Industrial biomass: the renewable alternative to replace gas and fossil fuels

Industrial biomass is the most efficient and competitive renewable energy solution to replace natural gas, fuel oil and diesel in the generation of high-intensity heat and steam process. 

Through the thermal recovery of organic, forestry and agricultural by-products, it is positioned as the operating pillar on which industrial decarbonisation is based on the sectors with the greatest energy demand. It allows manufacturing companies to decouple their costs from fossil markets and directly eliminate up to 100% of operational thermal emissions. 

What you need to know about industrial biomass:

• It is the only manageable renewable technology capable of providing steam and hot water at high pressure and temperature uninterruptedly (24/7).
• As it is a local resource, it shields the income statement against the volatility of international natural gas markets and the costs of CO2 rights.
• Plants can be implanted at an initial cost of ZERO CAPEX, assuming a specialized partner the design, financing, operation and maintenance of the installation.
• It is the ideal alternative for sectors with intensive thermal demand such as food, paper, chemical, ceramic and textile.

What is industrial biomass?

Industrial biomass is a renewable, manageable and high-density source that uses organic matter to generate electricity by cogeneration or thermal energy (steam, hot water or thermal oil) in factories. It works as a direct substitute for fossil fuels, decarbonizing production, reducing costs (COGS) and eliminating environmental impact without altering continuity or operational safety.

The relationship between industrial decarbonization and industrial biomass is objective and technical solution: while understanding globally what is industrial decarbonization Defines the framework strategy to achieve climate neutrality in the factory, bioenergy represents the most effective technological vehicle to execute it in thermal processes. Given that about 70% of the consumption of the manufacturing industry is destined for the generation of heat and steam, it is not possible to articulate a sustainable transformation in thermointensive sectors without placing the biomass at the center of the equation.

How does an industrial biomass system work?

An industrial biomass system works by controlled combustion of solid organic matter in high-efficiency boilers to transform the chemical energy of biofuel into thermal energy in the form of steam, hot water or thermal oil. The entire process is digitally automated and monitored to ensure optimal energy performance and a biomass supply continuous and uninterrupted to the manufacturing line.

Reception and storage of fuel

Solid fuel is received by tilting trucks and discharged into an automated storage silo (underground or surface). This space is designed with an autonomy capacity calculated in days or hours of production to guarantee the constant flow of raw material without depending on daily deliveries.

Automatic feeding

A mechanical extraction system moves the biofuel from the silo to the boiler mouth by means of auger or belt spindle conveyors. This process is fully automated and self-regulated according to the instant thermal demand of the plant.

Generation of heat and steam

Fuel is burned in the boiler’s home operating at optimized temperatures. The heat generated by the combustion is transferred to the carrier fluid through a multitubular boiler body, producing high pressure saturated or overheated steam.

Distribution of energy to the production process

The thermal fluid generated is channeled through the manifolds and infrastructures of the factory to directly feed the equipment of the production process (reactors, dryers, exchangers or distillation columns).

Control and monitoring systems

A programmable logic control system (PLC) and SCADA monitoring manages in real time the air-fuel ratio, steam pressure, combustion gas emissions readings and the performance of filtering equipment (electrofilters or filters of sleeves), ensuring Maximum operational efficiency and environmental compliance.

What types of biomass are used in industry?

The types of biomass used in industry encompass a variety of solid biofuels that differ by their origin, energy density, granulometry and moisture content. The choice of the type of resource depends on the thermal design of the boiler, the availability of regional supply and the specific needs of the plant.

Forest splinter

It is the biomass from the crushing of the remains of forest woods, clearings or first transformation industries. It presents a heterogeneous size and is the most widespread and economical solution for medium and high power industrial boilers.

Pellets

Pressed product made from sawdust or natural wood chips. It stands out for its high energy density, a homogeneous cylindrical shape and very low moisture content, which facilitates automation in smaller space installations.

Olive bone

By-product from the mill with a high calorific value and a reduced degree of humidity after drying. It is a highly competitive local fuel in olive production regions.

