BOILERS, PUMPS & VALVES
EFFECTIVE APPROACHES TO DECARBONISE EXISTING INDUSTRIAL PLANT
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cross UK manufacturing and processing sectors, the pressure to decarbonise is intensifying. Make UK’s ‘Manufacturing A Sustainable Future: Capitalising on Green Technologies’ report released in October 2025, reveals that 83 per cent of UK manufacturers are very or fairly likely to build green technology into their business plans over the next five years. This includes sustainable technologies that enable emissions reductions through productivity gains, energy efficiency, clean power, innovation, digitalisation and circular economy principles.
As one of the most emissions-intensive parts of manufacturing, thermal processes are increasingly being scrutinised. Yet, while the ambition to decarbonise is clear, the pathway is rarely straightforward.
THE SCALE OF THE INDUSTRIAL HEAT CHALLENGE
Provisional data shows 2024 UK greenhouse gas emissions decreased by 0.5 per cent compared with 2023, with the manufacturing sector seeing the largest emissions decrease among industries, with emissions falling by 7.4 per cent. Whilst this is positive news, progress has been uneven. While electricity generation has decarbonised rapidly, government analysis indicates
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that around half of industrial energy consumption remains fossil-based. The challenge is compounded by the nature of industrial
equipment. Many sites rely on long- life assets that remain operationally sound and economically valuable. Boilers, thermal fluid heaters and steam systems are typically
designed for operating lives measured in decades. It is not uncommon for well-maintained Babcock Wanson systems to run for 30 years or more. From both financial and sustainability perspectives, prematurely scrapping these assets can be difficult to justify.
In this context, the most pragmatic decarbonisation strategies are those that choose incremental, flexible decarbonisation pathways, adapting and optimising existing plant along the way.
START WITH EFFICIENCY: THE LOWEST-RISK CARBON REDUCTION
For many sites, the fastest and most cost-effective carbon savings still come from improving system efficiency. Before considering fuel switching or electrification, operators should ensure existing plant is
performing optimally. Measures such as advanced burner tuning, improved insulation, steam trap maintenance, and optimised blowdown control can deliver meaningful gains with relatively modest capital outlay. Certainly, consider investing in a
modern energy-efficient burner with a high turndown, such as our Modulo+ gas burners which are designed with digital micro-modulation control and specially developed combustion head for a turndown of 12:1. The condition of the water feed cannot be underestimated in efficiency and equipment longevity, so it is vital to use the correct water treatment chemicals. Depending on site water quality and the process at hand, additional measures may prove useful; these include ion exchange softening, thermal degassing (deaeration), and demineralisation by reverse osmosis or by resin exchange. Digital monitoring is also playing a growing role. Real-time performance data and predictive maintenance tools allow operators to identify inefficiencies early, reduce unplanned downtime, and
Summer 2026 UKManufacturing
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