Introduction: A Net-Zero Vision
As industries worldwide strive to achieve net-zero carbon emissions, the role of energy systems is under scrutiny. Steam, a tried-and-tested utility for industrial processes, is often overlooked in conversations about decarbonisation. Yet, steam holds significant potential to contribute to a sustainable future when coupled with innovative approaches and modern technology.
This whitepaper explores the role of steam in a net-zero future, demonstrating how its decarbonisation can unlock opportunities for efficiency, sustainability, and innovation across industries.
Steam: An Indispensable Industrial Utility
Steam has been the backbone of industrial energy systems for over a century. Its ability to transfer large amounts of energy efficiently and reliably makes it indispensable in sectors such as food and beverage, pharmaceuticals, chemical manufacturing, and power generation.
Key Advantages of Steam:
- Energy Transfer Efficiency: Steam’s high energy density allows for the efficient transfer of heat and power.
- Flexibility: Steam systems can be adapted for heating, sterilisation, drying, and mechanical work, making them suitable for diverse industrial applications.
- Scalability: From small-scale operations to large industrial complexes, steam systems can be tailored to meet specific energy demands.
Despite these advantages, traditional methods of steam generation often rely on fossil fuels, presenting a significant challenge for industries aiming to achieve net-zero emissions.
Decarbonising Steam Systems
The path to decarbonising steam systems is multi-faceted, involving improved efficiency, the adoption of renewable energy sources, and leveraging cutting-edge technologies.
1. Enhancing System Efficiency
Optimising steam systems is the first step in reducing emissions. Efficiency improvements not only lower carbon footprints but also cut operational costs. Key strategies include:
- Reducing Heat Losses: Using advanced insulation materials for pipes, valves, and fittings can minimise energy wastage.
- Recovering Waste Energy: Implementing condensate recovery systems, flash steam recovery units, and economisers can significantly reduce fuel consumption by capturing and reusing waste energy.
- Upgrading Boiler Technology: High-efficiency boilers equipped with modern controls and automation systems ensure optimal fuel utilisation and minimise emissions.
- Conducting Regular Maintenance: Preventative maintenance schedules help identify inefficiencies and extend the lifespan of system components.
2. Transitioning to Low-Carbon Fuels
Fuel choice directly impacts the carbon intensity of steam production. Transitioning to sustainable alternatives can drive significant emission reductions:
- Biomass and Biogas: Renewable fuels like biomass pellets and biogas are carbon-neutral options when sourced sustainably.
- Green Hydrogen: Produced using renewable electricity, hydrogen is an emerging zero-emission fuel for steam generation.
- Electrification: Electric boilers powered by renewable energy provide a direct route to decarbonisation, especially in regions with a green energy grid.
3. Integrating Renewable Energy
Renewable energy can complement steam systems by reducing reliance on conventional fuels. Examples include:
- Solar Thermal Systems: Solar collectors can preheat water, reducing the energy demand on boilers.
- Geothermal Energy: Geothermal heat can serve as a sustainable source for low-temperature steam requirements.
4. Leveraging Digital Tools
Digitalisation empowers industries to make data-driven decisions for improved sustainability. Advanced monitoring systems, predictive analytics, and real-time performance tracking can optimise steam system efficiency and minimise waste. Technologies such as the Industrial Internet of Things (IIoT) enable smarter control and better integration of renewable energy sources.
Steam in Emerging Technologies and Circular Economy Models
Steam’s versatility positions it as a key enabler in circular economy models and emerging technologies. For instance:
- Industrial Symbiosis: Excess steam generated by one facility can be redirected to nearby facilities, maximising resource efficiency and reducing energy waste.
- Carbon Capture and Storage (CCS): Steam plays a vital role in regenerating amines used in capturing CO2 from industrial processes.
- Hydrogen Production: Steam methane reforming (SMR) and electrolysis rely on steam as a critical input for producing hydrogen efficiently.
The Business Case for Decarbonising Steam
Decarbonising steam systems is not only an environmental imperative but also a business opportunity.
Key Benefits Include:
- Cost Savings: Efficiency improvements lead to lower energy consumption, reducing fuel costs.
- Regulatory Compliance: As emissions standards tighten, decarbonising steam systems ensures compliance with evolving regulations.
- Enhanced Reputation: Demonstrating a commitment to sustainability builds trust with customers, stakeholders, and investors.
- Future-Proofing: Transitioning to low-carbon technologies safeguards operations against rising carbon taxes and fuel costs.
Spirax Sarco: Your Partner in a Net-Zero Journey
At Spirax Sarco, we believe that steam has a vital role in the net-zero future. With decades of expertise, we provide tailored solutions to help industries:
- Optimise Steam Systems: Conducting system audits and implementing efficiency upgrades to maximise performance.
- Transition to Low-Carbon Fuels: Supporting the adoption of hydrogen, biomass, and electrification technologies.
- Leverage Digital Tools: Offering advanced monitoring and analytics solutions to optimise system performance in real time.
Whether you’re just beginning your decarbonisation journey or refining existing systems, our team of experts is here to guide you every step of the way.
Conclusion: A Sustainable Future with Steam
Achieving a net-zero future requires innovative thinking and a commitment to change. Steam, with its unparalleled efficiency and versatility, can remain a cornerstone of industrial energy systems when decarbonised effectively.
By investing in modern technologies, adopting renewable energy sources, and partnering with experts like Spirax Sarco, industries can harness steam’s potential to drive sustainability while meeting operational and financial goals.
Together, let’s make steam part of the solution for a greener tomorrow.
Contact Spirax Sarco today to learn more about decarbonising your steam system. www.spiraxsarco.com
This article appeared in the July/August 2025 issue of Energy Manager magazine. Subscribe here.