Plant Watch Top 10 Engineering Projects of December 2023

Related Vendors

Aker Carbon Capture

LG Chem Europe GmbH

Neste Oyj.

INEOS AG

Ørsted A/S

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Covestro AG

Haldor Topsoe A/S

Fluor corporation (Headquarters)

Idemitsu Kosan Co Ltd Chiyoda-ku

Solvay GmbH

Glatt Ingenieurtechnik GmbH

EDL Anlagenbau Gesellschaft mbH

Pörner Ingenieurgesellschaft mbH

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PROCESS Worldwide brings to you the ‘Top 10 plant engineering projects of December 2023’ from all over the world. Right from Ørsted starting work on Denmark’s first carbon capture project to Fluor securing two contracts for the world’s first net-zero ethylene cracker and derivatives complex, find out all the projects making headlines here

Ørsted Commences Work on Denmark’s First Carbon Capture Project

Dec 04 – Ørsted is embarking on the construction of two carbon capture (CCS) facilities designed to capture and store carbon emissions from the woodchip-fired Asnæs Power Station in Kalundborg and the straw-fired unit at Avedøre Power Station in Greater Copenhagen. This project represents Denmark's first full-scale carbon capture project and signals the dawn of a new era for carbon capture and storage in the country.

It is expected that the carbon capture project, which was awarded a 20-year contract by the Danish Energy Agency in May 2023, will capture 430,000 tonnes of biogenic CO2 annually from the two combined heat and power plants starting from early 2026. The capture and storage of carbon from straw- and woodchip-fired power stations remove CO2 from the atmosphere, making a substantial contribution to Denmark's climate targets for 2025 and 2030.

Ørsted will host a groundbreaking ceremony on December 4 at Avedøre Power Station to celebrate the commencement of construction of Denmark's first full-scale carbon capture project.

Covestro to Modernize Toluene Diisocyanate Production Plant in Germany

Dec 06 – To further strengthen the sustainability and competitiveness of TDI (toluene diisocyanate) production for the manufacture of flexible foams in Europe, Covestro is investing a mid to high double-digit million-euro amount in the modernization of its production plant in Dormagen by 2025. The plant was commissioned in early 2015 and is considered one of the most advanced TDI production facilities in the world due to the use of the gas phase technology developed by Covestro. The work will include the installation of a modern reactor that will enable the reaction energy to be used for energy-efficient steam generation in the future.

The modernization will significantly improve the plant's energy efficiency and thereby reduce CO2 emissions. After the modernization, the plant will consume up to 80 percent less energy than conventional processes for the production of TDI, and greenhouse gas emissions will be reduced by a further 22,000 tons per year. This not only makes a significant contribution to achieving the company's climate targets and safeguarding European TDI production in the face of sharply increased energy costs, but also improves the sustainability performance of the customer industries. The first phase of the project has now been successfully completed with the lifting of the equipment into the plant. All further measures will be implemented gradually until spring 2025. This will ensure a continuous supply of TDI to customers.

The TDI plant in Dormagen has an annual capacity of 300,000 tons. It uses the gas phase technology developed by Covestro, which even before modernization required up to 60 percent less energy and up to 80 percent less solvent than conventional processes. The current investment will significantly increase the efficiency and therefore sustainability of the plant even further. TDI is an important raw material for soft foams, which provide comfort in mattresses and upholstered furniture as well as car seats, for example. The material will continue to play an important role for Covestro and the processing industries in the future.

Fluor Secures Two Contracts for World’s First Net-Zero Ethylene Cracker and Derivatives Complex

Dec 06 – As previously announced and recognized in the third quarter on a confidential basis, Fluor Corporation was awarded two contracts from Dow for the construction of the world’s first net-zero scope 1 and 2 emissions integrated ethylene cracker and derivatives complex in Fort Saskatchewan, Alberta, Canada.

The reimbursable services contracts represent a total value of more than 3 billion dollars and consist of engineering, procurement and construction management for a new ethylene cracker unit and for the associated utilities, power and infrastructure facilities. The overall program also includes the expansion and retrofit of Dow’s existing manufacturing facilities.

Dow announced in November that its board of directors declared the Final Investment Decision for the project, which is part of Dow’s Path2Zero program, intended to lower the greenhouse gas emissions of its manufacturing facilities while growing capacity and delivering low-emissions products to customers.

Dow’s net-zero scope 1 and 2 emissions integrated ethylene cracker and derivatives complex is projected to decarbonize approximately 20 % of the company’s global ethylene capacity while growing its polyethylene capacity by approximately two million metric tonnes per annum.

