A scalable and replicable solution to decarbonise industry by the combination of captured “fatal” CO2 from lime production with green hydrogen, to produce carbon-neutral synthetic E-methane

Introduction

The Columbus project will demonstrate a first of its kind, industrial scale process of E-methane production in Wallonia, Belgium. The integrated process will first involve capturing carbon dioxide (CO2) emissions from an oxy-combustion lime kiln. The process then involves the production of hydrogen from a 100 megawatt electric (MWel) electrolyser using renewable electricity sources. This will up-scale and combine several innovative technologies.

Process Overview

The CO2 and hydrogen (H2) are then converted to E-methane by a thermocatalytic methanation plant. The by-products of the process, including water, heat, and oxygen (O2), will be reused inside and outside the process. The project plans to achieve a 284% drop in relative greenhouse gas emissions compared to the reference scenario.

Technological Innovations

The innovation combines new and established technologies in synergy, allowing the generation of 55 MW equivalent of E-methane through water electrolysis, lime kiln carbon capture, and methane synthesis. Specifically, the project includes:

1. Green-H2 production using electrolysis (through a Pressurised Alkaline Electrolyser (AEL) of 20 stacks), enhancing cost efficiency and downstream integration.
2. Pioneering a lime kiln carbon capture oxy-combustion technique, a first in industrial application.
3. Significantly upscaled thermocatalytic methanation process compared to the largest pilot plant currently active.

The produced E-methane has been recognised by the Walloon Region where the project will be implemented, as an equivalent to biomethane (July 2020), which will cause no process or infrastructure change due to its natural gas-like properties. The project plans to achieve an absolute greenhouse gas emissions avoidance of 1.8 million tonnes of CO2 emissions over the first 10 years of implementation.

Contribution to European Goals

The project will contribute to the REPowerEU objectives of reducing fossil fuel consumption in industry and transport. It will also contribute to the European Hydrogen Strategy in terms of domestic renewable hydrogen production by 2030. Columbus will operate the electrolyser on Renewable Energy (RE) based on Power Purchase Agreements (PPAs) compliant with the Renewable Energy Directive II (REDII) for the usage of renewable electric sourcing.

Quality and Applications

The produced E-methane will be of high quality and suitable for heavy industries such as the steel industry and as an alternative fuel in the transport sector (especially shipping), to support their decarbonisation.

Socio-Economic Impacts

The Columbus project will also have a range of socio-economic impacts. Firstly, it will contribute to positioning both Wallonia and Belgium as H2 and E-methane production pioneers, driving local economic growth. It also ensures cost-efficient deployment, and the potential creation of more than 45 operational jobs and 100+ construction roles.

The outcomes will further expand to other industries, offering E-methane for decarbonising sectors like glass, ceramic, and other industries producing materials for high-temperature industrial processes (refractory industries). Finally, this project presents a unique opportunity to forge new linkages, create new value chains, and foster collaboration with external stakeholders.