoring air quality is also critical because it is regulated by both state and federal authorities, and processors must comply with standards set by these agencies for emissions. Additionally, one of the most important utilities to monitor is steam, both generation and consumption, in an effort to make it as safe, reliable and efficient as possible. Measurement technologies can be used to address flow accuracy, energy content, purity and quality concerns” (Figure 1).

If a processor is interested in monitoring utilities, AutomationDirect’s Canfield says there are scalable programmable logic controller (PLC) platforms and extensive options for remote monitoring on a desktop or mobile device using internet or cell connectivity and industry-standard secure protocols.

“Once data is transmitted to the cloud, it can simply be viewed or can be integrated into a multitude of analytical systems,” he explains. “Users can use this data to optimize their processes and identify inefficient, broken or dangerous processes. A facility monitoring solution doesn’t need to interfere with existing core automation processes and can be added in parallel and progressively built out to provide a non-intrusive approach. Users can also incorporate logic or user data entries to the monitoring platform, so it becomes possible to implement direct changes to facility operating parameters for improving efficiency” (Figure 2).

For processors who want to dig a little deeper to improve insight into plant process conditions and control as a means to boost the efficiency and performance of their processes or to double down on sustainability initiatives, Emerson’s Fregelette, suggests the use of measurement instrumentation, both wired and wireless. This includes pressure, temperature, level, flow, gas analysis, liquid analysis, flame and gas detection instruments, which can transfer data and asset management information to control systems and automation software (Figure 3).

“Control, safety and data-acquisition systems collect and analyze information from measurement devices in the plant to determine optimal settings,” he explains. “That information is used to adjust valves, pumps, motors and drives to ensure product quality, process efficiency, sustainability and safety.

“Further,” Fregelette continues, “advanced industrial software, digital twins, process simulation, machine learning and artificial intelligence can empower staff to design, operate and maintain operations for maximum performance and efficiency.”

LEDs as a ‘green light’ solution

“There is currently a trend toward more efficient lighting solutions in the CPI, and LED [light-emitting diode] lights are quickly becoming the technology of choice because LED lighting technology is 40% more energy efficient, more compact and gives off less heat than incandescent lights,” says Peter Kohlert, special projects engineer with commercialLEDlights.com (Farmington, Mich.; commercialLEDlights.com).

“LEDs work quite differently from traditional light sources,” explains Thomas Geiger, president, LED2work (Chicago, Ill.; us.led2work.com). “They emit light in a 180-degree beam angle, while traditional light sources typically have a 360-degree beam angle. Additionally, heat is generated toward the back of the LED rather than the front, as with traditional light sources. Further, LEDs have a much longer lifespan, potentially lasting up to 60,000 hours.

“In addition, LEDs are significantly more energy efficient, and they produce less harmful waste when recycled. Fluorescent lightbulbs contain mercury, making them problematic for recycling,” says Geiger (Figure 4).

But while LED lighting technology offers some major advantages, there are often special considerations for the chemical industry. Geiger mentions challenges such as mechanical stresses from machinery, dust generated from material processing that can settle on lights and lead to increased surface temperatures or degraded performance and the need for protection against water ingress, humidity or gases, as well as chemicals, oils or cleaning agents.

For harsh chemical environments, LED2Work offers LED lighting solutions with an IP 69K rating to provide resistance to dust, water and high-pressure washers, oil and coolant resistance, chemical resistance, impact and vibration resistance and high-temperature tolerance. “These lights are specifically designed for manufacturing environments where standard lighting would fail prematurely,” notes Geiger. “In addition to their durability, our lights deliver exceptional light output and are available in a variety of forms and lengths to suit virtually any manufacturing setting. Task-lighting solutions for laboratories and quality control areas are also available to ensure precision and clarity.”

Additional challenges found in the CPI include high temperatures of about 50°C, which can result in shortened life expectancy and failed operations, says Neil Peterson, CEO at LED Lighting Supply (Nashua, N.H.; ledlightingsupply.com). For this reason, his company provides an alternative to standard LED lighting “Our long-lasting, UL [Underwriters Laboratories]-rated lighting options are capable of performing in high-temperature areas and have a longer life expectancy than standard LED lighting,” says Peterson. “And, our high-temperature, corrosion-resistant lights are designed with quality materials to withstand corrosion and operate in higher temperatures up to 150°C to meet U.S. Occupational Safety and Health Administration (OSHA; Washington, D.C.; www.osha.gov) approval requirements.”

Of course, chemical facilities may also have additional requirements due to the presence of hazardous materials, notes commercialLEDlights.com’s Kohlert. “Explosion-proof lighting fixtures are designed to prevent ignition sources from causing explosions in hazardous environments,” he says.

The major lighting classifications are: Class I Division I (concentrations of vapors, liquids or gases exist within the environment or under typical operating conditions) and Class I Division II (concentrations of vapors, liquids or gases exist within the environment under atypical operating conditions).

Kohlert suggests seeking guidance on hazardous locations from National Fire Protection Association (NFPA) 497 Recommended Practices for the Classification of Flammable Liquids, Gases or Vapors and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas; National Electric Code (NEC) Article 500, which describes the NEC Division classification systems, and Article 505, which describes the zone classification systems; and OSHA 1926.407 Hazardous (Classified) Locations.

That said, the type of activity dictates the type and amount of light needed. “The Illuminating Engineering Society (IES) provides comprehensive guidelines for recommended illumination levels for various industrial locations,” says Kohlert. “Regarding explosion-proof lighting, you must understand the nature of the specific hazards as they relate to NFPA 497 for classification.”

