Whilst the domestic transport sector remains the largest emitting sector in the UK, industry accounted for 13.7%. The drive to decarbonise industry is therefore understandably a high priority, especially when considering decarbonising industrial thermal processes.
Also read: £400,000 Funding for Graphene-Concrete Decarbonisation
Progress Toward Net Zero and Emission Reductions in the UK
According to the Climate Change Committee’s (CCC) ‘2024 Progress Report to Parliament’, UK GHG emissions were 423.3 MtCO2e in 2023, which is 49.5% lower than in 1990. Much of the progress to date has come from phasing out coal-generated electricity and, most recently from a fall in emissions from the iron and steel sector.
While this is a positive move toward net zero, it’s not nearly enough to get us over the finishing line. The government’s Review of Energy Policy 2024 states that 50% of industrial energy consumption is still provided by fossil fuels. The CCC estimates that only a third of the emissions reductions required to achieve the 2030 target – let alone 2050 – are covered by credible plans, and that action is needed to rapidly reduce oil and gas use, with low-carbon technologies becoming the norm.
The Role of Thermal Processes in Industry
Virtually all industrial processes require varying levels of heat. In the UK, the primary energy sources have been coal-generated electricity and gas. Moving to alternate fuel sources isn’t a case of simply switching off one supply for another. Equipment such as boilers and burners are mostly designed to work with one specific energy source, although dual fuel burners are becoming increasingly popular. Changes may also be required to wider facilities and operations. Furthermore, industrial assets are designed to have long lifetimes and are infrequently replaced. Babcock Wanson thermal fluid heaters, for example, frequently run for 30 or more years, although we are still servicing heaters that are more than 40 years old!
Decarbonising Light Industry vs. Hard-to-Abate Sectors
From a technological aspect, decarbonising industrial thermal processes in light industry is easier due to the lower temperature requirements (below 400°C). The main challenges here are the widespread distribution of sites, which requires suitable energy infrastructure to be in place, and the challenge of scaling up clean technologies.
In hard-to-abate industries, the challenges are more numerous and pronounced, especially in the upper half of the temperature range (>1000°C), where low-carbon technologies for many processes are still under development or too expensive to make commercial sense.
Challenges with Alternate Fuel Sources
Electrification of Industrial Heating Systems
The three key low-carbon fuel sources – electricity, biofuel, and hydrogen – that form the primary focus of a move away from fossil fuels, all present their own challenges, but these are not insurmountable. Decarbonising industrial thermal processes in light industry is by far the easiest to electrify. Heat pumps, resistance heaters, electric boilers, and combinations offer an efficient way to provide a wide range of temperatures for both direct and indirect heating using steam. Cost and infrastructure are the main obstacles to achieving electrification.
In the Net Zero Emissions by 2050 Scenario (NZE Scenario), the electrification of heating applications will see a 45% rise in electricity consumption in light industry alone by 2030. However, the UK electric grid is not in a position to handle this amount of energy or transmit enough electricity to every place that needs it.
Challenges in High-Temperature Processes and Hard-to-Abate Sectors
In hard-to-abate sectors, the NZE Scenario aims to significantly increase industrial electrification, with a projected 38% rise in electricity consumption by 2030. This will not be easy as the high-temperature heat requirements pose significant challenges. Available options include electromagnetic heating technologies, resistance heaters, and electric arc furnaces, but these need to be adapted to cater to specific applications; there is no one-size-fits-all solution. Furthermore, direct electrification technologies for many industrial processes are still in early stages of development.
Policy Support and the Role of Government in Decarbonisation
Policy mechanisms and support play a crucial role in encouraging industry to transition to electric systems, as does electricity pricing, which currently makes for higher operating costs compared to gas. The UK Government has rolled out the British Industry Supercharger scheme, which reduces electricity prices for some large industrial users, and has committed to the wider rebalancing of electricity and gas charges, although details have yet to be announced.
Hydrogen and Biofuels in the Transition to Net Zero
Much talk has been given to hydrogen as a successor to gas, and whilst it’s necessary as part of the decarbonisation pathway for hard-to-abate industries, hydrogen is not a direct replacement for natural gas. Hydrogen has different attributes and needs to be handled differently, meaning tanks, fuel lines, and burners must be adapted or, more likely, replaced. This adds to the cost of transition, which is already considerable when you factor in energy losses from production and transport. Hydrogen combustion also has an increased tendency to form harmful NOx gases – something we have spent years trying to reduce.
Lastly, we come to biofuels. On a positive note, biofuels are largely compatible with existing infrastructure, but there is limited scope for increasing the scale of biomass production, especially when sustainability is factored in. In the NZE Scenario, bioenergy is predicted to grow from 6% of total energy supply to 13% in 2030, rising to 18% in 2050.
Conclusion: The Future of Decarbonising Industrial Thermal Processes
To reach net zero in 2050, we must make fundamental changes to decarbonise industry by transitioning away from traditional energy sources. The role of governments around the world is critical to this, but industry itself has a part to play. We must ensure we have a versatile technological framework in place that encompasses the development and implementation of those technologies with reduced or no environmental impact, tailored to the specific needs of industrial sectors.
To achieve this, our solutions need to have complementarity and be technologically neutral. Energy transition is only possible on the scale needed by using a mix of technologies to reduce emissions. Adopting an open innovation strategy and fostering collaboration is essential for driving innovation and sustainability. At Babcock Wanson, we are committed to open innovation and have been working with 16 companies as part of the Boiler Ch0C consortium to develop an innovative and optimised solution for carbon-free steam production. Only by embracing innovation and fostering a culture of innovation can we hope to address environmental challenges effectively and secure a sustainable future for generations to come.
