Industry versus Ecology: The Role of Artificial Intelligence in Minimizing CO2 Emissions in Energy-Intensive Industrial Processes

In the era of the global climate crisis, the industrial sector faces a unique challenge. CO2 emissions related to energy-intensive processes such as cement production, steelmaking or power plant operation (CO2 emissions of power plants) are a significant problem from both an ecological and economic perspective. The solution may be the integration of new technologies, including artificial intelligence (AI), which is a key tool in supporting sustainable development in industry.

Energy-Intensive Industry and CO2 Emissions

Industry is responsible for a significant share of global greenhouse gas emissions, including carbon dioxide. Processes such as cement production, where CO2 emissions result not only from energy use but also from chemical reactions, are examples of industries that are particularly difficult to optimize.

According to the International Energy Agency (IEA), in 2022 the industrial sector was directly responsible for 9.0 Gt CO2 emissions, which was a quarter of the global energy system’s CO2 emissions. According to the IEA report, industrial emissions slightly increased in 2023.

CO2 emission regulations, such as emission fees, additionally influence the need for changes in business management. The costs resulting from these fees pose a serious financial challenge. In this context, advanced technologies such as artificial intelligence play a key role, supporting process optimization and reducing the carbon footprint.

How Can AI Help Reduce Industrial CO2 Emissions?

The threat of climate change forces the search for innovative solutions that will reduce greenhouse gas emissions. Artificial intelligence is proving to be an extremely effective tool in this field. Thanks to its ability to analyze huge amounts of data and learn from experience, AI can revolutionize many industrial processes, leading to a significant reduction in CO2 emissions.

The most important applications of artificial intelligence in the context of industrial decarbonization include among others: optimization of energy consumption and production processes, logistics and transport, maintenance, as well as CO2 capture and storage. In detail, we can talk about the following aspects:

• Energy Demand Forecasting – AI can predict future energy demand based on historical data, weather conditions and other factors. This makes it possible to adjust energy production to actual demand, which minimizes losses and leads to a reduction in CO2 emissions associated with overproduction.

• Demand Management – AI can optimize energy consumption in real time, for example by controlling the operation of devices during hours when energy is cheaper and comes from renewable sources.

• Manufacturing Process Modeling – AI can create accurate models of manufacturing processes, enabling the identification of bottlenecks and areas for improvement.

• Quality Control – AI-based vision systems can automatically control the quality of products, minimizing waste and reducing raw material consumption.

• Manufacturing Recipe Optimization AI can help develop new recipes that are more efficient and less carbon-intensive.

• Route Planning – AI can optimize transport routes, reducing the distance vehicles travel and therefore reducing CO2 emissions

• Fleet Management – AI-based systems can monitor the health of vehicles and optimize their use, resulting in reduced fuel consumption.

• Failure Prediction – AI can predict potential machine and equipment failures, allowing repairs to be made before more serious problems occur.

• Maintenance Optimization – AI can determine the optimal timing for inspections and maintenance, avoiding production downtime and reducing energy consumption.

• CO2 Capture Process Optimization – AI can help optimize CO2 capture processes, increasing their efficiency and reducing costs.

• CO2 Storage Site Identification – AI can analyze geological and geophysical data to identify safe and sustainable CO2 storage sites.

Benefits of Using AI to Reduce CO2 Emissions and More

The use of artificial intelligence in modern industry to reduce CO2 emissions allows companies to achieve numerous benefits, among which the following seem to be particularly valuable: reduction of operating costs, compliance with legal regulations and improvement of the company’s image. Firstly, lower emissions mean lower CO2 emission fees, which improves profitability. Secondly, advanced analytical tools based on AI effectively help to adapt to strict CO2 emission regulations. Thirdly, modern industry increasingly focuses on sustainable development as an element of its marketing strategy – investments in ecology are well perceived by customers and investors, which can contribute to, for example, increased sales.

The implementation of artificial intelligence in industrial processes also brings a number of benefits that go far beyond CO2 reduction. The most important of them include the following:

• Increased Energy Efficiency – one of the most obvious benefits is the ability to optimize energy consumption. AI is able to precisely determine which production areas have the greatest energy losses and help take appropriate corrective actions. This not only results in a smaller environmental footprint, but also significant financial savings.

• Cost Reduction – AI enables effective reduction of energy costs, but also optimization of other resources, such as raw materials or water. Moreover, thanks to early detection of failures, costly production downtimes can be avoided.

• Improved Product Quality – AI-based vision systems enable precise control of product quality, which results in fewer complaints and higher customer satisfaction.

• Improved Product Quality – AI-based vision systems enable precise control of product quality, which results in fewer complaints and higher customer satisfaction.

• Innovation and Development – AI implementation stimulates the development of new products and services that are more environmentally friendly. Companies using AI can develop a competitive advantage by offering customers more sustainable solutions (artificial intelligence in sustainability).

• Adaptation to Changing Conditions – artificial intelligence enables rapid response to changing market and environmental conditions. With the ability to analyze large amounts of data, AI algorithms can identify new opportunities and threats, enabling companies to make better decisions.

• Increased Occupational Safety – AI-based systems can monitor working conditions and identify potential risks, contributing to improved employee safety.

Artificial Intelligence in Sustainability: CO2 Reduction Ideas by Carbon Re

Carbon Re is a climate technology company that aims to reduce CO2 emissions from cement production, steel production and glass production by using AI to decarbonise. It uses a combination of deep reinforcement learning and industrial sustainability expertise from the University of Cambridge’s Institute for Manufacturing and UCL’s Energy Institute.

Carbon Re’s innovative AI solution optimizes cement production by reducing energy consumption and CO2 emissions by up to 5%, which can potentially save $1 million per plant annually. Its proprietary cloud-based platform Delta Zero uses machine learning to achieve operational efficiency in energy-intensive industries, reduce operating costs and reduce CO2 emissions to otherwise unachievable levels. Importantly, Delta Zero reduces energy consumption, costs and carbon emissions immediately and without capital expenditure.

Carbon Re uses AI to analyze its clients’ manufacturing data and recommend ways to reduce CO2 emissions from cement production, steel production and glass production. It models production environments and dynamically identifies optimal processes to achieve the lowest possible carbon output dioxide and fuel use. The AI is continuously retrained to match actual plant performance.

The company has already piloted its Delta Zero platform in cement plants on three continents, preventing more than 10,000 tons of CO2.

Ecology and Industry Supported by New Technologies

AI plays a key role in modern industry, helping to reduce CO2 emissions and support sustainable development. From smart energy management systems to precise process optimization – AI enables more ecological and efficient production management in energy-intensive industries and beyond.

In the era of rising CO2 emission fees and increasingly stringent regulations (CO2 emissions regulations), investments in AI-based technologies are not only a necessity, but also an opportunity for dynamic industry development. In addition to economic benefits for enterprises, they also contribute to climate protection.

If you want to find out how AI can support your business in reducing CO2 (CO2 emissions reduction), schedule a free consultation with Marcin Jabłonowski – Managing Director and AI Solutions Architect at Pragmile.