In February, Fluor was awarded the front-end engineering and design contract for the project. Construction began in July on early works and the program is expected to come online in phases, with the first phase starting up in 2027 and the second phase starting up in 2029.

Solvay to Build First Carbon-Neutral Soda Ash Plant in Saudi Arabia

Dec 12 – To establish the world’s first carbon-neutral soda ash production facility in Neom, Saudi Arabia, Solvay is partnering with Enowa, Neom’s energy and water company, Pending the results of an in-depth feasibility study and customary regulatory approvals, the companies plan to begin operation of the groundbreaking plant by 2030. The state-of-the-art facility will serve as a vital component in Enowa's Water Sustainability Strategy and is in line with Neom's plans to develop a zero-liquid discharge water management system.

Strategically located off of the Red Sea coast to support access to markets across the Middle East, Africa and Southeast Asia, the renewable-powered plant will convert seawater brine into soda ash and integrate the e.Solvay process for sustainable and carbon-neutral soda ash production. The partners aim to start 500,000 tons soda ash nameplate capacity by 2030 which would gradually increase up to 1.5 million tons by 2035, with the potential addition of sodium bicarbonate production.

Earlier this year, the e.Solvay pilot production process began operations in Europe. Designed to evaluate the viability of a more sustainable and competitive soda ash production technology, the pilot has yielded positive results, showcasing potential for low emissions, reduced resource and energy consumption, and complete removal of limestone residues. The next two-year pilot phase will set the stage for industrial-scale production to begin in the latter half of the decade, aligning with the Neom implementation timeline.

Neste Refinery in Porvoo is Preparing for Major Turnaround

Dec 14 – Scheduled to take place from April to June 2024, the major turnaround at Neste’s Porvoo refinery involves the temporary shutdown of the entire refinery. The primary objectives of this shutdown are to facilitate regulatory inspections, perform essential maintenance work, and undertake selected asset improvement initiatives. The estimated duration of this turnaround is approximately nine weeks.

Sami Wasström, Head of Turnarounds at Oil Products, Neste, emphasized the significance of this undertaking, stating, "The major turnaround is an investment in securing safety, availability, and competitiveness of the refinery. In addition, the turnaround will contribute to Neste’s ambition to make the Porvoo refinery the most sustainable refinery in Europe by 2030 and to reach carbon-neutral production by 2035. Together with our audited contractors, we are committed to creating a safe working environment at the Porvoo refinery and a successful turnaround."

One notable aspect of Neste's approach to the major turnaround is its emphasis on ethical and responsible practices. All contractors participating in the turnaround are required to commit to Neste's Supplier Code of Conduct, which covers various crucial areas, including human and labor rights, occupational health and safety, climate responsibility, environmental stewardship, and ethical business conduct. This commitment reflects Neste's dedication to upholding high standards throughout the duration of the turnaround.

Importantly, the company’s harbor and distribution terminal at the refinery will continue to operate normally during the major turnaround. This means that product deliveries to customers will proceed without disruptions.

Aker Carbon Capture Wins Feasibility Study for New Waste-to-Energy Plant

Dec 18 – Aker Carbon Capture has been awarded a feasibility study by Limeco, a Swiss company that is planning to construct a new waste-to-energy plant in Dietikon, in the canton of Zurich. Carbon Capture and Storage is expected to be mandatory for future waste-to-energy plants in Switzerland.

The new waste incineration plant will consist of two identical incineration lines. Aker Carbon Capture’s standardized and modularized Just Catch carbon capture units are developed for this volume of CO2 and will be able to provide a perfect fit with Limeco’s requirements. The CO2 will be liquified for transport by truck or train. Since Limeco’s waste-to-energy plant is a greenfield project to produce district heating, heat integration between the incineration plant and the carbon capture plant can be used to maximize the district heat production. This will provide an overall attractive business case for Limeco, while at the same time contributing to Switzerland’s national ambitions for reduction of greenhouse emissions.

Switzerland currently has 29 waste-to-energy plants that emit a total of 4.5 million tonnes of CO2 per year. Approximately 50 % of the CO2 emissions are biogenic, while the other 50 % are of fossil origin.

Ineos Phenol Begins Production at Europe’s Largest Cumene Facility

Dec 19 – The world scale 750,000 tonne facility produces up to 50 % lower CO2 emissions per tonne of product. The significant reduction in emissions is enabled by pioneering cumene technology in combination with unique heat integration at the Marl Chemical Park in Germany.

