De-steaming Is Not the Solution

When it comes to industrial energy systems, steam remains an essential and highly efficient utility. From power generation to food production, healthcare, pharmaceuticals, and beyond, steam plays a pivotal role in delivering energy and supporting critical processes. However, with sustainability high on the agenda and the pressure to decarbonise mounting, some may question steam’s place in a greener future. For consultants advising industries on energy strategies, the question isn’t whether to move away from steam but how to decarbonise it effectively and the steps to be taken before than can be achieved.

Why Steam Still Matters

Steam is unmatched in terms of energy transfer efficiency, versatility, and reliability. Its ability to deliver energy precisely where it’s needed, in forms like heat, pressure, or motive force, makes it indispensable. However, its environmental impact can vary significantly depending on the energy sources and operational practices employed.

The growing emphasis on carbon neutrality has led some to consider de-steaming removing steam systems entirely as a potential solution. However, de-steaming is often wrongly considered the only route to achieve low (or even zero) carbon thermal energy in many industrial and building service applications. This simply isn’t the case. The removal of steam infrastructure can cause a significant number of unforeseen issues and inefficiencies. In many cases, it may be cheaper, easier, and far less intrusive to the fabric of the building and the process to retain steam and instead change the fuel source.

The Benefits of Retaining Steam

High pressure and temperature steam systems are efficient for several reasons:

· Small pipework and low capital cost: High-pressure steam systems use small volume, small pipes, which are unobtrusive and easy to accommodate into the fabric of buildings.

· Low mass, less heat loss: Smaller pipework means less energy is lost, similar to a smaller radiator losing less heat.

· No pumps required: High-pressure steam systems don't need pumps to circulate energy, which reduces electrical demand.

· Energy density: Steam contains approximately 6 times more energy than water, meaning that smaller boilers, pipework, and heat exchangers are needed.

· Rapid response to demand: Due to its high energy content, steam can respond to energy demands more rapidly, making it ideal for meeting sudden, high energy needs for short durations throughout the day.

Removing steam may mean losing all of these advantages. De-steaming and a move towards a water-based system introduces the need for larger pipework, more complex electrical infrastructure, and new circulation pumps, all of which can cause significant costs, time delays, and potential disruptions to the building’s structure. Often, it may also require asbestos removal from old pipes, contributing to further environmental issues such as landfill waste.

In contrast, retaining steam and switching the fuel source is a far less intrusive and more cost-effective solution.

The Path to Decarbonising Steam

1. Improving System Efficiency The first step in decarbonisation is ensuring that existing systems operate as efficiently as possible. Inefficiencies lead to unnecessary energy use and higher emissions. Measures such as:

o Optimising boiler performance: Regular maintenance, tuning, and retrofits can significantly improve fuel-to-steam efficiency.

o Recovering waste heat: Installing economisers, condensate recovery systems, and flash steam recovery systems can reduce fuel consumption and carbon footprint.

o Upgrading insulation: High-quality insulation for pipes, valves, and fittings prevents heat loss and reduces energy demand.

o Manual Energy Audits : Can help understand and benchmark the process demand and identify other inefficiencies

2. Switching to Low-Carbon Fuels Fuel choice has a direct impact on the carbon intensity of steam generation. Transitioning from fossil fuels to low-carbon alternatives is a powerful way to decarbonise steam systems. Options include:

o Biomass and biogas: Renewable, carbon-neutral options that can replace traditional fossil fuels.

o Hydrogen: Green hydrogen, produced using renewable energy, is gaining traction as a sustainable fuel for steam generation.

o Electrification: Electric boilers powered by renewable electricity offer a direct route to zero-emission steam.

3. Integrating Renewable Energy Sources Renewable energy technologies, such as Aerothermal, solar thermal or geothermal systems, can supplement traditional steam systems. For instance, solar thermal systems can preheat water, reducing the energy demand on boilers.

4. Investing in Digital Solutions Digitalisation enables smarter, data-driven decisions that improve energy efficiency and reduce emissions. Tools such as steam system monitoring, predictive maintenance, and real-time analytics help identify inefficiencies and optimise performance. By leveraging Industrial Internet of Things (IIoT) technologies, consultants can support clients in managing their systems more effectively

Why De-steaming Isn’t the Answer

De-steaming is often perceived as a quick fix, but it’s far from ideal for most industries. Removing steam systems can lead to increased complexity and inefficiency when alternative methods are unable to match steam’s versatility and cost-effectiveness. Additionally, the capital costs of overhauling entire systems are often prohibitive.

In many cases, the removal of steam infrastructure can result in unintended consequences, such as the need for larger pipework, pumps, and potentially costly electrical infrastructure upgrades. Even worse, the cost and environmental impact of demolishing and replacing steam systems may make de-steaming a far less “green” solution than simply decarbonising the existing steam infrastructure.

Retain Steam, Remove the Fuel Source

Rather than dismantling steam systems altogether, it is often far more practical to retain them and change the fuel source. Doing so allows industries to maintain the benefits of steam while reducing carbon emissions. This approach offers a more sustainable and cost-effective solution, preserving efficiency while supporting the transition to greener energy sources.

Spirax Sarco: Your Partner in Decarbonising Steam

At Spirax Sarco, we understand the challenges and opportunities of decarbonising steam. With decades of expertise in steam systems, we offer tailored solutions that help industries reduce emissions while maximising efficiency and performance. Whether it’s through system audits, fuel transitions, or advanced digital tools, we are here to guide you and your clients on the journey to a greener future.

The question isn’t whether steam has a place in sustainable industry – it’s how we can decarbonise steam systems to unlock their full potential. Let’s work together to make steam part of the solution for a carbon-neutral future.

Contact us today to explore how Spirax Sarco can support your decarbonisation goals.