Why do it:

Steam systems are energy‑intensive and prone to inefficiencies through losses, poor maintenance, and outdated controls. Upgrading boilers, improving distribution, and adding measures such as condensate recovery, heat recovery, and TDS (Total Dissolved Solids) controls reduces waste, cuts fuel costs, and lowers carbon emissions.

Typical Savings:

• Boiler upgrades (modern high‑efficiency units): 10–20% fuel savings.

• Steam trap monitoring & maintenance: 10–15% savings (failed traps can waste up to 20% of steam).

• Condensate recovery systems: 10–20% savings by reusing hot condensate.

• Pipework insulation upgrades: 5–10% savings.

• Heat recovery (flue gas economisers, blowdown heat recovery): 5–15% savings by reclaiming waste heat.

• TDS controls (automatic blowdown management): 2–5% savings by reducing unnecessary water and energy losses.

• Total potential: 25–45% reduction in steam system energy costs.

• Example: A site spending £200,000 annually on steam could save £50,000–£90,000 per year.

Typical Costs:

• Rule of thumb: £250-£600 per kW (Thermal)

• High‑efficiency industrial boiler: £50,000–£200,000 depending on capacity.

• Steam trap monitoring systems: £200–£500 per trap; £10,000–£20,000 for site‑wide monitoring.

• Condensate recovery units: £10,000–£30,000 per system.

• Pipework insulation upgrades: £5,000–£15,000 per site.

• Heat recovery systems (economisers, blowdown recovery): £10,000–£40,000 depending on scope.

• TDS automatic controls: £3,000–£7,000 per boiler.

• Installation & commissioning: £20,000–£50,000 depending on scope.

• Ongoing costs: £5,000–£15,000 per year (maintenance, trap testing, calibration, controls).