ThermalCyclones’ Next-Generation Industrial Steam Boiler Replacement – an Industrial Revolution

Recipient organisation

THERMALCYCLONES LTD

Project reference

10191109

Funder

Innovate UK

Programme

Innovate UK Growth Catalyst – Investor Partnerships Round 2

Award value

£676,960

Project dates

1 Jul 2026 – 31 Oct 2027

Imported sector

Clean Growth & Energy Lvl3

Postcode area

NW (NW1 8HR)

Project status

Live

Source data quality

Description present in snapshot

Official project description

Industrial heat is one of the largest contributors to global emissions, consuming 22% of global energy and producing 20% of CO2_e,_ more than aviation and shipping combined. Most of this heat is generated by fossil-fuel steam boilers, which remain the backbone of manufacturing processes. However, current industrial heat pump (IHP) technologies cannot easily replace steam boilers, leaving a large and critical gap in decarbonization efforts. ThermalCyclones addresses this challenge with a breakthrough industrial heat pump system designed as a direct, drop-in replacement for steam boilers. Our technology enables up to 75% reduction in energy consumption and 70% reduction in CO2_e_ emissions, delivering rapid decarbonisation at low cost. The system is suitable for a wide range of sectors, including pulp and paper, food and beverage, pharmaceuticals, brewing, textiles, chemicals, and district heating. The innovation lies in our ability to upgrade ambient-temperature air directly to high-quality steam at 120C to 250C in a single, highly efficient step - a capability previously unattainable in industry, yet only now possible due to our novel approach. The system combines a high-efficiency compressor, a transcritical cycle, and a benign, non-flammable, non-PFAS working fluid, ensuring both performance and environmental safety. Housed in a compact 20ft container or skid-mounted unit, the system is modular and scalable from 500kWt to 5MWt, requiring only water and electrical connections for plug-and-play installation. Beyond steam generation, the system's large temperature lift enables simultaneous cooling and heating, including refrigeration down to -10C and steam up to 200C. For food and beverage industries, this means replacing chillers and boilers with a single integrated solution, cutting energy use dramatically. In sectors like pulp and paper, where heat accounts for up to 70% of operating costs, our system can halve OpEx, transforming competitiveness. With payback periods under two years, 2-4x faster than near-peers, ThermalCyclones offers a compelling business case alongside environmental benefits. The system supports variable steam rates and source temperatures without performance loss, future-proofing industrial operations for green electricity and net-zero compliance. This project positions the UK at the forefront of global industrial heat pump innovation, strengthening high-tech manufacturing, boosting exports, and enabling rapid decarbonization of heavy industry. By delivering a scalable, cost-effective solution, ThermalCyclones will help UK industry meet Net Zero targets while enhancing global competitiveness.