Turning waste into watts: E.ON and Imerys team up for a greener future
One man’s trash is another man’s treasure — and we’re taking that literally by turning industrial waste into enough electricity to power thousands of homes.
Imagine turning something that would usually go up in smoke into enough electricity to power thousands of homes — extracting every bit of potential energy from what would have otherwise been lost.
That’s exactly what we’re doing in Willebroek, Belgium, as part of a new partnership with Imerys, the world leader in production of carbon black, a dark black powder that is a key component for lithium-ion batteries. And here’s where it gets exciting, not only is this innovative project cutting emissions, it’s also helping create a more sustainable future for the region.
At the heart of this initiative is a clever bit of technology known as energy recovery. In a nutshell, it’s all about capturing energy from processes that would typically release it into the atmosphere, and finding a way of repurposing it.
In Willebroek, the production of syngas (a mix of hydrogen and carbon monoxide) at Imerys’s site produces huge amounts of heat. Instead of wasting that valuable heat energy, our new energy recovery plant (plans pictured below) will harness it to generate electricity – enough to power 40,000 homes!
How does it work?
Syngas is produced during the carbon black manufacturing process (think of it as the ‘waste product’ with hidden potential). The new facility will capture the syngas and, from there, it’s all about steam. The captured syngas can be used to heat water in a high-pressure boiler, producing steam which spins a turbine, generating electricity.
And since this steam is expanded and cooled down using air-cooled condensers, the efficiency of the plant continues to rise. The lower the pressure in the condenser, the more power we generate – a win-win for efficiency and sustainability.
Latest from the site? We’re full steam ahead.
On site, things are heating up – and not just because of the steam. Construction is well underway, with the giant two metre-wide pipe that links the steam turbine to the air-cooled condenser now fully in place. The first cooling cells – which help cool the steam back into water so it can be reused in the system – have been installed, with more ventilators being assembled as we speak.
Behind the scenes, the electrical systems are nearing completion too. Teams are preparing to energise everything from transformers to backup power supplies, with fire protection and pressure testing on deck next.
The syngas booster – delivered and installed by High Pressure Fans – is now in place. This clever bit of kit increases the pressure of the syngas (rich in hydrogen and carbon monoxide) to make it usable in the burners. Once combusted, the resulting heat drives the steam boiler, which then powers the turbine to generate electricity.
Even more exciting, cold commissioning – where equipment is tested without heat – has begun. Hot commissioning, which involves actual fuel combustion and steam generation, is just around the corner. We’re also closing in on the mechanical completion of the boiler, and roadworks around the plant are kicking off.
What role does hydrogen play?
Hydrogen is a key player in this whole process. The syngas we’re using is rich in hydrogen – one of the most promising clean fuels out there. Not only is it helping cut emissions today, but it opens up exciting possibilities for tomorrow. In the future, we plan to explore how this hydrogen-rich syngas can support local district heating systems – warming homes and businesses in the area.
Why does this matter for the UK?
Because it proves what’s possible. As the UK charts a path to net zero, projects like Willebroek offer a blueprint for how we can turn industrial waste into clean, reliable power. Hydrogen, energy recovery, and clever engineering aren’t just buzzwords – they’re tools we’re already using to shape a cleaner, greener energy future.