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 with existing gas or oil fired steam boilers, enabling customers to electrify their operations without making existing assets redundant.

Developed by Standard Fasel, part of the Babcock Wanson Group, the modular low-voltage Hybrid Add-on boiler provides an accessible and practical route to electrification. Rather than requiring full boiler replacement, the system connects directly into the existing installation, providing additional steam capacity using electricity while reducing fossil fuel consumption and associated emissions. This approach allows businesses to protect previous capital investment, minimise disruption, and take meaningful steps toward lower-carbon operation.

The Hybrid Add-on has been specifically designed to support long-term future proofing. By allowing operators to switch flexibly between fuel and electricity depending on energy prices and availability, the system supports resilience in an increasingly complex energy landscape. It can also utilise periods of surplus renewable electricity, helping organisations align with sustainability targets while contributing to smarter energy use.

Available in modular 200kW, 400kW and 800kW versions, the compact units can be connected to a standard 400V electrical supply and feature unlimited turndown, natural circulation with no pumps required, and minimal integration requirements. The design ensures fast, low-risk implementation with limited impact on existing boiler house infrastructure.

The launch builds on Babcock Wanson’s wider strategy of supporting industrial customers through the energy transition with practical, engineered solutions. It complements the company’s range of electric boilers and hybrid technologies, reinforcing its position as a partner for organisations seeking to decarbonise while maintaining operational performance.

“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.”