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Steam System Sustainability
Efficient Steam Solutions
The Force Group understand the critical role that steam systems play in various industries and the importance of designing these systems with sustainability at their core. Our mission is to create efficient, reliable, and environmentally friendly steam solutions that help our clients achieve their sustainability goals while optimising performance and cost-efficiency.
The Importance of Sustainability
Net Zero
Improving energy efficiency is a vital step towards achieving the UK's Net Zero goals. However, to meet these ambitious targets, we need to accelerate our efforts and make significant strides in sustainability.
By 2050, the UK is legally required to have reduced
its greenhouse gas emissions by 100% from 1990 levels.
Climate Change
In 2022, the UK experienced its highest temperature on record, reaching 40.3°C. The Met Office has warned that such extreme temperatures are likely to become more common due to climate change. Just a year later, 2023 marked the UK's second-hottest year on record.
It's not just the heat that's concerning. From October 2023 to March 2024, the UK and Ireland were hit by a series of violent storms and heavy rainfall. The Met Office predicts that these severe weather events will become more frequent and intense. There are only a few years left to avert the most severe impacts of climate change.
Decarbonisation
The industrial sector is known for its complex requirements and is now prioritising the decarbonisation of process heat as a matter of urgency.
Decarbonisation involves taking steps to reduce carbon emissions, like
carbon dioxide (CO2) and methane (CH4) to reduce the impact on the climate.
Historically, most industrial plants have depended on fossil fuels for thermal energy, as they are cost-effective, easy to store and provide the required steam needed for industrial processes. Alternative energy options have struggled to compete in these areas, until recently. However, the rapid growth of renewable energy sources is transforming the landscape. Renewable energy is becoming increasingly viable, offering new opportunities for industries to move away from fossil fuels while maintaining efficiency and reliability.
Switch to Clean and Renewable Energy in Steam Generation
In the pursuit of a sustainable and eco-friendly future, switching to clean and renewable energy sources is a must.
Improve Energy Efficiency in Steam Generation Systems
Steam generation plays a crucial role in various industries including healthcare, food and beverage, pharmaceuticals, and chemicals. Historically, steam generation has heavily relied on fossil fuels, resulting in substantial environmental impact and carbon emissions. By adopting sustainable practices in steam generation, we can significantly reduce greenhouse gas emissions, improve energy efficiency, and pave the way for a greener and more sustainable world.
Enhancing energy efficiency in steam generation systems is crucial for sustainable operations. By adopting energy-saving practices and advanced technologies, it is possible to make significant reductions in energy waste, and the overall systems performance can be enhanced.
Implementing the following strategies supports environmental sustainability and improves the economic viability of steam generation operations.
- High-efficiency boilers: Upgrading to modern, well-maintained boilers, with advanced combustion and heat transfer technologies, will enhance energy efficiency and lower fuel consumption.
- Waste heat recovery: Utilising waste heat from steam generation processes allows for preheating feedwater, generating additional steam, or providing heat for other operations. This approach maximises energy utilisation and minimises waste, contributing to sustainable practices.
Enhance Sustainability with Combined Heat and Power (CHP) systems
Combined Heat and Power (CHP) systems, or cogeneration systems, offer an efficient and sustainable solution for steam generation. By producing electricity and useful heat from a single fuel source, CHP systems enhance energy efficiency and reduce greenhouse gas emissions.
Benefits of CHP systems:
- Higher energy efficiency: Captures and utilises waste heat, significantly increasing efficiency.
- Reduced emissions: Lower fuel consumption results in fewer greenhouse gas emissions.
- Versatile applications: Ideal for various industries by generating electricity and harnessing waste heat.
- Economic advantages: Optimizes energy use, reducing operational costs.
How we help CHP System Providers
We collaborate with CHP system providers, offering services in:
- Pipeline layout and design
- Boiler feed tank systems
- Steam distribution control valves
- Pipeline ancillaries
- Steam trapping and condensate recovery
- Heat recovery packages
Implementing CHP systems not only supports sustainability but also enhances operational efficiency and cost savings.
Carbon Capture and Storage (CCS)
Carbon Capture and Storage (CCS) technology can help reduce or remove carbon emissions in areas where fossil fuels are still used for steam generation. CCS involves capturing CO2 emissions from steam generation processes and storing them underground, preventing them from entering the atmosphere and contributing to climate change. This technology prevents 90% of the carbon dioxide emissions from fossil fuels from entering the atmosphere.
