Increasing Production through Emission Savings:

Many industrial companies today face a critical challenge: production expansion runs into regulatory limits as the allowable emission capacities are nearly exhausted. In times of stringent environmental regulations and growing awareness of CO₂ and pollutant emissions, compliance with emission standards becomes a crucial economic factor. Especially for companies operating near their emission limits, the question arises: how can production be increased without exceeding the emission thresholds?

Emission Limits in Europe and the USA

Both Europe and the USA have strict legal requirements that regulate industrial emissions. In the European Union, the Industrial Emissions Directive (IED) plays a key role, requiring companies to use the Best Available Techniques (BAT) to minimize pollutants. Companies that reach the limits of their emission capacity must employ technologies that reduce emissions to continue operating within the allowable thresholds. Additionally, there is the European Emissions Trading System (EU-ETS), which caps CO₂ emissions and forces companies to adhere to their emission certificates. If companies exceed these certificates, they must purchase additional ones or face penalties.

In the USA, the Environmental Protection Agency (EPA), through the Clean Air Act, regulates air quality and sets strict limits for pollutants such as volatile organic compounds (VOCs), nitrogen oxides (NOₓ), and sulfur dioxide (SO₂). Companies that exceed these limits risk fines or need to make additional investments in emission credits. Regional programs such as the Regional Greenhouse Gas Initiative (RGGI), similar to the EU-ETS, regulate CO₂ emissions by making emission rights tradable.

These emission regulations create challenges but also opportunities for companies. By using more efficient and emission-reducing technologies, they can not only remain compliant but also create room to increase production.

Biofilters as a Key Technology for Emission Reduction.

One solution to this problem may lie in the use of biofilters for emission reduction. Compared to conventional technologies such as thermal oxidizers (TNV) and regenerative thermal oxidation (RTO), biofilters offer both economic and environmental benefits. They use biological processes to purify exhaust air, leading to a significant reduction in hydrocarbons, volatile organic compounds (VOCs), and other pollutants—while consuming considerably less energy.

While TNV and RTO rely on extremely high temperatures to thermally destroy pollutants—requiring vast amounts of energy and contributing to CO₂ emissions—biofilters operate at ambient temperature. This results in significantly lower energy demands, reducing both operating costs and CO₂ emissions.

Freed Emissions as Production Capacity

For companies that have nearly exhausted their emission capacities, the introduction of biofilters presents a new opportunity: the emissions saved by using this technology can potentially be used to increase production. Since total emissions are significantly reduced through filtration, companies create space within their permitted emission limits to expand production without causing additional emissions.

For example, a company using conventional RTO technology might be nearing its emission capacity limits. By switching to a biofilter system, VOC emissions could be reduced by up to 95%. The emissions freed up in this way can now be used to increase production, without violating new environmental regulations.

Ecological and Economic Benefits

Besides the obvious environmental advantages of reducing emissions, the use of biofilters also offers economic incentives. The lower operating costs associated with reduced energy consumption can quickly offset the initial investments required for the transition. Moreover, it allows companies to achieve their production goals without having to invest in expensive emission certificates.

Another advantage is the flexibility of biofilters. They can be used in many industries—from chemical and food production to waste treatment. This makes the technology a versatile solution for various sectors facing similar challenges with emission limits.

Conclusion: A Path to Sustainable Growth

For companies approaching their emission limits, biofilters provide an attractive way to reduce emissions while simultaneously increasing production capacity. Compared to conventional technologies such as TNV and RTO, biofilters offer both ecological and economic advantages. In an era where sustainability and economic growth must go hand in hand, biofilters could play a key role in uniting both.

Thank you to our customers and partners in the food processing industry – without your support, this success would not be possible!

With best Regarts 

Timo Weickert

CEO of PureAir BioTech Inc.