Plant Watch Top 10 Engineering Projects of March 2025

From BASF, ABB, OMV, Covestro, Thyssenkrupp Uhde, Mitsubishi Gas Chemical, Aramco, Invenergy, Total Energies, 13 min Reading Time

Related Vendors

PROCESS Worldwide brings to you the ‘Top 10 plant engineering projects of March 2025’ from all over the world. Right from ABB and Charbone Hydrogen collaborating for green hydrogen production units to Aramco launching Saudi’s first CO2 direct air capture test unit, find out all the projects making headlines here.

At a glance: Plant engineering projects from across the globe.(Source:  Sasint - stock.adobe.com)
At a glance: Plant engineering projects from across the globe.
(Source: Sasint - stock.adobe.com)

BASF Inaugurates Water Electrolyzer at Ludwigshafen Site in Germany

The individual electrolyzer modules are linked to each other and to the H2 network at the site in three so-called arrays.(Source:  BASF)
The individual electrolyzer modules are linked to each other and to the H2 network at the site in three so-called arrays.
(Source: BASF)

March 18 – Germany’s largest proton exchange membrane (PEM) electrolyzer has gone into operation at BASF’s Ludwigshafen site. Designed to produce CO2-free hydrogen, the electrolyzer has a connected load of 54 megawatts and the capacity to supply the main plant with up to one metric ton of this substantial chemical feedstock every hour. After a construction period of around two years, the plant was officially inaugurated recently in the presence of the Rhineland-Palatinate State Minister for Climate Protection, Environment, Energy, and Mobility Katrin Eder; and Udo Philipp, State Secretary at the German Federal Ministry for Economic Affairs and Climate Action.

Built in cooperation with Siemens Energy, the water electrolyzer is embedded in the production and infrastructure at the Ludwigshafen site, making it truly unique in terms of its interface and integration into a chemical production environment. A total of 72 stacks – modules in which the actual electrolysis process takes place – have been installed in the system. The electrolyzer has the potential to reduce greenhouse gas emissions at BASF’s main plant by up to 72,000 metric tons per year.

The emission-free production of hydrogen – using electricity from renewable sources – is fundamental to the market ramp-up of chemical

products with a reduced carbon footprint. Once produced, the hydrogen is fed into the site’s hydrogen Verbund network and distributed to the production facilities as a raw material. In addition to using, it as a feedstock for chemical products, BASF plans to supply hydrogen for mobility in the Rhine-Neckar Metropolitan Region, supporting the development of a hydrogen economy in the area.

In cooperation with the State of Rhineland-Palatinate, the German Federal Ministry for Economic Affairs and Climate Action provided funding of up to 124.3 million euros for the construction of the plant – 37.3 million euros of which was financed by the government of Rhineland-Palatinate. BASF’s investment in the project amounts to around 25 million euros. The project, entitled Hy4chem, was selected as part of the IPCEI Hydrogen expression of interest procedure and subsequently funded as an individual project.

Among other applications, hydrogen is used in the production of ammonia, methanol, and vitamins. Until now, hydrogen has been produced at the Ludwigshafen location primarily by means of natural gas-based steam reforming or as a coupling product and by-product. With the electrolyzer, BASF is now taking an important step in the transformation of hydrogen production technology.

ABB, Charbone Hydrogen Collaborate for Green Hydrogen Production Units

ABB and Charbone Hydrogen Corporation have signed a MOU agreement to collaborate on the development of up to 15 modular and scalable green hydrogen production facilities across North America over the next five years.(Source:  ABB)
ABB and Charbone Hydrogen Corporation have signed a MOU agreement to collaborate on the development of up to 15 modular and scalable green hydrogen production facilities across North America over the next five years.
(Source: ABB)

March 18 – ABB and Charbone Hydrogen Corporation – an integrated green hydrogen production company based in Montreal, Canada – have signed a Memorandum of Understanding (MOU) agreement to collaborate on the development of up to 15 modular and scalable green hydrogen production facilities across North America over the next five years, providing a clean fuel source for existing hydrogen users and heavy industrial processes such as steelmaking, which currently use grey hydrogen as an energy source.

