Integration of CHP and valorisation of all energy flows in Gyproc production process


Integration of a 2 MWe cogeneration

All energy flows, even engine exhaust gases, are fully integrated into the production process

Two 30m³ buffer tanks for storage of excess heat


Total return of more than 90%

High flexibility

CO2 savings of approximately 1700 tonnes per year

The collaboration between Luminus Solutions and Gyproc for the integration of a combined heat and power installation at the Gyproc site in the Antwerp port (Kallo) resulted in an innovative solution for a 2 MWe gas engine CHP in which all energy flows, even the engine’s exhaust gases, were fully integrated into Gyproc’s production process.

  • The generated electricity (2 MWe) is for own use on site.
  • The flue gases of almost 500°C are injected directly into the drying process. During normal operation of the CHP, therefore, no smoke comes out of the chimney!
  • The engine heat (45-90°C) is used in the production process throughout the year
  • Two 30m³ buffer tanks store the heat required for periodic heating and thus ensure greater flexibility and higher efficiency.

The main challenge was to ensure that all energy flows could be used simultaneously in the production process with sufficient flexibility to cope with variations in production (different raw materials, different production output, different production rates, etc.).

Thanks to a total efficiency of more than 90%, this innovative CHP enables Gyproc to reduce its carbon footprint by approximately 1700 tonnes of CO2 per year, which corresponds to the amount of CO2 stored by 57,000 trees when they grow for a year, or the average annual consumption of 170 families.

The timelapse video shows the progress of this innovative project, which was built in just 4 months.

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