How we can help with CCS
We can work alongside EPC contractors installing Carbon capture plants providing specialist knowledge on process control valves, such as high-performance butterfly valves, ball segment control valves, globe control valves and actuation for various media, steam de-superheating baths are often required for these processes, as well as steam and liquid drain traps.
Helping you on the Road to Net Zero
We can help you can optimise your energy recovery processes and achieve substantial efficiency gains throughout your steam system.
- Enhance your supply chain: We add significant value to your supply chain, starting with an initial energy recovery audit to identify key areas for improvement and delivers quick wins.
- Optimise steam plant operations: We evaluate the operation of steam-raising plants, focusing on heat recovery, Total Dissolved Solids (TDS) control, boiler flue economisers, and Hotwell steam injectors. These factors significantly impact gas consumption.
- Streamline steam distribution: Our assessments extend to steam distribution, where we examine valve stem leaks, conduct comprehensive steam trap surveys and analyses, and evaluate valve and pipe insulation.
- Specialised plant room audits: Our audits focus on efficient condensate recovery and ensure condensate pump sets operate correctly to avoid live steam losses.
- Advanced heat exchange technology: We analyse heat exchange technology, including non-storage and storage calorifiers, to identify opportunities for upgrading to compact plate heat exchanger technologies, often leading to significant savings and reductions.
Is your Steam Plant Energy Efficient?
Your plant may be operating smoothly and at peak productivity, but are you grasping all opportunities to optimise your steam system's energy efficiency? If not, The Force Group can help.
We specialise in transforming steam systems to meet energy efficiency targets while maintaining top performance and safety standards. The Force Group can help to significantly reduce your carbon footprint and transform steam generation into a cleaner, more environmentally friendly process.
Partner with The Force Group and together we can create a sustainable steam system for the future.
Steam System Audits
A comprehensive steam system audit uncovers opportunities to enhance process efficiency, energy efficiency, and productivity. These benefits make a strong case for investing in a thorough review of your steam system.
Our steam system audit will help you to manage your steam system’s health. Our engineers will work with you to evaluate all aspects of your system, from the boilerhouse to distribution and condensate return. Our assessment provides a roadmap for future improvements by identifying potential energy-saving and energy-recovery opportunities within your processes.
Steam Trap Surveys
A steam trap survey can uncover opportunities to recover and reuse residual energy, therefore enhancing the performance of your steam system.
Steam traps are essential for efficient temperature control, heat transfer, and condensate removal. Regular maintenance ensures your system runs smoothly, saving energy and improving efficiency.
Our engineers will help to manage and monitor your steam traps, ensuring optimal performance tailored to your needs.
Ongoing Monitoring and Optimisation
Continual monitoring, analysis, and optimisation of steam generation processes are essential for maintaining efficiency and pinpointing areas for improvement. Advanced monitoring systems and predictive analytics can detect inefficient areas, enhance operations, and reduce downtime, allowing for a more sustainable steam generation practice. Harness the power of continuous monitoring and optimisation for a cleaner, more sustainable future.
Benefits of continuous monitoring and optimisation:
- Peak Efficiency: Ensures steam generation processes operate at their highest efficiency.
- Sustainability: Supports cleaner and more sustainable steam generation for future generations.
Our expertise:
- Comprehensive support: Our team of experts can assist with data capture and flow metering requirements, ensuring optimal performance.
Sustainability by Sector
The food and drink sector aim to be net zero by 2050
According to a 2021 study published in Nature Food, the food and drink sector accounts for up to one-third of global greenhouse gas emissions. This industry is also highly vulnerable to increased crop failures due to extreme weather.
The UK's food and beverage industry has made progress in decarbonising, with a report noting a 16% reduction in greenhouse gases between 2015 and 2019. However, there’s still a long way to go.
In November 2022, the UK joined the Net Zero Government Initiative as a partner and signatory, committing to achieving Net Zero by 2050, with an interim target, including a 68% reduction in emissions by 2030 compared to 1990 levels.
NHS aim to be net zero by 2045
In October 2020, the NHS became the world’s first health service to commit to reach net zero carbon emissions. Their vision is: to deliver the world’s first net zero health service and respond to climate change, improving health now and for future generations.
The NHS have set two targets:
- For the emissions we control directly (the NHS Carbon Footprint), we will reach net zero by 2040, with an ambition to reach an 80% reduction by 2028 to 2032.
- For the emissions we can influence (our NHS Carbon Footprint Plus), we will reach net zero by 2045, with an ambition to reach an 80% reduction by 2036 to 2039.
“We can’t reach this goal alone. Building a greener NHS will require the support of all 1.3 million NHS people, its partners, and suppliers”.