The MOU scope positions ABB as the preferred supplier for the design, engineering, fabrication, testing and supply of modular and standard electrical substations (ehouses) for the interconnection between production facilities and local utilities. ABB will support Charbone in standardizing basic engineering for systems and components across its project portfolio, to increase energy efficiency and reliability. Future scope may also see ABB operate as the main automation, electrification and telecom contractor depending on project requirements.

Among the sites covered by the collaboration is Charbone’s flagship Sorel-Tracy facility near Montreal in Québec, Canada. The facility is expected to be connected to the Hydro-Québec grid by the end of quarter two in 2025, using hydro electricity to power green hydrogen electrolyzers. The plant will create a blueprint for the design and engineering of modular and scalable equipment for other sites being developed by Charbone. The next project to get underway will be in the greater Detroit area in the US, which is the manufacturing base for major automotive companies.

Gouvernement du Québec has developed a localized Green Hydrogen and Bioenergy Strategy to support the deployment of hydrogen and bioenergy to power industrial sectors such as transportation, primary metals and chemicals. It identifies green hydrogen and bioenergy as having the potential to reduce Québec’s consumption of petroleum products by nearly one billion liters a year by 2030. This could cut the region’s greenhouse gas emissions by four megatons of carbon dioxide a year – the equivalent of removing 1.2 million gasoline-powered vehicles from the roads.

Subscribe to the newsletter now

Don't Miss out on Our Best Content

By clicking on „Subscribe to Newsletter“ I agree to the processing and use of my data according to the consent form (please expand for details) and accept the Terms of Use. For more information, please see our Privacy Policy. The consent declaration relates, among other things, to the sending of editorial newsletters by email and to data matching for marketing purposes with selected advertising partners (e.g., LinkedIn, Google, Meta)

Unfold for details of your consent

OMV Inaugurates New Innovative Plant to Process Hard-to-Recycle Mixed Plastic Waste

OMV has now started-up the next-scale expansion of its innovative proprietary Reoil technology at the Schwechat refinery near Vienna.(Source:  OMV)
OMV has now started-up the next-scale expansion of its innovative proprietary Reoil technology at the Schwechat refinery near Vienna.
(Source: OMV)

March 21 – OMV has recently announced a significant milestone in the chemical industry following 15 years of pioneering research and development. The company has now started-up the next-scale expansion of its innovative proprietary Reoil technology at the Schwechat refinery near Vienna. OMV’s new plant can process up to 16,000 metric tons of hard-to-recycle mixed plastic waste annually - equivalent to the annual plastic waste generated by 160,000 Austrian households.

Reoil was initially developed in 2009, positioning OMV as one of the global pioneers in chemical recycling. Its goal was to enhance the sustainability of plastics by reintegrating valuable resources into the value chain, thereby avoiding their disposal through incineration or landfill. Reoil achieves this by transforming post-consumer mixed plastic waste into pyrolysis oil, which serves as a raw material for producing sustainable base chemicals. These chemicals are then converted into various essential everyday applications, including food packaging, healthcare products, and components for electric vehicles. The Reoil technology unleashes a positive environmental effect: In 2030, a 34 percent reduction of CO2 can be achieved if post-consumer mixed plastic waste is chemically recycled in the Reoil plant instead of being incinerated.

The initial Reoil pilot plant at the OMV Schwechat refinery has been operational since 2018, achieving nearly 30,000 cracking hours to date. During this pilot period, more than 2.1 million kilograms of plastic waste have been processed sustainably. The successful operations of the pilot plant prompted the decision to construct a larger, scaled-up facility, which OMV has now completed and started-up. Both Reoil plants are ISCC Plus certified.

As a next step, OMV is developing a first-of-its-kind full-scale industrial plant for chemical recycling. The final investment decision by OMV for this plant is subject to internal approvals. On March 12, 2025, OMV secured up to 81.6 million euros in EU funding for its industrial Reoil plant - the largest public grant ever awarded to the OMV Group.

