The Role of Steam in a Net-Zero Future

A Net-Zero Vision

As industries worldwide strive to achieve net-zero carbon emissions, the role of energy systems is in the spotlight. 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 blog explores the role of steam in a net-zero future, demonstrating how the decarbonisation of steam generation can unlock opportunities for efficiency, optimisation, 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, healthcare, 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 emerging 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.

· Routine Audits – ranging from insulation surveys, to steam trap surveys – or full steam system audits to fully understand the process demand and seek ways to optimise

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.

Consideration needs to be given to both the availability of fuel and also the infrastructure requirements.

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.

· Aerothermal : Harnessing the natural power of the wind can be an attractive source of energy

4. Leveraging Digital Tools

Digitalisation empowers industries to make real-time 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.

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.

A Sustainable Future with Steam

Today's industrial landscape is vastly different from four decades ago, when many of our current steam systems were first designed and installed. In an era of abundant, low-cost gas and little concern for environmental impact, these systems served their purpose well. However, in our current climate of rising energy costs and urgent sustainability targets, some might question whether steam remains a viable solution.

The truth is that steam itself isn't inefficient – it's still one of the most effective methods of heat transfer and process control. What's needed is a modern approach to steam system optimization that aligns with contemporary efficiency standards and environmental goals.

By updating and fine-tuning existing steam infrastructure, organisations can maintain the inherent benefits of steam while meeting today's demanding performance and sustainability requirements.

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.