The well-located plant will use existing pipeline connections between Ineos’ phenol and acetone production sites in Gladbeck, the Evonik Chempark in Marl, and the BP refinery and cracker complex in Gelsenkirchen. The site also benefits from the nearby Marl harbour waterway connection. Most of the waste heat from the plant is used for a district heating circle further reducing the carbon footprint of the site.

Cumene is an essential raw material in the production of phenol and acetone, which are used in a wide variety of applications including medical applications ranging from aspirin to throat lozenges and sprays. Their derivatives are also used in contact lenses, artificial joints, dentures and dental fillings, as well as many other applications.

Ineos is the world’s largest producer of phenol and acetone, and the largest consumer of cumene.

The plant was constructed in association with CAC Engineering, who managed the project under an EPCM model. CAC work included Feed verification, detail engineering, procurement, construction and pre-commissioning of the plant.

Topsoe Secures Hefty Grant for Developing Solid Oxide Electrolyzer Cells Factory

Dec 19 – Topsoe has signed a grant agreement with EU’s Innovation Fund for a total of 94 million euros. The grant is a recognition of Topsoe’s state-of-the art SOEC electrolysis technology and the innovation inherent in building this first of its kind SOEC factory. The factory is Topsoe’s single biggest investment to date.

The factory will manufacture advanced, energy efficient Solid Oxide Electrolyzer Cells (SOEC) that are essential in the production of green hydrogen and its derivatives. Electrolyzers are key for decarbonizing energy-intensive industries like steel, mining, and long-distance transportation that account for approximately 30 % of global greenhouse gas emissions and cannot easily be electrified. In Europe, the EU Commission has announced a proposal to deploy 40 GW of hydrogen electrolyzer installation and 10 million tonnes of green hydrogen production.

When used to produce green hydrogen, electrolyzers from Topsoe’s factory will reduce emissions by approximately 7.5 million tonnes of CO2 equivalent over the first ten years of operation when compared to hydrogen produced from natural gas.

Idemitsu Kosan Builds Second Syndiotactic Polystyrene Production Plant in Malaysia

Dec 20 – Idemitsu Advanced Materials (Malaysia), a subsidiary of Idemitsu Kosan Co., has newly constructed a second SPS (syndiotactic polystyrene) production plant in Pasir Gudang, Johor, Malaysia, and launched commercial operation in November 2023.

The production capacity of this plant is 9,000 tons per year, and with the second SPS production plant in operation, the production scale of SPS resin, our proprietary material, will be doubled. The new two-location system with the first SPS production plant at the Chiba Complex has realized a more stable production and supply system.

Pasir Gudang, Malaysia, where the second SPS production plant has been constructed, is one of our key manufacturing sites for petrochemical products. The construction of the plant has been promoted because it is located in Southeast Asia, where demand is expected to grow, and it is possible to procure SM (styrene monomer), the raw material for SPS, from Idemitsu SM (Malaysia) which is located next to the SPS plant.

LG Chem Breaks Ground for New Cathode Plant in U.S.

Dec 22 – LG Chem has commenced the construction of a cathode plant in the U.S., intending to establish a production hub for the global battery material market. The facility, located in Montgomery County, Clarksville, Tennessee, will locally produce cathode materials optimized for North American electric vehicles (EVs) and collaborate with key partners from development to supply chain.

On December 20, LG Chem held the groundbreaking ceremony for its cathode plant in Tennessee. The event was attended by guests including Tennessee Governor Bill Lee, Commissioner Stuart McWhorter, Senator Marsha Blackburn, Korean Ambassador to the United States Cho Hyun-dong, Clarksville City Mayor Joe Pitts and Montgomery County Mayor Wes Golden. Key attendees from LG Chem were CEO Shin Hak-cheol, President of Advanced Materials Company Nam Chul and Head of Battery Materials Business Unit Lee Hyang-mok.

LG Chem will invest around KRW 2 trillion (1.6 billion dollars) in the first phase to build a cathode plant with an annual capacity of 60,000 tons on a 1.7 million square meter site in Clarksville, Tennessee. The plant is expected to be the largest cathode material facility in the United States, capable of producing cathode materials for approximately 600,000 high-performance pure electric vehicles with a range of 500 km annually.

Starting from 2026, the Tennessee cathode plant will mass-produce NCMA (Nickel, Cobalt, Manganese, Aluminum) cathode materials. LG Chem plans to diversify its product portfolio through future-generation cathode material products and expand production capacity in response to increasing demand. LG Chem previously signed a comprehensive agreement for the long-term supply of 950,000 tons of cathode materials with General Motors (GM) last year and a North American cathode material supply contract worth KRW 2.9 trillion (2.5 billion dollars) with Toyota in October this year.

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