Plant Watch Top 10 Engineering Projects of January 2026

PROCESS Worldwide brings to you the ‘Top 10 plant engineering projects of January 2026’ from all over the world. Right from BASF starting up its steam cracker at the Verbund site in China to Wood securing a contract for the world's first full-scale iron nitride permanent magnet plant, find out all the projects making headlines here.

BASF Starts Up Steam Cracker at Verbund Site in China

Jan 13 – BASF has successfully commissioned the steam cracker at its newly built Verbund site in Zhanjiang in South China as scheduled. This is the first cracker in the world using 100 percent renewable energy to drive its main compressors (edrives).

As the heart of the Verbund, the steam cracker supplies important basic chemicals such as ethylene and propylene to multiple plants on site. It is the starting point for many chemical value chains: long chain hydrocarbons such as naphtha or butane are cracked with the help of steam. The ethylene capacity amounts to one million metric tons per year.

“This important milestone at our Zhanjiang Verbund site significantly strengthens BASF’s diversified value chains in China and positions us well to support customers across a wide range of industries,” said Dr. Stephan Kothrade, member of the Board of Executive Directors of BASF and Chief Technology Officer.

Wood Wins Contract for World's First Full-Scale Iron Nitride Permanent Magnet Plant

Jan 15 – Wood has secured the engineering, procurement and construction management (EPCM) contract for Niron Magnetics’ Plant 1 in Sartell, Minnesota, the world's first full-scale Iron Nitride permanent magnet facility.

This groundbreaking plant will manufacture 1,500 tons of Iron Nitride permanent magnets annually once fully operational in 2027, creating a resilient US supply chain for the magnets used in critical industries including automotive, defense systems, industrial motors, and consumer electronics.

Unlike traditional magnets that rely on rare earth materials and intensive mining, Niron Magnetics’ technology starts with iron and nitrogen- two abundant, easily sourced materials - to deliver magnets made with a fully-domestic supply chain and sustainable manufacturing processes. John Day, President of Projects Western Hemisphere at Wood, commented: “The Sartell Plant 1 project is a game-changer for sustainable magnet production at scale.”

“Having delivered the initial design, we’re now taking this project from concept to execution. Leveraging our EPCM expertise and first-of-a-kind scale-up experience, we’re enabling Niron Magnetics to deliver a high-production facility that reduces reliance on rare earths, helps power the future of sustainable energy and mobility, and creates a resilient supply chain for the U.S. economy.”

Wood’s scope will be delivered by a team of over 80 engineering and project delivery specialists based in the U.S.

Borouge Completes Proof of Concept for AI-Powered Autonomous Operations

Jan 19 – Borouge has recently announced the successful completion of a proof of concept for AI-powered autonomous operations at its Ruwais facility, delivered in collaboration with Honeywell. The milestone supports Borouge’s strategy to enhance operational performance, strengthen long-term competitiveness, and contribute to Adnoc’s ambition to become the world’s most AI-enabled energy company.

Building on trials conducted in 2025, the proof-of-concept marks tangible progress toward developing the petrochemical industry’s first AI-driven control room for full-scale, real-time operations. Conducted in a live production environment, the results indicate the potential to increase efficiency by up to 20 %, enhancement of reliability by reducing downtime by 20 %, and improve production performance while lowering operating costs by up to 15 %. The technology also enhances process safety and supports more sustainable operations by significantly reducing energy consumption and associated emissions.

The initiative is a core component of Borouge's AI, Digitalization & Technology (AIDT) programme, which targeted 575 million dollars in value generation in 2025 through a portfolio of AI- and digital-led initiatives. The programme reflects the Company’s continued focus on disciplined execution, operational impact and long-term value creation.

Jim Masso, President and CEO of Honeywell Process Automation, added: “Our collaboration with Borouge demonstrates how AI-enabled autonomous operations can be deployed safely and effectively in a live production environment. This milestone highlights the potential of advanced connected solutions to deliver meaningful improvements in efficiency, reliability and operational performance at scale.”

Following the successful proof of concept with Honeywell, Borouge will advance work to further demonstrate the potential of autonomous operations and assess

opportunities to scale the technology across its Ruwais facilities.

Veolia Launches Multi-Energy Cogeneration Plant in Poland

Jan 20 – Veolia has recently unveiled a flagship district heating project in Poznań: a multi-energy cogeneration plant that supplies heat to 60 % of Poznań's 560,000 residents. Thanks to an innovative technology, it has increased efficiency to 92 % and significantly advanced decarbonization, reducing CO₂ emissions by 25 %. This historic initiative in the city's coal phase-out strategy paves the way for the establishment of a completely coal-free district heating network by 2030, using biomethane, hydrogen, and other local energy sources.

This is the biggest change in the history of district heating in Poznań, improving air quality, enhancing energy security, and ensuring a stable heat supply for the city's residents.

