By Gary Shepherd, Managing Director.
Sustainability is no longer a distant target; it’s a daily operational priority. For industrial sectors where steam is integral to production, the journey to net zero must start by rethinking how we generate, manage and conserve this critical utility. We believe in practical engineering that delivers real-world impact. Decarbonising steam systems isn’t just a future aspiration; we’re already tackling it today.
The role of steam in a net zero landscape
Steam remains indispensable across many sectors including food and beverage, pharmaceuticals, manufacturing and energy. It’s reliable, efficient at transferring heat, and deeply embedded in existing infrastructure. However, it also presents a significant carbon challenge, and we must evolve how we produce and use it.
The electrification of boilers, the adoption of hydrogen-ready systems, and the integration of renewable energy into steam generation are becoming more viable. However, widespread adoption will take time, especially given the capital costs and complexity of retrofitting. That’s why a pragmatic approach is essential: act now where you can, while planning for the longer-term transition.
What’s possible today?
Decarbonisation starts with visibility and control. Modern steam systems equipped with intelligent monitoring tools can identify inefficiencies that were invisible just a few years ago. High-efficiency boilers, economisers and condensate recovery systems are already delivering measurable emissions reductions across industries.
We regularly help clients to upgrade outdated systems with high-performance alternatives that yield lower energy costs and smaller carbon footprints. Whether it’s switching to modulating burners or improving insulation on steam lines, the gains add up fast. And these aren’t futuristic solutions; they’re commercially available, proven technologies that offer quick ROI.
Heat recovery: sustainable engineering that pays for itself
One of the most underutilised opportunities in steam systems is heat recovery. In a typical process plant, vast amounts of energy go to waste through hot condensate, vented flash steam and flue gases. Capturing that lost energy through heat exchangers, flash steam vessels and recovery loops can slash both fuel consumption and CO₂ emissions.
We’ve seen clients reduce their boiler fuel needs by up to 15% simply by optimising condensate return systems and integrating heat recovery. These improvements not only reduce environmental impact but also build long-term operational resilience. As energy prices remain volatile, efficient use of what you already produce is the most sustainable and financially sound choice.
The hidden cost of steam leaks
In our work, one of the most common and costly issues we encounter is steam leakage. It’s often overlooked because the losses are incremental, but collectively they amount to significant energy and financial waste. A single small trap leaking or passing steam can waste thousands of pounds a year in energy alone. Multiply that by dozens or hundreds of traps and valves across a facility, and the cumulative cost is staggering.
Routine steam trap surveys and system audits are low-cost interventions with high-impact returns. Replacing failed traps, fixing insulation and addressing leaks isn’t glamorous engineering, but it’s the kind that delivers immediate value – environmentally and economically. It’s also a tangible step on the net zero journey.
Pragmatic engineering: a pathway to progress
At James Ramsay, we believe the journey to net zero doesn’t start with sweeping reinvention – it starts with smarter use of what you already have. Steam will continue to play a crucial role in industrial heat for years to come. The challenge is not to eliminate it, but to decarbonise it with intelligent, incremental improvements.
By focusing on practical engineering, whether that’s heat recovery, leak prevention or system modernisation, we help clients reduce emissions without disrupting operations. These are the kind of sustainable improvements that align with today’s business realities: targeted, cost-effective and deliverable.
Looking ahead
The future will no doubt bring transformative technologies – hydrogen boilers, carbon capture, smart thermal networks – but we don’t need to wait for them to start making progress. The tools for real change are already at our fingertips.
Decarbonising steam isn’t just possible, it’s essential. And the path forward is not paved with idealism but with informed, actionable engineering. Let’s get to work.
