PROCESS Worldwide brings to you the ‘Top 10 plant engineering projects of April 2025’ from all over the world. Right from Piller partnering with GIG Karasek for the world’s most powerful heat pump system to Indian Oil Corporation developing a mega petrochemical complex at Paradip, India, find out all the projects making headlines here.
At a glance: Plant engineering projects from across the globe.
(Source: Pixabay)
European Energy Starts Up E-Methanol Plant with Clariant Catalyst
Clariant has recently announced the successful startup of its Megamax 900 methanol synthesis catalyst at European Energy’s e-methanol plant.
(Source: Clariant)
April 07 – Clariant has recently announced the successful startup of its Megamax 900 methanol synthesis catalyst at European Energy’s e-methanol plant. Located in Kasso, Denmark, the facility is one of the world’s first and, up to now, largest commercial e-methanol plant, using biogenic CO2 and green hydrogen to produce up to 42,000 tons of green methanol annually. Clariant's Applied Catalyst Technology (ACT) technical service team provided on-site support throughout the startup procedure, overseeing the catalyst loading, reduction, and startup. Megamax 900 is operating with excellent activity and stability despite the challenging conditions of CO2-to-methanol conversion.
Clariant’s Megamax 900 is an ideal solution for European Energy’s Power-to-Methanol project, as it provides the enhanced stability required for green methanol production. The catalyst also offers outstanding activity – even at very low reactor temperatures and pressures. Moreover, Megamax is very well suited for CO2 to methanol process conditions delivering high conversion rates and long catalyst lifetime. The catalyst’s superior selectivity also widely prevents the formation of by-products in the yield, which greatly improves the sustainability and economics of green methanol synthesis.
Piller Partners with GIG Karasek for World’s Most Powerful Heat Pump System
From right to left: Andreas Schnitzhofer, Managing Director of GIG Karasek and Christoph Böhnisch, Managing Director of Piller Blowers & Compressors.
(Source: Piller)
April 07 – As the EPC contractor and technology provider, GIG Karasek is delivering the world’s most powerful industrial heat pump system for BASF’s Ludwigshafen site. Piller is supplying the 11 blowers, which are connected in series as part of the steam compression system and serve as the central element of GIG Karasek’s innovative Comprivap technology. The system demands maximum blower performance and will achieve an impressive thermal output of up to 50 MWth.
Andreas Schnitzhofer, Managing Director of GIG Karasek, explains: “We chose Piller because of its many years of experience in blower and compressor technology, and we regard Piller as a top-class supplier for our large-scale Comprivap system. We are combining our expertise and experience to accelerate industrial transformation using forward-thinking, energy-efficient solutions – for maximum performance and sustainability in heat pump technology.”
Christoph Böhnisch, Managing Director of Piller, adds: “We are proud to be part of this pioneering project. We are especially pleased that our globally recognized expertise is now being applied in Germany for the first time, in close collaboration with GIG Karasek and BASF at the Ludwigshafen site. With our specially developed Vapoline product line, we are strengthening our position as a technology leader in vapor (re-) compression.”
The goal of the project is to convert the steam supply at BASF’s Ludwigshafen site to a sustainable, CO2-free production process. This investment will allow BASF to reduce the greenhouse gas emissions currently generated during the production of formic acid by 98 percent.
Kazmunaygas, Sibur, Sinopec to Develop Polyethylene Plant in Kazakhstan
The grand construction project was launched by Serik Shapkenov, akim of Atyrau region; Askhаt Khasenov, Chairman of the Board of JSC NC "Kazmunaygas" (KMG); Kudaibergen Arymbek, Vice Minister of Energy of Kazakhstan; Pavel Lyakhovich, Member of the Management Board and Managing Director of Sibur; and Wan Tao, Senior Vice President of Sinopec.
(Source: Kazmunaygas)
April 08 – On March 31, 2025, the first piles were driven into the foundation of the future Silleno polyethylene plant within the Special Economic Zone "National Industrial Oil and Gas Chemical Technopark" in Atyrau region in Kazakhstan.
The grand construction project was launched by Serik Shapkenov, akim of Atyrau region; Askhаt Khasenov, Chairman of the Board of JSC NC "Kazmunaygas" (KMG); Kudaibergen Arymbek, Vice Minister of Energy of Kazakhstan; Pavel Lyakhovich, Member of the Management Board and Managing Director of Sibur; and Wan Tao, Senior Vice President of Sinopec.