Covestro Completes Modernization of its Toluene Diisocyanate Unit in Germany

In the modernized plant, reaction heat from production is used to generate steam, reducing CO₂ emissions by 22,000 tons annually.(Source:  Covestro)
In the modernized plant, reaction heat from production is used to generate steam, reducing CO₂ emissions by 22,000 tons annually.
(Source: Covestro)

March 21 – Covestro has successfully completed the modernization of its TDI (Toluene Diisocyanate) plant in Dormagen. At an event with around 60 invited guests from politics, business, and staff, including North Rhine-Westphalia Environmental Minister Oliver Krischer, Covestro officially commissioned the plant and announced its new target for increasing energy efficiency in production.

The modernized plant consumes 80 percent less energy than conventional processes, achieving a CO2 reduction of 22,000 tons per year. This is made possible by a new reactor weighing over 150 tons (330,700 lbs) and almost 20 meters (65.6 feet) high, which uses the generated reaction energy for steam production. Covestro started the modernization in summer 2023. In total, the project installed over 3.5 kilometers of new pipelines, around 14 kilometers of cables, and hundreds of new equipment, valves, and monitoring instruments in the plant.

During the event, Covestro also presented its new, ambitious energy efficiency target for global production. The company targets a 20 percent reduction in CO2 emissions from energy use per ton of product by 2030 compared to 2020, underlining the central importance of energy efficiency as a lever for achieving operational climate neutrality by 2035. The Dormagen TDI plant, with its annual capacity of 300,000 tons, serves as a prime example of the successful transformation of existing production facilities toward greater energy efficiency.

The Federal Ministry for Economic Affairs and Climate Action (BMWK) has supported this modernization through its federal funding program for energy and resource efficiency.

Thyssenkrupp Uhde Wins Contract for New Nitric Acid Plant in India

As one of India’s largest nitric acid facilities, the new plant will be equipped with Uhde’s highly effective and proven Envinox technology to reduce greenhouse gas emissions by eliminating nitrogen oxides from nitric acid production.(Source:  Thyssenkrupp Uhde)
As one of India’s largest nitric acid facilities, the new plant will be equipped with Uhde’s highly effective and proven Envinox technology to reduce greenhouse gas emissions by eliminating nitrogen oxides from nitric acid production.
(Source: Thyssenkrupp Uhde)

March 25 – Thyssenkrupp Uhde has been awarded a contract by Gujarat Narmada Valley Fertilizers & Chemicals (GNFC) for the construction of a Weak Nitric Acid (WNA - III) Plant in Bharuch, Gujarat, India. The scope of work includes license, basic engineering, detailed engineering, procurement, construction, commissioning, and start-up services.

Based on advanced Thyssenkrupp Uhde technology, the design puts a focus on operational efficiency, safety, and sustainability. The plant will have a capacity of 600 metric tons per day (MTPD) of weak nitric acid. As one of India’s largest nitric acid facilities, the new plant will be equipped with Uhde’s highly effective and proven Envinox technology to reduce greenhouse gas emissions by eliminating nitrogen oxides from nitric acid production.

The long-standing partnership between Thyssenkrupp Uhde and GNFC, spanning over three decades, is characterized by several successful projects, particularly in the nitric acid sector. The WNA - I as well as WNA - II plants were also licensed by Thyssenkrupp Uhde. This collaboration has laid a foundation of trust and technical excellence, which continues with the WNA - III project.

The project will be carried out by Thyssenkrupp Uhde’s local subsidiary in India.

Mitsubishi Gas Chemical Begins Construction of Methanol Demonstration Plant

The facility will have an annual production capacity of 100 tons of methanol and is expected to begin demonstration operations in FY2026.(Source:  Pixabay)
The facility will have an annual production capacity of 100 tons of methanol and is expected to begin demonstration operations in FY2026.
(Source: Pixabay)

March 25 – Mitsubishi Gas Chemical Company has commenced construction of a methanol production demonstration facility (hereinafter referred to as “the Demonstration Facility”) within its Mizushima Plant. The facility will utilize diverse gases, including CO2 and industrial by-product gases as raw materials.

