As the end of 2024 approaches, Clarke Energy and Eramet Norway are celebrating a significant achievement in their collaborative effort to revolutionise industrial energy efficiency and sustainability. The much-anticipated commissioning of the six Type-6 INNIO Jenbacher engines, part of the €32 million energy recovery project at Eramet’s ferromanganese production plant in Sauda, is set to conclude by the end of this year.
A Journey of Innovation and Sustainability
The project, initially launched with a pilot phase in 2021, marks a pivotal moment in advancing environmental and energy efficiency in the ferro-alloy industry. At Clarke Energy, we’re renowned for our expertise in decentralised power generation solutions and have played a central role in this ambitious initiative.
By transforming previously flared furnace gas—comprising a complex mixture of gases including hydrogen and carbon monoxide—into valuable electrical and thermal energy, the project underscores a commitment to sustainability and energy innovation.
From Pilot to Full-Scale Implementation
The journey began with the NewERA ERU pilot project, which successfully demonstrated the potential of recovering and utilising furnace gas from Eramet’s ferromanganese processing plant. The pilot’s success led to a substantial investment in a full-scale energy recovery unit, backed by the Norwegian authorities and supported by Enova’s industrial pilot program.
Clarke Energy’s role extended beyond installation to delivering a comprehensive solution. The project includes raw gas treatment, electricity generation, heat recovery, and integration into the local medium-voltage grid. The recovered gas, particularly notable for its composition—rich in carbon monoxide and containing hydrogen—has been carefully conditioned and processed to optimise energy output.
Key Achievements and Impact
The project’s impact is far-reaching:
- Utilisation of Complex Gases: A key innovation in this project is the effective utilisation of complex gases to produce energy. By converting these gases into electrical power and heat, the project demonstrates a significant reduction in carbon emissions and energy waste. This approach underscores the importance of managing and recovering energy from gases that are often considered difficult to use effectively.
- Energy Efficiency: The recovery unit is expected to enhance the plant’s energy efficiency by over 30%, recovering around 250 GWh/year in electrical and thermal energy. This represents a significant reduction in energy loss, with the recovered electrical energy equivalent to the consumption of approximately 5,000 households.
- Environmental Benefits: By repurposing furnace gas, the project aligns with Eramet’s CSR strategy to reduce CO2 emissions by 25% per ton of product by 2023. The initiative contributes to Eramet’s goal of capturing over 43% of CO2 emissions by 2030 and achieving carbon neutrality by 2050.
- Community and Industry Impact: Beyond the environmental benefits, the project supports the local community by integrating heat recovery processes that contribute to the district heating system in Sauda. This local benefit complements the broader goal of reducing greenhouse gas emissions and producing a low-carbon alloy.
Looking Ahead
As we approach the commissioning of the six INNIO Jenbacher JMS 620-F54 engines, Clarke Energy and Eramet Norway are preparing for an optimisation phase to further enhance plant performance. This phase will include detailed performance assessments and additional training for Eramet’s operating teams to ensure seamless integration and operation.
Jaques Soulayrac, Managing Director of Clarke Energy France and French-speaking Africa, reflects on the project’s significance:
“This project exemplifies Clarke Energy’s commitment to sustainability and technological innovation. It’s a proud moment for us as we contribute to the global net-zero initiative and advance the energy transition.”
The collaboration between Clarke Energy and Eramet Norway not only sets a new standard in energy recovery and efficiency but also demonstrates a shared dedication to a cleaner, more sustainable future.
Stay tuned for more updates as we finalise the commissioning and continue to drive forward with our mission of sustainable energy solutions.