The construction of the plant, which has a capacity of 1.25 million tons of polyethylene per year and an investment of approximately 7 billion dollars, is expected to be completed by 2028, with production set to begin in 2029. Silleno will become one of the largest projects in Kazakhstan's manufacturing industry.
The plant will be capable of producing over 20 different grades of polyethylene used in key industrial sectors.
The project will have a multiplicative positive effect on the national economy starting from the construction phase and will contribute to the growth of Kazakhstan's non-resource exports. Silleno products will play a vital role in substituting polyethylene imports, allowing for the replacement of about 90 % of the imported range. According to the data of the Bureau of National Statistics of the RK, in 2024, the polyethylene market in Kazakhstan was approximately 300 thousand tons, and experts estimate it could grow to 400 thousand tons by 2035. Most of the polyethylene demand from Kazakh consumers will be met by Silleno supplies.
Date: 08.12.2025
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The ethane feedstock for polyethylene production will be extracted at the KMG Gas Separation Complex from gas fields operated by Tengizchevroil and delivered to Silleno via a main pipeline, which will also be constructed by KMG.
The future complex will include the construction of a steam cracker for ethylene production using Lummus Technology (USA), ethylene polymerization units based on Chevron Phillips Chemical (USA) and Univation Technologies (USA) technologies, as well as a butene unit utilizing Axens technology (France).
Elyse Energy Selects Thyssenkrupp’s Technology for Biomass-to-SAF Project
The Biotfuel technology has been selected for the Biotjet project by Elyse Energy and its partners.
(Source: Elyse Energy)
April 08 – The Biotfuel technology has been selected for the Biotjet project by Elyse Energy and its partners. This project will produce sustainable aviation fuel (SAF) from end-of-life wood waste & local forestry residues with the addition of green hydrogen. By 2029, Biotjet will supply sustainable aviation fuel to reduce carbon intensity in air transport, and e-bio-naphtha for road transport and bio-sourced chemistry. Axens signed a license agreement for Biotfuel technology in 2024, which includes a Prenflo gasification technology from Thyssenkrupp Uhde, a Gasel technology from Axens (Fischer-Tropsch and Upgrading) with a basic engineering completed in November 2024 and currently being within the detail engineering phase.
The aviation industry is considered as one of the hard-to-abate sectors in the green transformation, and sustainable aviation fuels are required by the Refuel EU Aviation regulation, starting with a 2 % quota in 2025 and aiming for 70 % SAF in all EU airports from 2050. The Biotjet project is based on the E-Biotfuel concept, which combines biomass eligible to produce advanced biofuels (RED EU definition), and green or low-carbon hydrogen eligible to produce renewable fuel of non-biological origin (Red EU Definition, also called e-fuels). The technology brings proven process building blocks which have been developed and tested in a semi-industrial plant from 2010 to 2021 by the Bionext consortium consisting of Avril, Axens, CEA, IFP Energies nouvelles, Total Energies and Thyssenkrupp Uhde.
The Prenflo gasification technology is part of Thyssenkrupp's Decarbon Technologies portfolio and will contribute to the sustainable production of biomass-based synthetic products, including methanol, hydrogen, and SAF. With its origins in the Koppers-Totzek process, the Prenflo technology has been continuously refined to meet evolving industry needs. It is known for its robustness and flexibility, capable of handling a wide range of feedstocks.
Indian Oil Corporation to Develop Mega Petrochemical Complex at Paradip, India
Indian Oil Corporation has signed a MOU with the Government of Odisha to set up a world-class Petrochemical Complex at Paradip.
(Source: Indian Oil Corporation)
April 10 – In a landmark development, Indian Oil Corporation (Indianoil) has signed a Memorandum of Understanding (MOU) with the Government of Odisha to set up a world-class Petrochemical Complex at Paradip. The MOU was exchanged in the presence of Hardeep Singh Puri, Hon’ble Minister of Petroleum and Natural Gas; Dharmendra Pradhan, Hon’ble Minister of Education; Mohan Charan Majhi, Hon’ble Chief Minister, Odisha; and other senior dignitaries.
