Zero-emission strategies in industrial plants – how to effectively plan and implement them?

What is a zero-emission strategy?

A zero-emission strategy is a long-term plan for transforming a company to minimize and then offset its greenhouse gas emissions. This applies to both direct emissions – resulting from fuel combustion (Scope 1) – and indirect emissions – from purchased electricity and heat (Scope 2), as well as emissions from the entire supply chain (Scope 3).

Achieving net-zero emissions does not necessarily mean reducing greenhouse gas emissions to zero – rather, achieving a balance between the company's emissions (reduced to a minimum) and the amount of greenhouse gases removed from the atmosphere through offsetting residual emissions (e.g., reforestation, CO₂ capture technologies). Therefore, a zero-emission strategy involves not only decarbonization directly at the plant but also monitoring and managing the entire emissions cycle.

Emission analysis – calculating the company's carbon footprint

The first step in developing a zero-emission strategy for an industrial plant is a thorough diagnosis of the current situation – both in terms of energy consumption and greenhouse gas emissions. The primary tool at this stage is calculating the company's carbon footprint, which is the amount of emissions expressed in CO₂ equivalents generated throughout the company's entire business chain.

The carbon footprint is calculated in accordance with international standards, such as the GHG Protocol and ISO 14064. The audit analyzes emissions across three scopes:

• Scope 1 (direct emissions) – covers emissions from fuel combustion, industrial processes, and company transportation;
• Scope 2 (energy-related indirect emissions) – covers emissions from purchased electricity, heating, cooling, or steam;
• Scope 3 (other indirect emissions) – covers emissions from the supply chain, freight transportation, business travel, and product use.

The data collected during the audit provides a starting point for identifying priority areas for decarbonization and allows for the setting of realistic reduction targets.

We wrote about how to calculate a company's carbon footprint in the knowledge base: Calculating your carbon footprint

Emission reduction strategy

After the carbon footprint audit and analysis phase comes the design and implementation phase of an emissions reduction strategy. This typically encompasses activities in four main areas:

• increasing energy efficiency

Optimizing energy consumption is the first and most cost-effective step toward decarbonization. Modernizing heating, ventilation, drive systems, and production processes can significantly reduce emissions.

• decarbonizing energy sources – switching from fossil fuels to renewables

At the next stage, the transition to low- or zero-emission energy sources is crucial. Depending on the specific plant, these may include:

• cogeneration plants fueled by biomass or biogas,
• photovoltaic power plants (on-site or off-site),
• purchasing green energy from suppliers (based on PPA contracts),
• electrification of industrial processes – to use electricity that can be more easily "greened"

• CO₂ capture and utilization

For industries that are difficult to decarbonize (e.g., cement, chemical, or steel), a zero-emission strategy may include carbon capture, storage, and utilization (CCS/CCU) technologies. These solutions require significant capital expenditures, but they are an important element of long-term climate plans. Currently, their potential is not yet fully realized, but they could become a crucial decarbonization tool in the future.

• supply chain management and scope 3 emissions

More and more companies are analyzing emissions across their entire value chain, collaborating with suppliers. Scope 3 emissions at a given company are primarily Scope 1 and 2 emissions from their suppliers. Scope 3 emissions constitute the largest share of a company's total emissions, while also being the most difficult to quantify and eliminate. In practice, these initiatives can include switching to more sustainable suppliers, selecting materials with a lower carbon footprint, or optimizing logistics.

"Implementing a zero-emission strategy in industrial plants is a necessity today, driven by regulations and market expectations, but also a strategic step for companies that want to remain competitive in the long term. We observe that many companies, especially global corporations, are approaching this challenge very responsibly – starting with reliable audits and realistic reduction plans, and then consistently implementing measures to optimize energy consumption and transform power sources. This process requires time and investment, but without it, it is difficult to imagine stable industrial development adapted to climate requirements." says Katarzyna Kuśnierz, Project Manager at DB Energy.

Long-term benefits of implementing a zero-emission strategy

Implementing a zero-emission strategy involves capital expenditures and a time-consuming transformation process. However, there is no doubt that even a small reduction in emissions brings benefits – emissions do not have to be completely eliminated. Such benefits include:

• cost reduction thanks to lower energy consumption and reduced dependence on fossil fuels,
• an advantage in the eyes of investors – in tenders and negotiations with customers and suppliers, who increasingly require ESG data,
• access to financing programs – banks and funds increasingly condition access to capital on compliance with the EU taxonomy and climate goals,
• compliance with regulatory obligations and avoidance of fines – willingness to comply with reporting obligations (e.g., CSRD, CBAM) and potential emissions fees.

What do zero-emission strategies look like in practice?

One example of successfully implementing a zero-emission strategy is a project delivered by DB Energy for a chemical plant in Jiangmen, southern China. This plant belongs to a global group specializing in the recycling of batteries and critical raw materials. The plant was preparing to double its production capacity while simultaneously setting itself the ambitious goal of achieving net-zero emissions by 2035.

After a disappointing experience with another audit firm, which failed to deliver a strategy that met the client's expectations, the company turned to us. In just four months, we developed a precise CO₂ emissions reduction map, enabling a 70% reduction in emissions without interfering with production processes. Key actions included heat recovery from compressors and wastewater and optimization of process steam parameters.

Even during the initial implementation phase, the plant reduced steam consumption by 50%. Our strategy enabled increased production while simultaneously reducing emissions and energy consumption, supporting the client in meeting its environmental commitments and implementing its circular economy strategy. 
You can find the full case study here: Higher production and lower emissions – a chemical Client on the path to net zero

Summary

Implementing zero-emission strategies in industrial plants requires not only the right technical tools but also a strategic approach, management commitment, and long-term planning. Success in this area relies on a reliable diagnosis, realistic reduction targets, and flexible implementation of solutions tailored to the specific needs of a given facility.

A zero-emission strategy is a path to increasing a company's resilience to economic change, strengthening its market position, and building company value based on sustainable development. Facilities that invest in energy efficiency and emission reduction become more attractive to investors, business partners, and customers.