Industrial Decarbonization · South Africa

Coal Zero
by Green Steam.

Clean industrial steam for a low-carbon future. A modular solution that replaces coal-fired boilers with solar thermal energy, thermal storage, mechanical vapor recompression, and smart digital control.

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The Challenge

Coal Dependency in South African Food Industry

The food and beverage sector continues to rely heavily on coal for process steam. Aging coal-fired boilers deliver low efficiency, high costs, supply risk and significant emissions with few proven alternatives matching continuous steam supply above 170 °C.
Low Efficiency

Average coal boiler efficiency ≈ 71%. Requires 888 kWh input energy and 0.1184 tons of coal to produce 1 ton of steam.

High Operating Cost

Current levelized cost of coal-based steam: $21.92 / ton. Unstable energy supply and rising carbon tax exposure.

Heavy Emissions

≈ 2.7 tCO₂e per ton of coal. Decades-old boilers with limited automation keep the sector locked into high-carbon process heat.

The solution​

Coal-Free Industrial Steam Supply Architecture

Coal Zero uses a combination of proven technologies to replace coal-based steam generation with a cleaner and more modern alternative delivering a modular, retrofit-ready clean steam platform that integrates into existing industrial infrastructure with minimal disruption.

1. Solar Collection Heats fluid to 85–120°C 2. Thermal Storage Holds heat in a 85°C PCM battery 3. Industrial Water Preheat Raises feedwater from 25 to 85°C 4. Vapor Compression Raises steam to 178°C, 8.7 barG 5. Digital Control Monitors system performance

Objectives & mission

Decarbonize industrial heat, affordably and at scale.

Our mission is to make clean industrial steam the default — replacing coal with a solution that is reliable, commercially viable, and built for replication across the sectors that need it most.
  • Replace coal combustion in industrial steam generation with a zero-combustion solution
  • Deliver continuous, reliable process steam at a competitive cost
  • Reduce CO₂e emissions and coal dependency in industrial operations
  • Demonstrate a replicable, modular model for multiple sites and sectors
  • Build local manufacturing and supply-chain capacity in South Africa
  • Foster an inclusive clean-energy workforce through training and participation

Sustainable Development Goals

Advancing the global development agenda.

Coal Zero by Green Steam contributes to several Sustainable Development Goals (SDGs), most notably:
Gender Equality
GESI action plan targets ≥50% women trainees, ≥40% women & youth in O&M, and contracts for female-owned enterprises.
Affordable & Clean Energy
Delivers continuous clean steam at $14.40/ton LCOH using solar thermal, PCM storage and high-COP heat pumps.
Decent Work & Economic Growth
Creates skilled green jobs, retrains existing staff, and builds local O&M capacity in the Cape Winelands.
Industry, Innovation & Infrastructure
Modular, container-ready clean-steam technology that retrofits existing industrial infrastructure with minimal disruption.
Responsible Consumption & Production
Replaces coal with zero-combustion process heat, cutting resource intensity and eliminating combustion waste streams.
Climate Action
Avoids 2,754 tCO₂e per year and 1,020 tons of coal, a scalable model for industrial decarbonisation in emerging markets.
Partnerships for the Goals
International consortium combining technology, finance, local implementation and academic GESI expertise under a Steam-as-a-Service model.

Partners

A Multinational Consortium

Partner Map