Steam: A timeless solution for industrial net zero

In the ever-evolving landscape of net zero, steam stands out as a powerful tool to fight climate change. The Sustainable Industry team recently sat down with Rebecca Bowen, Solution Delivery Manager at Spirax Sarco, a company at the forefront of global sustainable technology solutions to understand more about the opportunities steam presents in terms of decarbonising manufacturing operations.

Spirax Sarco and sustainable steam Steam – water under pressure – offers a powerful tool in our drive to achieve net zero production methods. Spirax Sarco’s Rebecca Bowen explains.

In manufacturing operations, steam serves as a vital energy carrier and utility. It is employed for various processes from heating, power generation, and as a motive force for mechanical operations. Its ability to retain and transfer heat efficiently, makes it indispensable in a variety of industrial applications.

Steam's applicability is broad, spanning sectors from power generation and pharmaceuticals to hospitals, manufacturing, and even food and beverage production.

The intrinsic renewability of steam, especially when focusing on the recovery and reuse of water within systems, makes it a standout solution.

Spirax Sarco is also leading the way in the transition to renewable sources and low-carbon alternatives. This shift can drastically cut greenhouse gas emissions, with complementary technologies such as electrification, renewable energy integration, biomass, biogenic fuels, and green hydrogen also presenting exciting prospects.

Spirax Sarco is also supporting progressive businesses in the retrofitting and modernisation of existing infrastructures.

Steam's role in net zero As industries worldwide grapple with decarbonisation, it becomes clear that no single technology can bear the weight of this responsibility. Instead, a blend of renewables, time-tested technologies like steam, as well as novel tools and processes will all play a part.

The beauty of steam lies in its adaptability. It effortlessly integrates with other technological advances. Spirax Sarco's recent launch of the Target Zero range is a testament to this adaptability.

By electrifying boilers and introducing innovations like Thermal Energy Storage, which focuses on storing renewable energy for on-demand usage, steam integrates seamlessly into a sustainable framework. In addition to Combined Heat and Power systems (CHPs), waste recovery units, and more, a range of tools converges to support steam generation, ensuring companies don't lose momentum in their sustainability pursuits.

Translating these innovations into tangible outcomes, Spirax Sarco has range of case studies and success stories. For example, the UK-based company Eastwood Park located at Falfield, Gloucestershire Easter Park, which serves as an training facility for the NHS. They've innovatively combined a Steam Battery with solar panels, ensuring their steam generation is entirely renewable. This renewable steam finds its application in a multitude of essential operations, from sterilisation to heating.

A food and drink company, and Spirax customer in Turkey has changed its whole production by using electricity and other clean energy sources. This means they produce steam without creating any carbon pollution.

This customer was the first in the world to retrofit an existing combustion boiler to become fully electric. The customer not only has removed scope 1 and 2 emissions, but also has seen an operational increase in efficiency.

Steam is essential to the site's distillation process and having the ability to utilise the existing site equipment and electrifying the boiler provided distinct operational, time and user advantages and with the company’s ambitious global and local commitments to reduce carbon emissions, electrification of the steam generating process was seen as the best solution. The site used natural gas for combustion and needed minimum disruption to their processes as well as reduce the installation period and minimise site disruption associated with installation and commissioning of innovative technology.

Spirax Sarco's main message is to improve the control of processes and reduce carbon. By using digital tools, smart enterprise technology, and data analytics, companies can save a lot of energy, while simultaneously using less carbon. Among these modern tools, steam remains important and shows the way for cleaner solutions.

Efficient steam generation Heat recovery stands out as a primary solution for many companies. By perpetually recycling and reusing energy, companies can significantly minimise the wastage commonly associated with steam generation. Alongside, the efficacy of steam traps, as previously discussed, further underscores the potential to harness every bit of energy.

Efficiency is not just about using advanced tools but also about their proper installation. Spirax Sarco's innovative solution in the form of 'Fall Insulation Jackets' is a testament to this principle. By packaging steam pipes, these jackets effectively mitigate the thermal losses, ensuring that the steam retains its energy.

Yet, the pathway to efficiency doesn't end at implementing advanced tools or methods. Periodic assessments, like energy audits, play a pivotal role.

These audits thoroughly examine systems to identify areas where they aren't efficient or are losing energy. Rebecca gave an example of a customer who changed their approach to managing Total Dissolved Solubles (TDS).

This change resulted in significant money savings and reduced carbon emissions. Even when a system is running well, there's often potential to improve it further.

The future of steam The global push for cleaner production is making us rethink many old technologies. Among these, steam is changing its role. People used to mainly link it with old machinery like steam trains, but now we're seeing its great potential for modern and future uses.

Steam has always been central to producing energy. As Rebecca highlighted, even though steam is an old energy form, it's adapting to today's green needs.

“Steam isn't just old technology; it's a cost-effective, clean, and safe energy option, which is vital as the world works towards reducing emissions to zero.”

Innovation remains at the core of steam's evolutionary journey. With a strong focus on research and development, industry leaders like Spirax are continually seeking game-changing solutions for steam users.

The integration of steam with digitalisation elements such as advanced control systems, artificial intelligence, and data analytics further amplifies its relevance in today's industrial landscape.

Beyond traditional uses, steam's potential is vast. For instance, its role in hydrogen production showcases its adaptability to emerging energy needs.

The technology is not limited to industrial sectors alone; its adaptability extends to urban planning, where it can be seamlessly integrated into heating and cooling systems, offering efficient energy solutions for cities and urban areas.

Additionally, steam is key to turning greenhouse gases into useful products. The growing use of hydro-treated vegetable oil (HVO) as a man-made fuel shows how important steam is in today's green fuel production.

Steam's significance in the age of net zero production is not merely as an energy source of yesteryear, but as a dynamic force propelling innovative solutions for a sustainable future. Its adaptability, efficiency, and integration with cutting-edge technologies make steam an exciting space for both today's industries and tomorrow's sustainable solutions. The versatility of steam When we think about the things that power our industries and daily lives, steam often goes unnoticed.

Yet, as Rebecca shows, steam is everywhere, and plays a big role in many industries and our everyday activities. The lasting importance of steam is what makes it so interesting. It's not simply an age-old technology, it's something that's still very relevant today and will be in the future.

Companies like Spirax Sarco are leading the way in steam technology to increase plant efficiency. They're always looking for new ways to improve and innovate, not just for their products but to help their customers move towards more environmentally friendly production.