Hybrid and Conversion
Energy Systems
Upgrading Industrial Steam, Hot Water & Heating to Lower-Emission Energy
A Practical Pathway to Lower Emission Industrial Energy
Keep the system. Change the energy source.
Many industrial facilities across New Zealand rely on steam and hot water systems to power production, heating, cleaning, and process loads. In many cases, the system itself remains sound but the challenge is the fuel source.
Our hybrid and conversion energy systems help businesses reduce emissions by upgrading the combustion and energy delivery components while retaining valuable existing infrastructure where it makes sense. The result is a practical pathway to modernise your energy system with reduced disruption and improved long‑term flexibility.
What Are Hybrid & Conversion Energy Systems?
Hybrid and conversion systems adapt an existing steam or hot water boiler plant to operate on a different fuel using modern combustion equipment, controls, and safety systems.
A conversion project may include:
- Burner or combustion system replacement / modification
- Fuel handling and storage integration (where required)
- Controls, automation, and safety upgrades
- Flue and emissions considerations
- Integration with existing distribution systems (steam/hot water)
Each system is engineered specifically for the site, considering boiler condition, load profile, fuel strategy, operating hours, and process requirements.
Why Sites Choose Conversion Instead of Full Replacement
Conversion is often considered when businesses want to:
- Reduce emissions without replacing the entire boiler plant
- Extend the life of existing assets
- Avoid unnecessary downtime and high capital spend
- Transition energy sources in stages
- Improve reliability and combustion control
Conversion Pathways
Coal → Biomass Conversion
Convert coal-fired steam and hot water systems to renewable biomass energy
Coal-to-biomass conversion is a strong option when the boiler pressure vessel remains serviceable and the site is suited to biomass fuel logistics. For many ex‑coal plants, existing infrastructure (including ash removal and plant layout) can sometimes be reused or adapted and help reduce project complexity.
Benefits can include:
- Reduced CO₂ emissions compared to coal
- A practical step toward renewable industrial energy
- Improved combustion control with modern automation
- Retention of existing steam/hot water distribution systems
- Lower disruption than a full plant replacement (site dependent)
Coal → Waste Oil → Biomass
If you moved away from coal previously, you may still have a pathway to biomass
Many New Zealand sites have already transitioned from coal to diesel or waste oil as an interim step — often to simplify operations or respond to supply and compliance pressures at the time.
If your boiler was originally coal and is now firing liquid fuel, you may still be able to progress toward biomass as part of a staged decarbonisation plan. This is depending on the boiler design, current configuration, space, and performance requirements.
This staged approach helps sites:
- Avoid “rip and replace” decisions
- Build a longer-term energy plan
- Reduce fossil fuel exposure over time
- Improve outcomes without stranding existing assets
Important note: Not every liquid‑fuel system will be suitable and feasibility must be confirmed via engineering assessment.
The Technology We Use for Biomass Conversions
Industrial rotary pellet burner systems for conversion environments
For coal-to-biomass (and some staged conversion) projects, we use robust rotary pellet burner technology designed for demanding industrial operation, stable combustion, and automated control.
Key features include:
- Rotary combustion design for even heat release
- Automated ignition, modulation, and shutdown
- Strong performance under varying steam/hot water loads
- Designed for industrial conversion applications
KIPI Rotary Burner
Designed for industrial conversion environments requiring lower thermal outputs.
- 3 – 300 kW biomass firing range
- Rotary combustion chamber for stable heat release
- Pellet‑fuelled operation
- Automated ignition, modulation, and shutdown
- Designed to operate with induced‑draft / exhaust fans
- Suitable for hot water and light steam applications
Used where compact, efficient biomass combustion is required below 300 kW.
John Thompson Triumph
Engineered for industrial steam and hot water systems at scale.
- Up to 6 MW biomass firing capacity
- Chain‑grate stoker system
- Designed for retrofit and conversion projects
- Can be integrated as conversion components
- Double‑length ignition arch
- Secondary air fan and nozzle system
- Straight‑sided industrial biomass hopper
This technology is suited to industrial processing plants, large manufacturing sites, and high‑duty steam applications.
We select and integrate equipment based on site requirements and performance outcomes, not a one-size-fits-all template.
Designed for Steam + Hot Water Performance
Hybrid and conversion systems must deliver dependable process heat, not just theoretical efficiency.
We engineer around:
- Steam pressure and stability (process-critical loads)
- Hot water temperatures and flow (space/process heating, wash-down, etc.)
- Load variation (day/night shifts, seasonal demand, batch processes)
- Reliability, maintenance access, and operational simplicity
Energy management and control integration
Is Your System a Good Fit? (Quick Indicators)
A conversion assessment is worthwhile if you have:
- An existing steam or hot water boiler system with ongoing demand
- A boiler that was originally coal (even if now diesel or waste oil)
- Space to support a biomass fuel solution (or the ability to reconfigure)
- A desire to reduce emissions and fossil fuel exposure over time
Our Process: From Feasibility to Operation
End-to-End Conversion Support
We deliver conversion projects with a focus on long‑term outcomes:
- Initial consult + site review (steam/hot water loads, existing plant)
- Feasibility & concept design (options, constraints, staged pathway)
- Engineering & integration plan (mechanical, controls, safety)
- Installation & commissioning (minimising disruption)
- Optimisation & ongoing support (service plans, performance tuning)
Ready to modernise your industrial energy system?
If your boiler was previously coal, whether it still runs coal, or has already been converted to diesel or waste oil, we can assess your pathway to biomass and lower‑emission energy.
If your boiler was previously coal, whether it still runs coal, or has already been converted to diesel or waste oil, we can assess your pathway to biomass and lower‑emission energy.
FAQ's
In some cases, yes. If the boiler was originally coal and later converted to diesel, it may still be suitable for biomass conversion, depending on boiler design, condition, load profile, space, and integration requirements.
Some waste oil systems may have a pathway to biomass, but suitability needs to be confirmed through an engineering assessment due to combustion configuration, controls, and site constraints.
Yes. We assess both steam and hot water systems and engineer conversions around the required temperature, pressure, flow, and operational stability.
Not always. Many projects focus on upgrading the combustion and energy system components while retaining serviceable existing assets where practical.