“Questions to ask include: A) Are there flammable gases, vapors or liquids, combustible dusts or ignitable fibers in the area? B) Are these present under typical operating conditions or under atypical operating conditions? C) Specifically, what types of gases, vapors or liquids, combustible dusts, or ignitable fibers are present in the area?” says Kohlert.

“Before ordering a lighting fixture, questions listed in A, B and C need to be answered. A and C will dictate whether the fixture should be Class 1, 2 or 3. Item B will indicate Division 1 or 2,” he explains. “Then there are the questions: What fixture wattage or lumens do you need? How many fixtures and what lighting color? The wattage/lumens are based on the area you wish to illuminate. The color is dependent on the task and somewhat on personal preference or experience. The shape of the room also may dictate the shape of the fixture.”

Because lighting is not one-size-fits all and chemical facilities can present complex and unique challenges and may need to adhere to regulatory requirements, Charles Kughn, president of commercialLEDlights.com, recommends a lighting design study, which provides a resource to ensure that facilities get a lighting solution that meets their needs and regulatory requirements, while still maintaining a safe, sustainable and properly illuminated environment (Figure 5).

Greener cleaners

“There is a growing trend toward using more sustainable cleaning products and techniques in the chemical manufacturing industry,” says Joshua Schwartz, president and co-founder of Viking Pure Solutions (Port Orange, Fla.; vikingpure.com). “This shift is driven by various factors, including regulatory pressures and the increasing awareness of the environmental and health impacts of traditional cleaning methods.”

He continues to say that governments and regulators are now enforcing stricter environmental laws and standards, so chemical processors are required to reduce emissions, minimize waste and improve overall environmental performance, leading to the adoption of more sustainable cleaning practices. In addition, as consumers become more aware of what sustainability means in a broader sense, companies are setting more ambitious sustainability goals, often linked to reducing their carbon footprint, water use and waste generation. “Sustainable cleaning practices help achieve these goals,” he says.

Aaron Martin, regional account manager with PathoSans Technologies from Spraying Systems (Glendale Heights, Ill.; pathosans.com), adds: “A more recent development driving new, more sustainable cleaning products is they are proving more efficient — not only providing improved working safety and protecting the environment, but providing an operational advantage. A true win-win!”

Among the choices for effective, yet sustainable, cleaning solutions are electrolyzed water systems that generate cleaning and disinfecting solutions, which are offered by both Viking Pure and PathoSans.

“Viking Pure solutions are created through an electrochemical process that uses salt, water and electricity to produce two distinct products: a cleaning solution (sodium hydroxide) and a disinfecting solution (hypochlorous acid),” says Schwartz. “Both are effective, safe for use around people and equipment and environmentally friendly” (Figure 6).

Produced through on-site generation systems, the cleaning solution is a highly effective cleaner that can break down grease, grime and organic residues. It’s suitable for cleaning floors, walls, equipment and other surfaces where chemical residues may accumulate and, because it is non-toxic and non-corrosive, it is safe for workers and reduces the risk of damaging sensitive equipment.

Similarly, PathoSans offers on-site electrochemically activated (ECA) generators that allow users to generate eco-friendly cleaners and disinfectants on site and on demand without the storage of hazardous chemicals (Figure 7). “These chemicals can and have been used within chemical processing facilities for a multitude of different applications, from CIP processes, cross-contamination prevention, equipment and machinery wash down and odor control to the offices where the operators work,” says Martin. “Implementing PathoSans chemicals into routine cleaning and disinfection systems has helped reduce the overall carbon emissions, lowered the demand on wastewater management and improved overall safety.”

In addition to being effective while also reducing greenhouse gas emissions when compared to the use of traditional cleaning processes, the use of on-site generation reduces the need to manage chemical shipments and storage and reduces the demand on personal protective equipment, as well as the need for hazardous chemical disposal, which provides an operational advantage to any cleaning process, says Martin.

Alternatively, Cold Jet (Loveland, Ohio; coldjet.com), an original equipment manufacturer (OEM) for industrial equipment used to produce dry ice and dry ice blasters, uses recycled CO₂ that has been captured from a carbon capture and utilization process to manufacturer and blast dry ice. “Dry ice is an environmentally sustainable, water-free and chemical-free solution that replaces other harmful processes,” explains Steve Wilson, director of dry ice cleaning applications and ESG, with Cold Jet. “It is dry, non-abrasive and does not cause corrosion. Because it is dry, it can be used around electronics and other sensitive components where cleaning with water or other solvents would be problematic.

“Dry ice [solid CO₂] is putting recycled CO₂ to work and is an environmentally responsible solution that does not add additional CO₂ to our environment,” he continues. As a matter of fact, both the Environmental Protection Agency (EPA) and California Air Resource Board (CARB) have noted: “Due to the fact that dry ice is recycled CO₂, it will not contribute to your greenhouse gas score. In the calculation of a carbon footprint, the CO₂ is accounted for at the producer level. It is not counted a second time at the point of use.” Currently the EPA states that dry ice blasting does not need to be reported under the Greenhouse Gas Reporting Program (GHGRP, 40 CFR Part 98).

“Dry ice uses a gas that is found naturally in our environment,” explains Wilson. “Cleaning with dry ice replaces traditional cleaning methods, which often have a higher carbon footprint and often contain human-made fluorinated gases.”

Whether driven by regulatory requirements to reduce emissions, the desire to improve overall operating efficiency to minimize costs and waste or corporate initiatives to enhance their brand image, chemical processors should consider incorporating any, or all, of these housekeeping-related strategies to assist with their sustainability goals.

Joy LePree