Industrial emissions arise from combustion processes, chemical reactions, and fugitive releases

Dr Bijal Sanghvi, Managing Director, Axis Solutions Limited.

What are the main sources of industrial emissions that remain difficult to control, despite existing regulations and technologies?

The Pollution Control Board classifies industries into Red, Orange, Green, and White categories based on their pollution potential, with the 17 categories of highly polluting industries; such as thermal power plants, cement, iron and steel, fertilizer, petroleum refineries, pulp and paper, textile dyeing, tanneries, and distilleries; receiving stricter monitoring and reporting norms. The Central Pollution Control Board (CPCB), along with State Pollution Control Boards (SPCBs), sets and enforces emission control standards under the Air (Prevention and Control of Pollution) Act, 1981. CPCB issues comprehensive guidelines for industries, prescribing emission limits, stack monitoring requirements, and Continuous Emission Monitoring Systems (CEMS). SPCBs implement these at the state level through consent mechanisms, ensuring adherence to national emission standards.

According to CPCB, the main sources of industrial emissions arise from combustion processes, chemical reactions, and fugitive releases. Thermal power plants and process furnaces contribute to high levels of SO₂, NOx, and particulate matter; while refineries, fertilizer, and chemical units emit volatile organic compounds (VOCs) and greenhouse gases. Cement, iron and steel, and metallurgical industries generate large quantities of dust and heavy metals. Smaller clusters such as foundries, brick kilns, and dyeing units, though individually minor, contribute cumulatively to localised air degradation.

Despite robust regulations and available technologies like electrostatic precipitators, bag filters, scrubbers, catalytic converters, and CEMS control remains challenging due to outdated equipment in existing plants, inadequate operation of pollution control devices, inconsistent monitoring, and weak enforcement at the SME level. Furthermore, fugitive and intermittent emissions from storage tanks, material handling, and transport are hard to quantify and capture. Thus, while CPCB’s regulatory framework is comprehensive, consistent technology adoption, data-driven compliance, and enhanced SPCB capacity remain critical for effective industrial emission control in India.

How have tightening environmental regulations and global net-zero commitments influenced industry priorities around emission reduction?

Tightening environmental regulations and India’s commitment to achieve Net Zero by 2070, announced at COP26 in Glasgow, have significantly reshaped industrial priorities. Under the ‘Panchamrit’ vision, India aims to achieve 500 GW of non-fossil energy capacity, fulfill 50% of energy needs through renewables, reduce carbon emissions by one billion tonnes, and lower carbon intensity by 45% by 2030. These commitments, supported by CPCB and SPCB emission norms, are driving industries to adopt cleaner technologies, efficient monitoring systems, and stricter compliance to maintain competitiveness in a low-carbon economy.

Industries in energy-intensive sectors such as Oil and Gas, cement, steel, power, and chemicals are now prioritising decarbonisation through fuel substitution, process optimisation, and energy efficiency improvements. The focus is shifting towards renewable integration, hydrogen adoption, carbon capture utility and storage (CCUS), and waste-to-energy conversion. Regulations like Continuous Emission Monitoring Systems (CEMS), performance-based standards, and sustainability-linked financing are aligning operational practices with national climate objectives.

However, the transition is not without challenges. Legacy infrastructure, dependence on fossil fuels, and limited access to green financing continue to hinder progress. Yet, the Net Zero 2070 roadmap acts as a catalyst, compelling industries to reimagine growth through innovation, collaboration, and responsible manufacturing, positioning India’s industrial landscape toward a sustainable, climate-resilient future.

Which emerging technologies hold the greatest promise for reducing industrial emissions?

Emerging technologies are transforming industrial emission control, with Tunable Diode Laser Spectroscopy (TDLS) standing out as a highly promising innovation. TDLS enables real-time, in-situ gas analysis for critical parameters like O₂, CO, CO₂, NH₃, and H₂O, offering superior accuracy and reliability even in harsh process conditions. This non-contact measurement method ensures faster response and minimal maintenance compared to conventional extractive systems, making it ideal for combustion optimisation and emission reduction.

Three key TDLS-controlled technologies include combustion efficiency optimisation, process gas monitoring, and flue gas desulfurisation (FGD) control. In combustion systems, TDLS precisely measures oxygen and carbon monoxide to maintain the ideal air-fuel ratio, improving fuel efficiency and minimising NOx and CO emissions. For process gas monitoring, it ensures consistent product quality while reducing waste and unburned hydrocarbons. In FGD systems, continuous monitoring of gases like SO₂ and H₂O optimises reagent dosing, reducing operational costs and environmental impact.