With an investment of 61,077 crore rupees (7.1 billion dollars), this marks Indianoil’s largest-ever investment at a single location and a transformative step in India's petrochemical and industrial growth. The upcoming complex will house a dual-feed cracker and associated downstream units for the production of wide range of petrochemicals including Phenol, Polypropylene (PP), Isopropyl Alcohol (IPA), High-Density Polyethylene (HDPE), Linear Low-Density Polyethylene (LLDPE), Polyvinyl Chloride (PVC), Phenol, and Butadiene. These products will serve as key raw materials for specialty chemical sectors like pharmaceuticals, agrochemicals, coatings, and adhesives, significantly reducing import dependency and supporting the Aatmanirbhar Bharat and Make in India missions.
This project builds on Indianoil’s existing 15 MMTPA Refinery-cum-Petrochemical Complex at Paradip and will boost downstream industries and MSMEs across Eastern India.
Cellasto to Develop Second Plant in Shanghai, China
Cellasto is investing roughly 60 million euros to establish a second plant in Shanghai, China.
(Source: BASF)
April 16 – Cellasto, the world leader in Noise, Vibration and Harshness (NVH) components, is investing roughly 60 million euros to establish a second plant in Shanghai, China. This production expansion aims to capitalize on China’s booming electric vehicle market. The new facility will feature advanced mold lines, resulting in a capacity increase of nearly 70 %, with operations expected to start in 2027. A commencement ceremony was held on April 14th to celebrate this expansion.
“BASF has made substantial investments in China since entering the Chinese market 140 years ago. Today’s expansion is another strong testament to BASF’s commitment to staying close to the local market and our customers. As the leading chemical supplier to the automotive industry, BASF strives to accelerate business growth in the automotive sector in China, by leveraging our local production network, strong innovation capabilities and deep market insights,” adds Dr. Jeffrey Lou, President and Chairman Greater China, BASF.
“Four years ago, we celebrated Cellasto's 60th anniversary and the 10th anniversary of our Shanghai plant. This year, with the addition of a second plant, we are achieving another significant milestone. With our state-of-the-art facilities, we are eager to seize the opportunities presented by this dynamic market,” concludes Bjoern Kophstahl, Vice President of Cellasto.
Hidrogenii Commissions Hydrogen Liquefaction Plant in USA
The newly commissioned facility will liquify hydrogen produced by Olin for trailer shipments across the U.S.
(Source: Pixabay)
April 18 – Olin Corporation has recently announced that Hidrogenii, the joint venture between Olin and Plug Power, commissioned its 15 TPD hydrogen liquefaction plant in St. Gabriel, Louisiana. Among the largest electrolytic hydrogen liquefaction facilities in North America, the site marks a major milestone in strengthening the regional hydrogen supply chain and accelerating the U.S. transition to low-carbon energy.
The newly commissioned facility will liquify hydrogen produced by Olin for trailer shipments across the U.S., serving Plug's material handling customers and utilizing Plug's novel spot pricing market. The plant is designed to liquefy up to 15 TPD of hydrogen at maximum capacity, increasing Plug's total production capacity to 40 TPD.
"This Louisiana plant, a milestone in expanding our U.S. hydrogen network, bolsters our financial position by leveraging a dependable, cost-effective hydrogen source, reducing our reliance on third-party suppliers," noted Plug CEO Andy Marsh.
Technip Energies Wins Feed Contract for SAF Project in Australia
Technip Energies has been awarded a Feed contract by Jet Zero Australia for Project Ulysses, a bioethanol to SAF project located in Townsville, Australia.
(Source: Pixabay)
April 22 – Technip Energies has been awarded a Front-End Engineering Design (Feed) contract by Jet Zero Australia (Jet Zero) for Project Ulysses, a bioethanol to sustainable aviation fuel (SAF) project located in Townsville, Australia.
The Feed covers an extensive package of engineering activities, documentation and planning to refine the cost estimate for the project and develop detailed timelines. The project aims to produce 102 million liters of SAF and 11 million litres of renewable diesel annually by 2028 using Australian bioethanol and technologies from Technip Energies and Lanza Jet. Technip Energies’ Hummingbird technology converts the bioethanol to sustainable ethylene and Lanza Jet’s alcohol-to-jet technology transforms the ethylene to SAF.
Sylvain Cabalery, SVP Sustainable Fuels, Chemicals & Circularity at Technip Energies, stated, “We are very pleased to see Project Ulysses moving forward to provide the first alcohol to-jet SAF plant in Australia. With the global aviation industry looking for ways to further secure their supply and lower emissions, Technip Energies and Lanza Jet integrated technology is a smart solution, bringing energy security while at the same time eliminating up to 70 % of greenhouse gas emissions.”
