Industrial Seals Prevent 100M Tonnes of CO2 Emissions

One Australian natural gas facility just proved that cutting industrial emissions doesn't mean compromising on reliability or performance.

John Crane, a global flow control technology company, has helped the facility reduce emissions by 40% using advanced dry gas seals. Since installation, the seals have prevented more than 100 million tonnes of carbon dioxide from entering the atmosphere while maintaining perfect uptime with zero failures.

The technology replaces conventional sealing systems in energy operations like refineries and natural gas plants. These advanced seals can reduce fugitive emissions by up to 98% while actually improving how efficiently the equipment runs.

It's a solution to one of industry's toughest challenges: meeting environmental goals while keeping essential energy systems operating safely. Even small leaks in high-demand energy operations can translate into massive environmental impact over time.

The company's latest innovations are delivering results beyond emissions cuts. Their new coaxial separation seal reduces nitrogen consumption by up to 80% compared to traditional designs, lowering both energy use and the carbon footprint of compression systems.

Seal gas recovery systems are capturing process gases that would otherwise vent into the atmosphere, moving operations closer to near-zero emissions. These aren't small tweaks but fundamental engineering improvements that deliver measurable benefits.

The Ripple Effect

The impact extends far beyond individual facilities. Over the past decade, John Crane's technologies have prevented millions of tonnes of greenhouse gases from entering the atmosphere, with ongoing programs reducing approximately 278,000 tonnes of carbon dioxide equivalent emissions every year.

The company is also supporting emerging lower-carbon energy systems including carbon capture, hydrogen production, and sustainable fuels. In geothermal and other demanding applications, their technologies are enabling continuous operations that help unlock more stable, lower-carbon energy sources.

For many operators, the fastest emissions reduction comes from improving existing assets rather than replacing them. Digital monitoring solutions like John Crane Sense Turbo provide near real-time performance data, enabling better decisions and avoiding unnecessary shutdowns that create maintenance-related emissions.

"Reducing emissions in industry comes down to how systems perform in the real world," said Mike Eason, the company's Chief Technology Officer. The focus is helping customers cut emissions while keeping critical operations running safely and reliably.

John Crane has also reduced its own operational carbon footprint by more than 50% over the past decade, with 72% of energy now from renewable sources. But their greatest impact remains in enabling customers to operate massive industrial systems more efficiently.

Engineering solutions are proving that environmental progress and industrial performance can advance together.