Additionally, plant flexibilisation; integrating TDLS data with advanced control systems; enables adaptive operation across varying loads, ensuring sustainable, efficient, and low-emission industrial performance.

How effective are digital tools like IoT-based monitoring, AI analytics, or digital twins in identifying emission hotspots and optimising energy use?

Digital tools such as PEMS – IoT-based monitoring, AI analytics, and digital twins are proving highly effective in identifying emission hotspots and optimising industrial energy use. These systems enable continuous, real-time tracking of parameters like fuel consumption, process efficiency, and air quality, allowing for instant corrective actions and predictive maintenance.

Aligned with India’s evolving Emission Trading Scheme (ETS) and Carbon Monetisation initiatives, such digital ecosystems help industries generate verifiable and traceable emission data, which can be translated into measurable carbon assets. This promotes not only transparency and accountability but also allows organisations to participate in carbon credit mechanisms, turning sustainability into a value-generating activity.

By integrating IoT sensors with AI-based predictive models and digital twin simulations, industries can visualise energy flows, simulate process changes, and implement targeted emission-reduction strategies. Together, these tools enhance operational efficiency, ensure regulatory compliance, and accelerate the shift toward a data-driven, low-carbon industrial future.

What role do renewable-energy integration and electrification of processes play in emission reduction for hard-to-abate industries?

Renewable energy integration and process electrification are central to decarbonising hard-to-abate industries such as steel, cement, refining, and chemicals. By replacing fossil fuel-based energy with renewables, industries can significantly cut Scope 1 emissions (direct emissions from operations) and Scope 2 emissions (indirect emissions from purchased electricity), enhancing both sustainability and energy security.

A key enabler in this transition is Green Hydrogen (GH₂); produced through renewable-powered electrolysis; which serves as a clean substitute for coal, natural gas, or other carbon-intensive feedstocks. In steelmaking, for instance, GH₂ can replace coke in direct reduction processes, while in refineries and fertilizers, it offers a zero-carbon pathway for hydrogen-dependent operations. Its integration into industrial processes not only reduces carbon intensity but also supports deep decarbonisation goals under India’s Net Zero 2070 mission.

Complementing GH₂, Battery Energy Storage Systems (BESS) stabilise renewable power supply by storing excess renewable energy sources for continuous industrial operation. BESS enables round-the-clock electrification, grid balancing, and peak-load management, making renewable adoption technically feasible and economically viable for heavy industries pursuing sustainable transformation.

In your view, what are the biggest operational or economic barriers preventing industries from adopting cleaner technologies?

The adoption of cleaner technologies across industries faces multiple operational and economic barriers, primarily centered around energy affordability, infrastructure readiness, and grid stability. One of the key challenges is peak load management, as renewable energy sources are intermittent. Without stable supply, industries hesitate to rely fully on clean power. This underscores the need for microgrids, Battery Energy Storage Systems (BESS), and large-scale pump storage projects to ensure uninterrupted energy during fluctuating demand cycles.

On the fuel side, the transition from fossil fuels to cleaner alternatives such as methanol which is derived from coal gasification, biogas conversion, and bass degasification offers promise but faces technological, cost, and scalability hurdles. India’s initiatives, including NTPC’s joint venture with NPCIL, Coal India Ltd, and IGEA, aim to develop methanol-based power generation and expand nuclear power through small, medium, and large modular reactors, ensuring reliable baseload clean energy.

However, the broader shift to clean power must balance energy affordability and socio-economic impacts. Reducing fossil fuel dependence could affect employment in coal mining, railway freight, and associated industries. Hence, a just and inclusive transition, supported by policy incentives, financial viability, and workforce reskilling, is essential to drive large-scale adoption of cleaner technologies without compromising economic stability.

(The views expressed in interviews are personal, not necessarily of the organisations represented)

Dr Bijal Sanghvi is the Managing Director of Axis Solutions Limited, a distinguished first-generation company having a Domestic as well as Global Presence, which has achieved remarkable milestones. His role spans across various verticals ranging from managing the overall development and operations of the firm with leadership roles across business strategy, business development and management of various business functions such as Production, Engineering, Manufacturing and R&D.