Decarbonise Process Heat Without Compromising Safety
Heat integration, steam optimisation and electrification programmes engineered for ATEX environments and continuous operations. Independent engineering, with results verified to IPMVP.
What Makes This Sector Different
Chemical sites live and die by process heat, and the verified numbers explain why.
Why Chemical Sites Are Hard To Decarbonise
Six problems we hear in almost every first conversation with a chemical site.
Process heat is hard to abate
Gas is still cheaper than power per unit of heat on most grids, so a one for one fuel switch rarely passes the board. The viable route is engineering: cut the demand first, then electrify the loads where heat pump economics actually work.
ATEX zoning complicates every retrofit
Every new exchanger, drive or heat pump has to respect the site's hazardous area classification. That means certified equipment, ignition risk assessments and permit to work overhead that generic advisers consistently underestimate.
EU ETS exposure compounds the energy bill
Allowances averaged around €65 per tonne in 2024, and the cap is tightening towards a 62% cut by 2030 against 2005. Every wasted megawatt hour now carries a carbon cost on top of the fuel cost.
Distillation columns run far from optimal
Commercial columns typically operate at under 10% thermodynamic efficiency, and reboilers are usually the largest single steam consumers on site. Reflux ratios, pressures and control settings drift over years of campaign changes, and nobody has time to chase them.
Ageing steam and condensate systems
Failed traps, missing insulation and dumped condensate quietly burn boiler fuel all year. US DOE assessment experience puts typical steam system savings at 10 to 15%, much of it with paybacks under a year.
Electrification cases stall without engineering
Corporate wants a net zero trajectory; the site team knows the constraints. Without temperature band heat mapping and engineering grade feasibility, the business case never leaves the slide deck.
What We Engineer In Your Plant
This is where strategic advisers stop and engineers begin: the sub systems on a chemical site where the energy actually moves.
Process heat integration and pinch analysis
We build the site's hot and cold composite curves, set a realistic minimum approach temperature, and redesign the exchanger network so heat currently rejected to cooling water preheats feed instead.
Steam generation and distribution
We tune boiler combustion and O2 trim, fit economisers and blowdown heat recovery, rationalise header pressures and replace letdown valves with backpressure turbines where the flows justify it.
Condensate and flash steam recovery
We raise condensate return rates and recover flash steam to the low pressure header, measures that commonly cut boiler fuel by 5 to 10%.
Distillation column optimisation
We optimise reflux ratio, column pressure and feed preheat and apply advanced process control, which credibly cuts an individual column's reboiler duty by 5 to 15%.
Mechanical vapour recompression and heat pump assisted distillation
We retrofit MVR to evaporators, strippers and close boiling splits, where recompressing overhead vapour to drive the reboiler can cut that duty's primary energy by half or more.
Electrification of low and mid temperature heat
We map heat demand by temperature band and design heat pump and electrode boiler conversions for loads below 200 °C, the band where roughly 30% of sector process heat sits.
Cooling towers and chilled water plant
We optimise condenser water temperatures, fan and pump control and chiller staging so the cold side of the plant stops quietly eroding the power bill.
ATEX compliant project delivery
We engineer every measure against the site's hazardous area classification, specify certified equipment, and deliver construction inside your permit to work and management of change systems.
How The Work Gets Done
Every engagement follows the same engineering discipline, whatever the sector.
Discover
Audits, assessments and baseline development that establish what actually drives your energy cost and carbon.
Design
Feasibility, concept design, modelling and the business case that turns an opportunity into a fundable project.
Deliver
Tendering, procurement, engineering design, delivery and commissioning, around production rather than in spite of it.
Manage
Continuous improvement and verified performance, so the gains are still there years later.
Proof, Not Promises
Anonymised case studies, real engineering measures, results verified to IPMVP.
Frequently Asked Questions
How do you deliver projects in ATEX zones?
We engineer for the zone from concept stage. Hazardous area classification drawings sit on the table during option screening, equipment is specified to the relevant ATEX category, and we locate heat pumps, electrode boilers and switchgear outside zoned areas wherever the hydraulics allow. Ignition risk assessment is part of design review, construction runs inside your permit to work and management of change systems, and tie-ins are sequenced into planned turnaround windows. Our delivery teams work on Seveso establishments routinely.
Is electrification viable at current power prices?
For some loads, yes, and the engineering tells you which. A heat pump turning one unit of electricity into three or more of heat only needs power to cost less than roughly three times your effective gas plus carbon price. With EU allowances averaging around €65 per tonne in 2024, carbon increasingly tips the balance for loads below 200 °C. We model your actual tariffs, run the sensitivities and tell you plainly which conversions pay and which should wait.
What does a pinch study involve?
We extract stream data from your DCS and heat and material balances, build hot and cold composite curves for the site, and set energy targets against a realistic minimum approach temperature. The output is not a chart; it is a ranked list of exchanger network changes, feed preheat opportunities and utility savings, each costed and sequenced into your turnaround calendar. On most continuous chemical plants the study takes a few weeks and pays for itself in the first project.
Start With An Engineering-Grade Audit
Bring us a year of steam data, your ETS returns and your hardest column. We will come back with an engineered plan and numbers you can verify.
