Decarbonizing the Biorefinery: Is an End to Fossil Steam Possible? Discover Sulzer's Solutions

The biorefinery sector stands at a critical crossroads. As the world pushes toward cleaner energy and sustainable production, the reliance on fossil steam in biorefineries presents a significant challenge. Can these facilities truly eliminate fossil steam and move toward full decarbonization? This post explores the possibilities, challenges, and practical solutions, including how Sulzer’s technologies support this transition.

Steam rising from biorefinery equipment at eye level

Why Fossil Steam Remains a Challenge in Biorefineries

Biorefineries convert biomass into fuels, chemicals, and materials, offering a renewable alternative to fossil-based products. However, many still rely on fossil steam—generated by burning coal, natural gas, or oil—to provide the heat and power necessary for processing. This dependence creates a paradox: while the end products are greener, the process itself contributes to carbon emissions.

The reasons fossil steam persists include:

• High energy demand: Steam is essential for heating, drying, and chemical reactions. Biomass alone often cannot meet these energy needs efficiently.

• Infrastructure limitations: Existing plants are designed around fossil fuel boilers, making a switch costly and complex.

• Intermittency of renewable sources: Biomass availability and renewable energy supply can fluctuate, making fossil steam a reliable backup.

  
  

Reducing or eliminating fossil steam requires rethinking energy sources and improving process efficiency.

Alternatives to Fossil Steam in Biorefineries

Several strategies can help biorefineries cut fossil steam use:

1. Biomass-Derived Steam

Using biomass residues or dedicated energy crops to generate steam can close the loop. This approach reduces net carbon emissions since the carbon released was recently captured by plants.

• Example: Some pulp and paper mills use black liquor, a byproduct, to produce steam, cutting fossil fuel use by up to 50%.

• Challenge: Biomass supply must be consistent and sustainable to avoid deforestation or competition with food crops.

  
  

2. Electrification of Heat Processes

Switching from steam to electric heating powered by renewable electricity offers a clean alternative.

• Heat pumps and electric boilers can replace fossil steam in some processes.

• Example: A biorefinery in Scandinavia uses electric steam generation powered by hydropower, achieving near-zero emissions.

  
  

3. Waste Heat Recovery and Process Integration

Improving energy efficiency reduces steam demand.

• Recovering heat from exhaust gases or other process streams can preheat feedstock or generate steam.

• Integrating processes to share heat reduces overall fossil steam needs.

  
  

4. Use of Green Hydrogen

Hydrogen produced from renewable electricity can fuel boilers or turbines, generating steam without carbon emissions.

• This technology is emerging but faces cost and infrastructure hurdles.

  
  

How Sulzer Supports Decarbonization in Biorefineries

Sulzer offers a range of solutions designed to help biorefineries reduce fossil steam use and improve energy efficiency.

Efficient Pumps and Mixers

Sulzer’s pumps and mixers optimize fluid handling and chemical reactions, reducing energy consumption and improving process control. This efficiency lowers steam demand indirectly by making processes more effective.

Heat Transfer Equipment

Sulzer designs heat exchangers that maximize heat recovery and transfer, enabling better use of waste heat and reducing the need for fresh steam generation.

Steam Turbines and Compressors

Sulzer’s steam turbines can operate with biomass-derived steam or green hydrogen, providing flexible power generation options that reduce fossil fuel dependence.

Case Study: Biorefinery Transition in Europe

A European biorefinery partnered with Sulzer to retrofit its steam system. By integrating Sulzer’s heat exchangers and pumps, the plant increased waste heat recovery by 30%, cutting fossil steam use by 25%. The upgrade also improved process stability and reduced maintenance costs.

Practical Steps for Biorefineries to Eliminate Fossil Steam

• Assess current steam usage: Identify where fossil steam is used and how much.

• Evaluate biomass availability: Determine if onsite or nearby biomass can supply steam sustainably.

• Invest in energy efficiency: Upgrade equipment to recover waste heat and reduce steam demand.

• Explore electrification: Consider electric boilers or heat pumps powered by renewables.

• Plan for green hydrogen: Monitor developments and pilot hydrogen-based steam generation.

• Partner with technology providers: Work with companies like Sulzer to implement tailored solutions.

  
  

The Road Ahead

Eliminating fossil steam in biorefineries is challenging but achievable with a combination of strategies. The transition requires investment, innovation, and collaboration. As renewable energy costs fall and technology advances, biorefineries can become truly sustainable, producing green fuels and chemicals without fossil steam.

Sulzer’s expertise and solutions play a vital role in this transformation, helping biorefineries improve efficiency, integrate renewable energy, and reduce emissions.

Explore how Sulzer can support your biorefinery’s decarbonization journey by visiting their solutions page.