Shells and agricultural residues

Woody residues from the processing of nuts. They have excellent combustion properties due to their reduced ash and high volatility.

Agro-industrial by-products

organic waste generated by the company’s own production process. Its energy revaluation in situ allows a perfect model of circular economy.

How to choose the right fuel?

To choose the ideal biofuel, the local supply logistics must be balanced with the technical parameters of the boiler. The following table compares the most common options:

What industries can benefit from biomass?

The industries most benefited by biomass are thermointensive ones, where the thermal cost is decisive in production costs. Integrating bioenergy stabilizes EBITDA against external energy shocks and eliminates climate penalties.

Food industry

Requires constant supply of steam for pasteurization, sterilization, cooking, concentrate and drying processes. It allows to align with the sustainability commitments required by mass consumer distributors.

Paper and cardboard

Intensive sector in the consumption of medium pressure industrial steam for paper drying trains and pulp pulp treatment, where the energy cost is critical for the viability of the plant.

Chemical industry

Demand uninterrupted thermal energy at constant temperatures and pressures to power reactors, distillation towers and evaporators, a profile in which the stability of bioenergy stands out against gas.

Ceramics

Use of powdered or gasified biomass to feed atomizers and dryers, replacing significant volumes of natural gas in the thermal phases prior to cooking.

Wood

It closes the circle of the circular economy by using the chips, barks and chips generated during industrial processing as a biofuel to feed the stoves and dryers of the facility itself.

Textile

It needs constant hot water and steam in the fixing, dyeing, bleaching and washing phases, benefiting from a direct reduction in the cost per megawatt-hour consumed.

Biomass vs. Natural Gas: Which option is more profitable?

For industries with high and continuous heat consumption, biomass outperforms natural gas. Contrary to fossil gas, conditioned by volatile international markets and CO2 rights, biomass provides lower, stable, thermal MWh costs and no climatic tax burdens.

Fuel cost

The price per megawatt-hour thermal from the solid biomass is usually between 20% and 50% below the thermal equivalent of natural gas, depending on the proximity to the supply center.

Price stability

The solid biofuel market is local and regional, totally unrelated to geopolitical crises that alter the international price of piped gas and liquefied natural gas (LNG).

CO2 emissions

The use of natural gas carries a growing cost under the EU emissions trading regime (EUGR). On the other hand, biomass is considered by the regulations as a neutral carbon-neutral resource, exempt from payment for tons emitted.

Energy dependency

Migrating to proximity bioenergy prevents logistical risk and supply cut-offs associated with the external gas distribution network, increasing the factory’s strategic resilience.

Operating costs

Although the technical maintenance of a biomass boiler room is higher than that of a gas boiler due to the management of ash and feed peripherals, the savings achieved in the fuel heading comfortably compensate for this operating cost.

Return on investment

the return period (Payback) In the substitution of gas by biomass, it is usually between 3 and 5 years in plants with operating schemes of more than 6,000 hours per year.

Benefits of implanting industrial biomass

Implementing an industrial biomass plant generates a direct benefit in the competitiveness of the company, by simultaneously optimizing the structure of operating costs, the security of supply and the environmental profile of the organization.

• Reduction of energy costs: Substantial savings in the thermal bill for the difference in price between biomass and hydrocarbons.
• Less dependence on fossil fuels: Operational autonomy in the face of shortages, cuts or arbitrary cost of natural gas.
• Decarbonisation of thermal processes: Elimination of up to 100% of direct scope 1 emissions in boilers replaced.
• Improvement of ESG indicators: Elevation of the environmental profile to meet the sustainability requirements of international customers and investors.
• Access to aid and financing: Priority in the granting of public subsidies and preferential green credit lines.
• Greater competitiveness: Reduction of the energy cost passed on the final product, expanding the commercial margins of the factory.

What needs to be analyzed before implementing a biomass facility?

