BOILERS, PUMPS & VALVES
reducing fuel consumption and associated emissions. In the case of our R-Eco, the overall efficiency of a boiler can be increased by up to 98 per cent whilst also reducing NOx emissions.
By Etienne Fourie, process engineering department manager, Babcock Wanson UK
build a clearer picture of energy use across the plant. Our Navinergy digital platform, for example, provides 24/7 boiler room performance monitoring alerting users to deviations in equipment operation and water quality enabling them to take action where required. This improved visibility supports more informed long- term investment decisions.
WASTE NOT, WANT NOT
Waste heat recovery is particularly valuable. By installing flue gas economisers or condensing heat exchangers, sites can capture exhaust gas energy generated by the combustion process that would otherwise be lost and feed it back into the process,
But it’s not just heat that can be recovered. Solvent recovery systems, such as those manufactured by DCT, allow for a very high level of purity for the recovered solvents to then be reused in production. These interventions are often described as “no-regrets” actions because they typically deliver both carbon and cost savings while preparing the system for deeper decarbonisation later.
ELECTRIFICATION AND THE ROLE OF HYBRID SYSTEMS
Electrification is widely recognised as a key route to industrial decarbonisation, particularly for low and medium temperature processes. Technologies such as electric boilers and thermal fluid heaters, resistance heating and heat pumps are already technically capable of meeting a large proportion of industrial heat demand, although the most challenging applications remain at very high temperatures. However, full electrification is not always immediately feasible. Many sites face constraints including limited grid capacity, high peak electrical loads, space constraints in existing boiler houses, capital budget pressures, and concerns around operational resilience.
Electricity pricing also remains a major factor, recognised in the Autumn Budget 2025, which confirmed that the existing British Industry Supercharger scheme, which provides relief on network charges for heavy electricity users, will see the discount increase from 60 per cent to 90 per cent. Furthermore, a new British Industrial Competitiveness Scheme (BICS) is planned for launch in 2027 which aims to reduce electricity costs for eligible energy intensive and manufacturing firms by roughly £35-40 per MWh. As a result, a growing number of operators are adopting phased electrification strategies that introduce electric capacity alongside existing
UKManufacturing Summer 2026
combustion plant, often in the form of hybridised systems. Rather than replacing working assets, hybrid systems allow electric and fuel-fired technologies to operate in parallel, giving operators flexibility over how process heat is generated.
For example, our Hybrid Add-on electric boiler is designed to integrate quickly and seamlessly with existing gas or oil fired steam boilers, with minimal integration requirements. Developed by Standard Fasel, part of the Babcock Wanson Group, the modular low-voltage Hybrid Add-on boiler connects directly into an existing installation, providing additional steam capacity using electricity. By allowing operators to switch flexibly between fuel and electricity depending on energy prices and availability, the system supports resilience in an increasingly complex energy landscape. It can also utilise periods of surplus renewable electricity, helping organisations align with sustainability targets while contributing to smarter energy use.
BUILDING A PRACTICAL ROADMAP In practice, the most successful decarbonisation programmes tend to follow a staged pathway to reduce risk, spread capital expenditure and maintain operational continuity - all critical considerations for manufacturing environments where downtime is costly. Initially, sites focus on optimising what they already have, capturing quick efficiency wins and improving data visibility. The next phase typically involves introducing flexible low-carbon technologies, such as electric steam generation operating alongside existing assets, rather than wholesale replacement. Over time, as infrastructure, economics and policy evolve, sites can move toward deeper electrification or alternative fuels where these make technical and commercial sense. For operators navigating an uncertain energy landscape, flexibility, system thinking and this careful staging are key.
Babcock Wanson
www.babcock-wanson.com
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