Babcock Wanson UK launches Hybrid Add-on boiler to electrify steam systems without replacing existing plant
Industrial process heating specialist Babcock Wanson UK has launched a new Hybrid Add-on electric boiler to the UK market, designed to integrate seamlessly with existing gas or oil-fired steam boilers and enable industrial operators to electrify their steam systems without making existing assets redundant.
Developed by Standard Fasel, part of the Babcock Wanson Group, the modular low-voltage Hybrid Add-on boiler offers manufacturers and process industry operators a practical and accessible route to industrial electrification. Rather than requiring a complete boiler replacement project, the system connects directly into an existing steam installation, delivering additional steam capacity using electricity while helping to reduce fossil fuel consumption and associated carbon emissions.
The approach is designed to help organisations protect previous capital investment whilst minimising operational disruption and supporting long-term decarbonisation goals. For many industrial sites, replacing an entire steam generation system can be both costly and operationally challenging. The Hybrid Add-on concept instead allows businesses to modernise incrementally and introduce electric steam generation alongside existing infrastructure.
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This flexible approach is particularly relevant for UK manufacturers facing increasing pressure to improve energy efficiency, reduce industrial emissions and align with sustainability and net zero targets. By combining existing boiler assets with electric steam generation capability, operators can begin reducing their environmental impact without compromising operational reliability or production continuity.
Designed for industrial energy flexibility and future proofing
The Hybrid Add-on boiler has been specifically engineered to support long-term future proofing within industrial steam systems. Operators can switch flexibly between fuel and electricity depending on energy pricing, site demand and energy availability, helping businesses respond more effectively to changing market conditions and fluctuating utility costs.
The system can also take advantage of periods where surplus renewable electricity is available, enabling organisations to increase renewable energy usage and support smarter energy management strategies. This capability is becoming increasingly important as UK industry continues to transition towards lower-carbon manufacturing and more flexible energy consumption models.
Available in modular 200 kW, 400 kW and 800 kW versions, the compact Hybrid Add-on units can be connected to a standard 400 V electrical supply. The system also features unlimited turndown, natural circulation with no pumps required and minimal integration requirements, helping simplify installation and reduce engineering complexity.
The compact footprint and modular design enable rapid deployment with limited impact on existing boiler house infrastructure. This helps industrial operators introduce electrification technology with lower implementation risk and reduced downtime compared with full plant replacement projects.
Supporting steam system decarbonisation in UK industry
The launch forms part of Babcock Wanson UK’s wider strategy to support industrial customers through the energy transition using practical engineered solutions that can be integrated into existing process environments.
The Hybrid Add-on boiler complements the company’s broader portfolio of electric boilers and hybrid technologies, reinforcing its position within industrial process heating and steam system decarbonisation. As manufacturers continue to seek realistic pathways towards lower-carbon operation, hybrid steam technologies are expected to play an increasingly important role in balancing sustainability objectives with operational demands.
Industries including food and beverage, pharmaceuticals, chemicals, paper manufacturing and general process industries are all under growing pressure to improve energy performance whilst maintaining production efficiency. Hybrid boiler systems offer a practical route to achieving measurable emissions reductions without the financial and operational challenges associated with completely replacing existing steam infrastructure.
“With many industrial sites, the challenge is not a lack of ambition around decarbonisation, but the fear of stranding valuable assets,” said Etienne Fourie, Technical Sales Manager for Babcock Wanson UK’s Process Engineering Division. “The Hybrid Add-on boiler addresses this directly. It enables businesses to electrify their steam systems in a pragmatic way, reducing emissions today while keeping their existing equipment productive and future-ready.”
Hybrid Add-on boiler availability in the UK
The new Hybrid Add-on boiler is now available in the UK through Babcock Wanson UK. For more information and a copy of the latest brochure, contact Etienne Fourie at Babcock Wanson on efourie@babcock-wanson.com or on +44 (0)20 8953 7111.
