Harnessing Renewables for Steam Systems

An eBook by Spirax Sarco UK & Ireland

Contents

1. Introduction
2. Why Steam Still Matters in a Low-Carbon Future
3. The Role of Renewables in Modern Steam Generation
4. Exploring Hybrid Steam Solutions
5. Overcoming Practical Challenges
6. Real-World Opportunities
7. Where to Start
8. Final Thoughts

1. Introduction

As the global energy landscape shifts, industries are under more pressure than ever to decarbonise but without compromising performance, uptime, or reliability.

For organisations that rely on steam, this presents a specific challenge: how do you reduce carbon emissions from a system that has, for good reason, stood the test of time?

At Spirax Sarco, we believe the answer lies not in discarding steam, but in improving how it's generated, managed, and integrated with cleaner energy sources. By combining steam with renewable technologies, and embracing hybrid solutions, businesses can unlock meaningful sustainability gains without starting from scratch.

This eBook explores how steam systems can work together with renewables to support a net-zero future.

2. Why Steam Still Matters in a Low-Carbon Future

Steam remains one of the most effective ways to deliver heat. It's consistent, controllable, and able to serve multiple loads across a plant. It’s also inherently efficient particularly when it's well-managed.

The idea that all steam must be phased out to hit carbon targets is not only unrealistic it’s also unnecessary. Steam systems can be part of the solution, not the problem.

The key lies in how we generate the steam and how that energy fits into a broader, cleaner strategy.

3. The Role of Renewables in Modern Steam Generation

There are several viable routes to integrating renewables into your steam system, and many sites are already further along than they think. Here are the most common:

a) Electrification with Renewable Power

Switching to electrically powered boilers particularly when paired with on-site or purchased renewable electricity is a straightforward way to cut Scope 1 emissions dramatically.

Electric steam boilers:

• Require no combustion
• Offer fast response times
• Are ideal for smaller or decentralised loads
• Have lower maintenance needs compared to traditional gas-fired boilers

When powered by renewables (e.g., solar PV or green grid electricity), they provide a genuinely low-carbon route to steam.

b) Solar Thermal and Biomass Preheating

While full steam generation using solar or biomass is more complex, many sites are using these systems to preheat feedwater or reduce the load on existing boilers.

Solar thermal can provide warm water for condensate return systems or boiler makeup, reducing energy input. Biomass systems can be incorporated for baseload or supplementary heating.

4. Exploring Hybrid Steam Solutions

For many organisations, a fully electric or renewable solution isn’t practical on day one and that’s where hybrid systems offer real value.

What is a hybrid steam system?

A hybrid system combines traditional boiler capacity (usually natural gas or LPG) with electric or renewable-powered alternatives. The system can switch between or balance sources based on:

• Energy costs
• Site demand
• Carbon reduction goals
• Available renewable supply

Benefits include:

• Flexibility to adapt to changing energy prices or carbon pricing
• Lower capital costs compared to full system replacement
• Resilience – keeping gas-fired capacity as a backup
• Measurable emissions reductions, especially during low-demand periods

Hybrid systems allow steam users to move forward in stages, rather than waiting for a wholesale infrastructure shift.

5. Overcoming Practical Challenges

Renewable integration is achievable, but not without its hurdles. Common challenges include:

• Space constraints for new equipment (e.g., electric boilers, solar arrays)
• Grid capacity limits for all-electric conversions
• CAPEX pressures during transition planning
• Lack of clarity on payback periods and funding mechanisms

At Spirax Sarco, we work closely with customers to develop transition plans that suit real-world sites, budgets, and timescales. Whether it’s modular installations, load sharing strategies or grant support, there’s often more room to manoeuvre than you might think.

6. Real-World Opportunities

There’s no one-size-fits-all solution, but plenty of starting points.

Here are a few examples of where renewable or hybrid solutions have worked well:

Healthcare Sector

Switching sterilisation and heating loads to electric boilers during off-peak hours, powered by green grid electricity, while retaining gas-fired units for high-demand periods.

Food & Beverage Plants

Integrating electric steam boilers for CIP (clean-in-place) processes, reducing boiler cycling and energy waste.

Pharmaceutical Manufacturing

Using biomass to preheat water and reduce the primary steam load, a measurable reduction in fuel use with minimal process impact.

Universities and Research Facilities

Implementing small electric boilers alongside legacy systems to reduce emissions from campus heat networks.

7. Where to Start

Every site is different, but the first steps are often the same:

1. Audit Your Steam System
   Understand your current usage, emissions profile, and system layout.
2. Explore Load Matching
   Identify smaller loads that could be electrified easily, e.g., washdown stations, autoclaves, lab equipment.
3. Consider Phased Upgrades
   Begin with pilot areas and build out once performance and savings are proven.
4. Tap Into Expertise
   Bring in a partner with both steam and sustainability knowledge, like Spirax Sarco.
5. Look for Funding and Policy Incentives
   Grants and carbon schemes may support the case for hybrid or electric steam.

8. Final Thoughts

There’s no need to choose between steam and sustainability.

By integrating renewable technologies and adopting hybrid systems, businesses can reduce emissions, control energy costs and take meaningful steps towards net-zero — all while maintaining the performance and reliability that steam is known for.

At Spirax Sarco, we don’t believe in a one-track solution.
We believe in practical, engineered answers to real operational challenges. And that’s what renewable steam integration is all about.

Want to know what a hybrid or renewable-ready steam system could look like for your site?
Let’s start the conversation. Our engineers are here to help you take the next step.