"Leveraging Veolia's district heating expertise, we're taking a decisive step in Poland's energy transition. This two-phase project that we're unveiling will eliminate over 300,000 tons of coal use annually, ultimately reaching zero coal consumption. For Poznań, this means cleaner air, improved quality of life, and a more affordable, reliable & resilient energy network," said Estelle Brachlianoff, Chief Executive Officer of Veolia.

Jacobs Selected for Modernizing Mega Advanced Wastewater Treatment Plant in USA

Jan 22 – Jacobs has been selected as the progressive design-build contractor for upgrades to the San José–Santa Clara Regional Wastewater Facility (RWF) in California. This 200-million-dollar project will modernize the city’s biosolids treatment infrastructure, delivering long-term reliability at the second largest advanced wastewater treatment plant in the western United States.

As the design-build partner, Jacobs will upgrade and replace aged mesophilic digesters. These digester improvements will reduce the amount of solids to be

hauled offsite for disposal while also enhancing the conversion of biogas produced which directly fuels the facility’s award-winning cogeneration system — also designed and built by Jacobs. A new Fats, Oils & Grease (Fog) receiving station will accept high-strength waste from local businesses and convert it to clean energy, cutting natural gas use and lowering greenhouse gas emissions.

Jacobs’ innovative design approach, including the potential integration of its Microbial Hydrolysis Process (MHP), is expected to increase biogas output by up to 36 % and reduce biosolids production by as much as 74 wet tons per day — about the weight of 50 mid-size cars. The project also prioritizes seismic resiliency and operational flexibility to meet future growth through 2077.

Jacobs will deliver the additional digester facility upgrades under a design-build contract, supported by Walsh Construction and Structural Technologies as lead contracting partners.

Borealis to Expand Polypropylene Production in Germany

Jan 23 – Borealis has announced a 49-million-euro strategic investment to scale up production of Borstar Nextension polypropylene (PP) at its manufacturing site in Burghausen, Germany. This will expand commercial production of next-generation single-site polypropylene (SSPP) grades that deliver enhanced purity, processability, and performance - supporting customers in key sectors including packaging, healthcare, mobility, and fibers, to meet evolving market and regulatory demands.

The investment will support the transition to high-performance monomaterial PP solutions. By integrating a tailored combination of performance properties into a single PP material, Borstar Nextension technology facilitates material substitution in complex multilayer structures – supporting design for circularity, reducing weight, and improving overall performance.

In packaging, this innovation enables brand owners and converters to comply with the EU Packaging and Packaging Waste Regulation (PPWR), including the target of achieving 100 % recyclable packaging by 2030. A growing portfolio of Borstar Nextension PP grades is already demonstrating these benefits in flexible packaging applications, combining improved processability with superior sustainability and a step change in purity, clarity and sealing performance.

“By scaling up Borstar Nextension PP production, we empower our customers to stay ahead in a rapidly changing regulatory and market landscape. It’s another example of our commitment to increase the availability of innovative, recyclable polymer materials suitable for a wide range of applications across multiple industries,” says Craig Arnold, Borealis EVP Polyolefins, Circular Economy Solutions and Base Chemicals.

Covestro Begins Production of Thermoplastic Polyurethanes at New Site in China

Jan 27 – Covestro has commenced production at its new thermoplastic polyurethanes (TPU) manufacturing site in Zhuhai, a coastal city in South China. The first phase, representing a mid-double-digit million-euro investment, will produce approximately 30,000 tons of TPU annually, meeting growing demand for this versatile material across industries including IT, automotive and footwear.

The investment in this entirely new site, originally announced in 2023, marks a significant milestone in Covestro’s region-for-region strategy and its commitment to growth in its Solutions & Specialties business. The Zhuhai site will be developed in three phases across a 45,000-square-meter area, with maximum production capacity estimated to reach 120,000 tons a year upon completion of the final phase, expected in the 2030s. This will then make it the company’s largest TPU production facility globally.

The Zhuhai site will be strategically supported by a regional TPU R&D Center in Changhua and a new TPU application development (AD) center in nearby Guangzhou, which integrate technical acumen with innovative solutions and tailored services. Together, these facilities are expected to generate powerful regional synergies through collaborative and complementary strengths, positioning Covestro optimally to serve its customers throughout the region.

The Zhuhai site is capable of producing TPU with the label “CQ”. Covestro materials with this designation contain at least 25 percent alternative, non-fossil raw materials, supporting customers in reducing their carbon footprint in final products, especially important in sectors such as electronics where sustainability has become a global trend.

Topsoe Selected as Ammonia Technology Licensor for Saudi Project

Jan 28 – Topsoe has recently announced its selection as the ammonia technology licensor for Acwa's Yanbu Green Hydrogen Project in the Kingdom of Saudi Arabia.

The technology delivered by Topsoe will enable the produced green hydrogen from the Yanbu Project to be converted into ammonia. Besides the dynamic ammonia technology, Topsoe will also deliver engineering, proprietary equipment and catalysts to Sinopec and Tecnicas Reunidas, who have jointly been awarded the Feed-contract (Front-End Engineering Design).

