At Imerys' production site in Willebroek, Belgium, E.ON is starting a major investment to build an energy recovery plant. Imerys' syngas production will be used as an energy source for the new power plant. An off-gas cleaning system will provide significantly improved air quality.
Imerys is a leading manufacturer of conductive additives, for example for lithium-ion batteries and engineering polymer applications. The rapid development of electromobility and the increasing global demand for lithium-ion batteries has led Imerys to expand its production capacity for high-purity carbon black in Belgium from two to four production lines. The high electrical conductivity of carbon black is used to improve the performance and lifetime of lithium-ion batteries. During production, heat is released and significant amounts of synthesis gas are produced. The syngas, which contains high concentrations of hydrogen and carbon monoxide, is currently flared, losing its energy content.
Full recovery of syngas
E.ON's planned energy recovery plant at the Imerys site will fully utilize and recover the energy content of syngas by generating steam. The new E.ON power plant will generate electricity in a highly efficient steam turbine with a capacity of up to 29 MWel, enough power to supply the Imerys site and 40,000 families in the region all year round. In the future, E.ON also plans to explore the possibility of using the power plant's residual heat as a source for a possible district heating network.
"The project represents a step towards the sustainability of carbon black production at Willebroek and is in line with Imerys' efforts to improve the environmental performance of our overall operations. We are pleased to work with E.ON to deliver this project for the benefit of the Willebroek mill, the environment and the local community," said Frank Wittchen, VP & GM of the Graphite & Carbon Division at Imerys.
The energy recovery plant will be built and operated by E.ON Power Plants Belgium, a wholly owned subsidiary of E.ON SE. The plant is scheduled to start operations in the second half of 2025. The supply of electricity to Imerys is secured by a long-term partnership agreement between the companies.
"Together with Imerys, we will improve the energy efficiency of the production facility. As the carbon black produced will primarily be used for lithium-ion batteries, the environment will benefit firstly through its importance in the transition to e-mobility and secondly through the generation of electricity by recovering energy from the exhaust gases - a double win for the environment. I am pleased that with this exemplary project we are supporting E.ON's growth strategy and contributing to the decarbonization of our customers' processes with sustainable solutions," says Manfred Wirsing, Managing Director of E.ON Energy Projects.
Reduced CO2 emissions
The electricity generated by the energy recovery plant reduces the need for conventional power generation and results in a saving of more than 25,000 tons of CO2 per year (based on the average CO2 emissions of power generation in Flanders). The project will help improve air quality on site by reducing sulfur and nitrogen emissions through an exhaust gas cleaning system.
