Exploiting excess steam production for power generation of around 200 megawatts (MW) or less (dubbed industrial-scale steam turbine solutions) is more viable and attractive.

Industries—including pulp and paper, sugar, and petrochemicals—are utilising on-site steam to generate electricity. They are improving operational efficiency, reducing costs, and may even establish future revenue streams.

Yet, the journey to generating power from industrial steam turbines requires certainty and reliability, prompting original equipment manufacturers (OEMs) of steam turbines and accessories to invest in their value chains.

From steam to electricity

Steam is a staple industrial energy source that companies can use to drive systems such as blowers, mixers, and shredders. However, the ability to generate electricity is encouraging wider adoption and support of industrial steam turbines. Industrial sites are achieving energy self-sufficiency, reducing reliance on public grids, and mitigating the impact of fluctuating electricity prices.

To generate electricity from steam, companies use turbo-alternator systems. The turbine extracts thermal energy from pressurised steam, rotating a shaft coupled to an alternator which converts the mechanical energy into electricity.

Companies enhance established steam turbines with gearboxes and turbo-alternators, producing electricity or direct motor power. The long-term gains are considerable if the turbine has reliable access to support, maintenance services, and parts.

"Companies want access to the right design, installation, support, and maintenance services—then the return on investment looks good," says Alastair Gerrard, WEG Africa's Executive for Energy Systems. "WEG's capabilities in Africa to support steam turbines are making such energy investments much more viable, especially among mines, manufacturers, and the pulp and sugar industries that have turbine footprints or see the value of installing steam turbines."

Supporting steam generation's growth

The bulk of the steam energy market is still in utility-scale systems typically found at major power stations. However, industrial steam systems producing around 200 MW and less represent the fastest-growing steam turbine segment.

Two major factors underpin this momentum. The market has improved industrial steam turbine technologies, particularly integrated and smart solutions that incorporate turbogenerator sets, turbo gearboxes, panels, substations, and accessories.

Robust support systems play a significant role. Steam turbines require specialised expertise for scoping, designing, and maintenance. African companies are particularly reliant on imports, raising costs and dependency.

This situation has prompted companies with African customers to build stronger local value chains that ensure seamless operation and affordability, says Gerrard.

"Owners increasingly seek simplified servicing, ideally from a single and reliable provider. WEG responds to this demand by bolstering our manufacturing, assembly, parts, and service capabilities, providing comprehensive support throughout the lifecycle of steam turbine systems. The goal is to bring costs and complexity down by providing everything under one roof or through a closely-knit partnership network."

Creating circular gains

Steam turbines also help industries develop their circular economies, eliminating waste and adopting sustainable energy practices that significantly lower their environmental impact.

The ability to generate excess power can open up new revenue generation possibilities. For example,numerous sugar mills in Brazil generate 100% of their energy production through steam turbines and sell their excess energy back to the grid. In several cases, the revenue from energy sales is larger than their staples of sugar and bioethanol.

Local energy regulations are adapting to such possibilities, creating future potential for a similar business model in South Africa and other sub-Saharan African nations.

Harnessing steam for on-site electricity creates immediate savings and establishes a potential long-term investment in new revenue streams. OEMs with robust manufacturing and comprehensive service support are making steam turbine technology more accessible and reliable, helping industrial companies improve their energy security.

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