The agreement further strengthens the strategic partnership between Topsoe and Acwa, and by integrating Topsoe’s advanced dynamic ammonia technology, the project will support the production of green ammonia at scale.

Driss Berraho - EVP Business Development Green Hydrogen at Acwa, said: “As one of Saudi Arabia’s leading enablers of the green hydrogen economy, Acwa is developing full-scale, utility-level facilities. Our collaboration with Topsoe at the Yanbu Green Hydrogen Project will convert competitive renewable-energy into green hydrogen-based fuels, including green ammonia, at industrial scale. This development strengthens the hydrogen corridors that will connect competitive renewable resources with global demand centres and contribute to achieving the Kingdom’s Vision 2030 industrial transformation.”

The Yanbu Green Ammonia Project is a large-scale development for GW scale green hydrogen, and with Topsoe’s technology, Acwa will be able to convert the hydrogen into ammonia. The licensing agreement covers the first mega-scale green ammonia units in Yanbu, with a capacity of 2,700 metric tons per day (MTPD) and the interest to replicate the scheme in subsequent units.

Green Ammonia is expected to play a critical role in the journey towards net zero: It can be transported using existing infrastructure; and it has multiple end-uses, not only as a fuel or hydrogen carrier but also to help decarbonize industrial processes like steel and cement production.

Solvay Inaugurates Europe’s First Bio-Circular Silica Facility

Jan 29 – Solvay inaugurated its new bio-circular silica facility at its plant in Livorno, Italy, marking a major milestone in Europe’s industrial transformation toward sustainability. This investment positions Solvay as a proactive partner in achieving the European Green Deal objectives and the upcoming Ecodesign for Sustainable Products Regulation (ESPR), while reinforcing Italy’s role as a hub for green innovation.

The new unit produces highly dispersible silica (HDS) using bio-based sodium silicate derived from rice husk ash, an agricultural byproduct. This breakthrough process reduces CO₂ emissions by 35 % per ton of silica compared to traditional methods and creates a local circular value chain that benefits the agricultural sector, industry and communities.

Philippe Kehren, Chief Executive Officer of Solvay opines, “By acting now, Solvay is helping tire manufacturers prepare for future EU requirements and meet their own sustainability goals,” said Philippe Kehren, CEO of Solvay. “Livorno is a tangible example of how we turn circular economy principles into industrial reality, enabling progress for generations.”

"Solvay has managed to transform an agricultural byproduct into a high-performance material on an industrial scale. We are looking forward to integrating more and more rice husk ash silica as a recycled material in our tire production and are very satisfied with its performance. We are keen on innovative, renewable and recycled materials because they support our ambitious sustainability roadmap,” said Jana Striezel, Head of Purchasing at Continental Tires.

This inauguration is part of Solvay’s global circular silica strategy, which will convert other silica production sites worldwide to use ISCC Plus certified raw material by 2026. Livorno remains unique as the first site to use rice husk ash, while other sites will leverage other local industrial waste streams. By adopting Solvay’s circular silica, tire manufacturers can already achieve up to 15 % recycled or renewable materials in their tire composition, contributing significantly to their target of 40 % by 2030.

Lanzatech to Develop Next Generation Ethanol Facility

Jan 30 – Lanzatech Global (Lanzatech) has been awarded a contract by Spray Engineering Devices (SED) to build a next generation ethanol facility using sugarcane bagasse, a widely available agricultural waste product, for production of sustainable fuels and chemicals.

The facility, projected to process up to 300 tons per day of bagasse, will be in the state of Uttar Pradesh, India, and is a key component of the "SED Smart Village" concept. The SED Smart Village framework is designed to capture the full economic value of renewable power and carbon resources. The model anticipates that abundant low-cost power will shift carbon demand toward high-value products like green chemicals, polymers, aviation fuels, and e-fuels. In addition, the Lanzatech project is expected to generate nutrient-rich biochar (5–10 %), that can be used in local farming communities to improve soil fertility.

Lanzatech equips industrial facilities with bioreactor hardware that works like a brewery, but instead of using yeast to convert sugar into beer, proprietary microbes convert carbon-rich gases, including CO2 coupled with green H2, to ethanol, a key building block for the production of consumer goods and profitable fuels, including sustainable aviation fuel (including e-fuels) and renewable diesel.

By leveraging the existing supply chain, the facility will divert bagasse/biomass waste from being burned and enable local production of fuels, chemicals, and raw materials. This innovative approach supports circular economies and helps build a more resilient future for sugarcane-growing communities. The plant is expected to begin operations within two years.

This project will mark one of the first instances of a private company developing an ethanol project, using sugar industry by-product bagasse, under the PM JI-Van Yojana, an Indian government program designed to support the production of advanced bioethanol from agricultural and other industrial waste.

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