COMMERCIAL HEATING SYSTEMS A multi-solution approach to decarbonisation


The decarbonisation of industrial heating is less about single technologies and more about flexible strategies that balance performance, cost and long-term resilience, says Etienne Fourie.


Etienne Fourie


Technical sales manager for Babcock Wanson UK’s Process Engineering Division


www.babcock-wanson.com A


Left, the EPC EL range of electric thermal fluid heaters from Babcock Wanson


with. Finding a supplier that is able to provide a solution best suited to your needs, rather than a solution that is limited to their product range, is an important consideration. Equally important is the shift in how


s UK industry works toward net-zero targets, many businesses are focusing on one of the most emissions-


intensive areas: process heating. Whether generating steam, hot water or thermal fluids, industrial heating systems are central to production – but also a significant source of carbon emissions. Decarbonising these systems is both a challenge and an opportunity. The technology landscape is expanding, offering electric boilers, heat pumps, hydrogen-ready systems, thermal fluid heating, and advanced energy monitoring. With no single solution for every site, the answer increasingly lies in a flexible, long-term approach tailored to each facility’s realities.


Landscape of technologies For decades, natural gas has dominated industrial heating, valued for affordability, availability and ease of use. Its role is now being re-evaluated in light of decarbonisation goals and evolving energy policy. Many sites are exploring how to diversify or transition away from gas, while managing productivity and economic viability. This often means combining technologies rather than switching entirely. Some businesses introduce electric boilers for variable loads while retaining high-efficiency gas systems for base load. At Babcock Wanson, we offer a full


range of energy-efficient low- and high-voltage electric boilers with precise temperature control. Sales are expected to rise under the UK government’s Industrial Strategy, which includes a Connections Accelerator Service and a British Industrial Competitiveness Scheme to fast-track grid connections and reduce electricity costs for energy-intensive industries. Hybrid solutions that let customers


use the best available energy at any time could be one way forward. Hybrid Condor boilers from Babcock Wanson Group company VKK Standardkessel combine flanged electric heaters with traditional combustion to reduce CO₂ emissions, operate flexibly according to fuel prices, and provide standby capacity.


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Below, the Navinergy digital platform provides constant monitoring of boiler room performance


companies think about performance. Traditionally, energy systems were judged largely by capital cost and reliability. Today, lifecycle impact is becoming the key metric. Businesses are increasingly considering how systems will operate and evolve over 10, 15, or even 20 years. This includes the carbon footprint, maintenance demands, upgrade pathways, and the ability to integrate with future energy sources. Services that support ongoing optimisation – such as remote diagnostics, predictive maintenance, and performance-based service models – are helping industrial sites manage their systems more proactively. Rather than reacting to problems, operators are moving towards continuous improvement, using data to drive decisions and reduce both emissions and operating costs. 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.


Standard Fasel also offers electric


boilers that connect to existing Firetube boilers for a hybrid approach. Other options include thermal fluid systems for tighter process control, and electric thermal oxidisers to treat effluent, VOCs and carbon emissions. Circular economy approaches, such as solvent recovery and enhanced water treatment, reduce water consumption and blowdown losses. For hydrogen- ready applications, operators are specifying compatible equipment now, as the UK aims for 10 GW of clean hydrogen by 2030, scaling to 250 to 460 TWh by 2050.


Make do and mend Many businesses are starting by optimising existing systems. Enhancements such as heat recovery, real-time monitoring, and smart controls can significantly reduce energy use and emissions, often without major infrastructure changes. Waste heat recovery using flue gas and condensing economisers reduces a site’s carbon footprint, as each kW of recovered heat is a kW not fired. Economisers are heat


exchange devices that extract residual heat from exhaust gases generated by combustion. This heat is typically returned to the process, often via boiler feedwater, optimising plant efficiency in a compact and cost-effective way. Different economisers suit a wide


range of processes and site needs. Our R-Eco solution, for example, is a combustion air preheater that uses flue gas recirculation to increase boiler efficiency up to 98% while also reducing NOx production. These ‘quick wins’ can pave the


way for deeper decarbonisation later, by improving system visibility and informing smarter investment decisions.


Complex sites This kind of blended strategy recognises that every industrial site has unique constraints and opportunities. Space availability, electrical supply capacity, process demands and capital budgets all shape what’s feasible in the near term. Flexibility – both in technology and in planning – is essential for progress, as is selecting the right partners to work


Skills and sustainability The drive toward decarbonisation is also reshaping the industrial workforce. As experienced engineers retire, companies are facing growing skills gaps – particularly in low-carbon technologies and digital system management. At the same time, younger professionals entering the industry are looking for roles that align with their values and offer opportunities to make a real-world impact. Organisations that can demonstrate a clear commitment to innovation, sustainability, and engineering excellence are increasingly well- placed to attract and retain this next generation. This makes the energy transition not just an environmental or economic issue, but a people one.


An uncertain future Looking ahead, industrial decarbonisation will be a process of continuous change. Businesses that embrace this complexity – and that invest in flexible, informed strategies rather than chasing one-off solutions – will be best equipped to lead the transition. ■


EIBI | FEBRUARY 2026


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