At the Imerys site in Willebroek, E.ON Power Plants Belgium is carrying out an innovative energy recovery project that converts syngas, a by-product of Imerys’ production process, into sustainable energy. With a maximum capacity of 29 MW, this installation will not only be able to supply the entire Imerys site, but also provide electricity to 40,000 households in the region.
Actemium was entrusted with the task of integrating all these systems into a smart, safe, and efficient industrial control environment. Thanks to a fully redundant Siemens PCS7 platform, decentralized remote I/O, and a segmented network, all process modules were integrated into a single coherent plant. Through close collaboration with E.ON and the various equipment suppliers, the interfaces from turbine protocols to boiler signal lists were validated and optimized step by step.
The true strength of this project lies precisely in this collaboration. Each party contributes its expertise, and we ensure that everything functions as one reliable and perfectly integrated whole.
A fully automated and autonomous installation
The heart of the new installation is a fully automated control system, centrally managed via a Siemens PCS7 DCS. Actemium contributed to the development of the automation network architecture. Thanks to logical segmentation, redundant hardware, and a cybersecurity-focused structure, the system operates reliably and securely.
A control system that brings all disciplines together
The new installation is a technical patchwork of specialized equipment: a steam boiler, steam turbine, turbine bypass, air-cooled condenser (ACC), and flue gas treatment system. In addition, smaller utilities such as demineralized water production, a nitrogen generator and compressor, HVAC, and a cooling unit are also included. Each component is supplied by a different technology partner, each with its own specifications, requirements, and interfaces.
Behind all this technology lies, above all, an intense and multidisciplinary collaboration between E.ON, Actemium, and the various other suppliers. Actemium was responsible for the software engineering of the balance of plant. All different process sections from the syngas booster and flue gas treatment to the ACC and the interfaces with the boiler and turbine were integrated into a single uniform control platform. This makes the complexity of the installation manageable and ensures that the process remains safe, efficient, and transparent.
Engineering, panel building, and commissioning
Actemium also played a unifying role in hardware engineering. The control cabinets, server panels, and remote I/O cabinets that form the heart of the automation system were entirely designed by Actemium. The engineering was carried out in close consultation with E.ON and the various technology partners, ensuring seamless alignment of all signals, field components, and interface requirements.
Meanwhile, commissioning of the plant is in full progress, and syngas is already being used by the boiler to generate steam. Optimization of the various control loops is ongoing, and the turbine will be commissioned shortly.
Together towards a sustainable future
The Energy Recovery project perfectly illustrates how smart automation, reliable network infrastructure, and sustainable engineering reinforce each other. By converting a by-product into valuable energy, Imerys significantly reduces its ecological footprint. Actemium supports this transition with innovative, safe, and efficient technologies, thereby contributing to the realization of the sustainable factory of the future.
For Actemium, this project serves as a concrete example of how smart automation, reliable infrastructure, and human collaboration can strengthen one another.
