Europe’s First Fully Automated Large-Scale CHP Plant

E.ON, together with Mayr-Melnhof Karton Group (MM Neauss), successfully commissioned a fully automated combined heat and power (CHP) plant. For the first time in Europe, a CHP plant of this size is being fully controlled by an intelligent control solution and operated in a market-oriented manner thanks to E.ON IQ Energy. At the Neuss site, the MM Neuss cartonboard factory will be reliably and flexibly supplied with electricity and heat in the future. According to E.ON, the project demonstrates how modern energy infrastructure must be designed with low emissions, operate reliably, and be economically viable to be ready for the challenges of the energy transition.

The integrated control system connects the power plant, production processes, and grid connection in real-time and dynamically responds to changes in market prices, production, or technical conditions. The fully digitized control allows for unattended operation for up to 72 hours. Intelligent software autonomously controls start, stop, and partial load operation, data-based and market-optimized for maximum efficiency and flexibility in ongoing operations.

“With the CHP plant in Neuss, we are setting new standards for sustainable energy supply in the industry. By combining state-of-the-art CHP technology, digitized control with E.ON IQ Energy, and hydrogen readiness, we are creating a future-proof infrastructure. The system is more than just a power plant – it is a beacon of modern energy infrastructure and demonstrates how industrial partners can be reliably, flexibly, and efficiently supported on their path to climate neutrality,” said Manfred Wirsing, member of the management board of E.ON Energy Projects GmbH.

“The modernization of our plant will make our production site in Neuss sustainable and future-proof,” said Thomas Knapp, managing director of MM Neuss. “With the combination of state-of-the-art power plant technology and digitization, we will achieve a very high level of energy efficiency, automation, and independence in our energy supply.”

The combined cycle gas turbine (CCGT) operated in combined heat and power achieves an electrical output of 22 MW and a thermal output of 59 MW. According to E.ON, this saves up to 22,000 tons (19,958 tonnes) of carbon dioxide (CO₂) annually compared to conventional generation. With a fuel utilization rate of up to 91%, the power plant is one of the most efficient of its kind, according to E.ON.

In addition to the main system, a new fully automated reserve boiler system has been installed. The system allows for quick and uninterrupted switching between main and reserve operation as needed. It is completely unmanned and controlled by technical and market-related parameters. This high redundancy ensures maximum supply security and underscores the project’s commitment to balancing efficiency and reliability.

Construction of the plant began in September 2022 and was completed on schedule in December 2024. E.ON will operate the plant and plans to do so long-term until at least 2045.

The power plant was designed for hydrogen compatibility from the outset. Already today, a hydrogen content of 10% percent can be used in the fuel mixture. In the future, the plant can be converted to up to 100% hydrogen operation, which E.ON said is a crucial step towards climate-neutral energy supply.

E.ON supports its own corporate goals for climate neutrality by 2040 and simultaneously ensures that the plant remains technologically and regulatory future-proof in the medium term.