To verify if your plant meets the optimal conditions to carry out the technological change, review the key aspects listed in this list:

• Thermal demand: Analyze the steam or hot water consumption profiles (load curves, peaks and hours of annual operation).
• Type of industrial process: Determine the minimum pressures and temperatures required by the heat receiving equipment.
• Available space: Evaluate the free physical plot to locate the storage silo, the boiler room and the truck maneuver zones.
• Fuel supply: Verify the existence of guaranteed solid biomass suppliers in an efficient logistics radius
• Integration with existing installations: Study the viability of hydraulic interconnection with pre-existing steam collectors without interrupting production.
• Regulatory requirements: Check compliance with the regulations on pressure equipment, local air emissions regulations and environmental licenses.

Use cases: industrial scenarios where biomass already generates value

Bioenergy projects demonstrate their maximum profitability in industrial scenarios with intensive and continuous consumption patterns.

Food plant

A dairy industry with constant steam demands for sterilization replaces your natural gas boiler with a biomass unit. It manages to set the cost per giga calorie produced in the long term and eliminates its emission penalties, maintaining maximum hygiene and operational continuity.

Paper industry

A corrugated cardboard factory installs a forest biomass plant connected to its steam collectors for drying. The plant manages to reduce its annual thermal expenditure by 85% compared to the maximum price periods of piped gas.

Ceramic Factory

An atomizing plant integrates synthesis gas generators or hot air from biomass to feed the drying tunnels, reducing the purchase of CO2 rights in the European market.

Chemical industry

A polymer synthesis facility integrates a biomass thermal oil boiler to power its reactors at 250 Cº, shielding its fixed energy costs against market fluctuations.

Processes with steam production

In any heavy factory with continuous steam demands at more than 10 bar, biomass acts as the most stable renewable substitute, replacing traditional fossil burners without compromising the power required by the machinery.

To find out how these alternatives are integrated into a global strategy, you can consult the services of industrial decarbonisation of ENSO or explore specific biomass solutions for industry.

How does ENSO help implement industrial biomass projects?

On ENSO We help companies to implement industrial biomass projects by acting as their integral technological, operational and financial partner. We approach each case from a specialized technical consulting approach, ensuring that the transition marked in the Industrial Decarbonization Plan of your company is technically impeccable and economically profitable. 

• Energy audit: We evaluate on the ground the real demands for heat, pressures and consumption of your factory to determine the technical feasibility of the change.
• Engineering and Design: We develop custom execution projects, selecting the combustion and filtering technology that optimizes performance according to the chosen local biomass.
• Turnkey execution: We assume the construction management, the assembly of the boiler, the silo civil works and the interconnection with your collectors without interfering with the activity of your factory.
• Financing models: Through our energy project financing proposal, we structure contracts under the Energy Services Company (ESE) format. We assume 100% of the capex, selling to the customer only thermal energy at a guaranteed price.
• OPERATION AND MAINTENANCE: through our area energy operation and maintenance, we take care of the control of the plant and the global supply of certified biofuel, freeing the customer from all operational loads.

Frequently asked questions about industrial biomass

What is the difference between industrial biomass and domestic biomass?

The industrial biomass uses high-powered boilers designed to operate continuously with heterogeneous fuels such as splinters or by-products. The domestic uses small-powered boilers fed with high-quality commercial pellets.

Can biomass completely replace natural gas?

Yes, it is technically capable of replacing 100% of the consumption of natural gas in the generation of steam, hot water or thermal oil, providing the same power curve and technical stability as traditional fossil boilers.

Is a lot of space required for the biomass storage silo?

The space depends on the power of the boiler and the desired days of autonomy. Generally, silos are designed to store the raw material corresponding to between 3 and 7 days of continuous consumption at full load.

What maintenance does an industrial biomass plant require?

Requires automated ash removal and cleaning of smoke passages, as well as periodic checks of mechanical feeding elements (spindles, grills) and the calibration of the gas filtering system.

Do biomass boilers meet EU polluting limits?

Yes, modern plants integrate advanced gas treatment systems (sleeve filters or electrofilters) that reduce suspended particles and nitrogen oxides, comfortably complying with the Medium Combustion Installation Directive (MCPD).