Lhyfe Secures 149 Million Euro Grant for Green Hydrogen Production Plant
The facility is expected to reach a capacity of up to 34 tonnes per day.
(Source: Lhyfe)
April 28 – Lhyfe has announced that the French Prime Minister has officially confirmed, by signature, a 149 million euro grant for its future green hydrogen production plant located near the Grand Canal of Le Havre. The facility is expected to reach a capacity of up to 34 tonnes per day. The project was selected in 2022 by the European Commission as part of the third wave of IPCEI (Important Projects of Common European Interest) dedicated to hydrogen. In March 2024, the French Government announced its decision to award this grant to Lhyfe, through Roland Lescure – then Minister Delegate for Industry and Energy – during a visit to Le Havre.
The contract signed with Bpifrance outlines the terms of implementation for the public funding. Lhyfe will receive an initial advance of 18 million euros by June 2025, enabling it to cover investments already made since 2022 and to launch the next stages. A second tranche will be released in the following months based on the achievement of milestones specified in the contract. Subsequent payments will take the form of reimbursements for eligible and duly justified expenses, contingent upon the successful completion of predefined annual milestones, over a four-year period and up to a maximum total amount of 149 million euros.
With the Green Horizon project, Lhyfe intends to produce up to 34 tonnes of green hydrogen per day near the Grand Canal du Havre (Normandy), one of Europe’s largest industrial port areas.
This site will supply the region’s needs in terms of decarbonization of industry and mobility. The plant will be located near the Yara site in Le Havre, whose decarbonization roadmap includes the use of green hydrogen. Yara is interested in and supports Lhyfe’s project.
The Lhyfe production site, to be located on a 2.8-hectare plot of land in Gonfreville-l’Orcher, is expected to be completed by 2029 and will be one of the first large-scale production sites for decarbonized hydrogen produced by water electrolysis in France and Europe.
Completion of this project will help demonstrate the technical feasibility and economic viability of this solution, which is an essential complement to direct electrification for decarbonizing economies, reducing dependence on fossil fuels and meeting the greenhouse gas emission reduction targets set out in the Paris Agreement.
This type of pioneering project must be implemented swiftly to pave the way for the larger-scale facilities needed to meet the ambitious targets for installed electrolysis capacity (4.5 GW targeted in France by 2030) and greenhouse gas emission reductions outlined in the French and European hydrogen and decarbonization strategies.
This project has been selected by the French Government as part of the call for expressions of interest on hydrogen carried out in France in 2021, integrated into the third wave of IPCEI on hydrogen in 2022 and validated by the European Commission in February 2024. IPCEI are transnational projects identified as strategic by the European Union.
For this project, Lhyfe has already submitted the building permit and the environmental authorization request. Grid connection and availability of the necessary power have been secured.
BASF to Develop New Semiconductor-Grade Sulfuric Acid Plant in Germany
The new production facility at its Ludwigshafen site in Germany will feature cutting-edge purity capabilities to serve growing demand for advanced semiconductor chip manufacturing across Europe.
(Source: BASF)
April 29 – BASF will expand its production capacity for semiconductor-grade sulfuric acid (H2SO4), which is an essential ultra-pure chemical. The new production facility at its Ludwigshafen site in Germany will feature cutting-edge purity capabilities to serve growing demand for advanced semiconductor chip manufacturing across Europe. Operations are expected to start by 2027, coinciding with the capacity expansion of key customers. The BASF investment will be in a high double-digit million-euro range.
With several new chip manufacturing plants being constructed or expanded in Europe, there is an increasingly strong demand for high-quality and high-purity semiconductor-grade chemicals, such as sulfuric acid. This need has been accelerated by a close cooperation partner of BASF, who is currently building a new chip production plant in Europe. These chips are used in automotive, mobile communications and AI chip applications. BASF is investing in the semiconductor chemical value chain based on mutual long-term customer-supplier commitments with its strategic partners.
This expansion will greatly enhance supply chain reliability for BASF’s partners by ensuring a dependable and consistent supply of high-quality semiconductor-grade sulfuric acid produced locally.
Located at the heart of BASF’s integrated chemical production site in Ludwigshafen, the state-of-the-art production plant, backed by rigorous quality control measures, will ensure that customers receive chemicals of exceptional purity and quality, necessary for advanced semiconductor manufacturing processes. Additionally, production in proximity to key customer operations allows BASF to better meet their needs, providing prompt support and minimizing lead times.