The construction of the Demonstration Facility aligns with the objectives outlined in the Memorandum of Understanding signed with JFE Steel Corporation and Mitsubishi Chemical Corporation, as announced in a release dated 24 March this year. The facility will have an annual production capacity of 100 tons of methanol and is expected to begin demonstration operations in FY2026.

The Demonstration Facility has been selected as an indirect subsidy project for FY2024 under the “Subsidy for Petroleum Supply Structure Improvement Projects” program operated by the Ministry of Economy, Trade & Industry’s Agency for Natural Resources and Energy.

Reducing GHG emissions in the industrial sector is a major societal challenge in addressing climate change. Methanol, one of the fundamental chemical substances, can be synthesized from captured CO2, waste plastics, biomass, and other sources. It is gaining attention as a sustainable next-generation energy source, including marine fuel, and is widely regarded as a key material for GHG reduction and the establishment of a carbon-recycling society due to its diverse applications in various industries.

MGC, as a comprehensive methanol manufacturer, leverages its long-standing expertise, knowledge, and experience to promote its platform "Carbopath," which aims to create a resource-recycling society through methanol in partnership with cross-sectoral collaborators. The Demonstration Facility will enable the demonstration of methanol production technology utilizing diverse gases as raw materials, including CO2 and by-product gases from industrial processes.

From FY2026, the facility will seek to validate technology for producing methanol by directly reacting by-product gases emitted from the steel-manufacturing process with hydrogen. Furthermore, the facility is being designed as a mobile plant that can be relocated, thereby enabling future demonstrations of methanol production technology from diverse gas sources across various locations in Japan.

Through the operation of the Demonstration Facility, MGC is committed to contributing to the realization of a sustainable, resource-recycling society through methanol.

Aramco Launches Saudi’s First CO2 Direct Air Capture Test Unit

The pilot plant, developed in collaboration with Siemens Energy, represents a significant step in the company’s efforts to expand on its DAC capabilities.(Source:  Aramco)
The pilot plant, developed in collaboration with Siemens Energy, represents a significant step in the company’s efforts to expand on its DAC capabilities.
(Source: Aramco)

March 26 – Aramco has launched the Kingdom’s first CO2 Direct Air Capture (DAC) test unit, capable of removing 12 tons of carbon dioxide per year from the atmosphere. The pilot plant, developed in collaboration with Siemens Energy, represents a significant step in the company’s efforts to expand on its DAC capabilities. Aramco intends to use the facility as a testing platform for next-generation CO2 capture materials in Saudi Arabia’s distinct climate. It will also seek to achieve cost reductions that could help accelerate the deployment of DAC technologies in the region. Aramco and Siemens Energy intend to continue working closely together with the aim of scaling up the technology, potentially laying the foundations for large-scale DAC facilities in the future.

Such projects illustrate Aramco’s strong focus on carbon capture, which represents a key pillar in the Company’s ambition to achieve net-zero and Scope 2 greenhouse gas emissions across its wholly-owned operated assets by 2050. The Company is exploring options to capture CO2 both at the point of emissions and directly from the atmosphere, through its circular carbon economy approach and the deployment of innovative technology solutions.

The launch of the DAC test facility follows the December 2024 announcement that Aramco and its partners, Linde and SLB, had signed a shareholders’ agreement that paves the way for the development of a Carbon Capture and Storage (CCS) hub in Jubail, Saudi Arabia. Phase one of the CCS hub will have the capacity to capture nine million tonnes of CO2 from three Aramco gas plants and other industrial sources.

Invenergy’s First Clean Hydrogen Unit to Begin Commercial Production

Sauk Valley can produce up to 40 metric tons of clean hydrogen annually with the capacity to store up to 400 kilograms of clean hydrogen on site.(Source:  Pixabay)
Sauk Valley can produce up to 40 metric tons of clean hydrogen annually with the capacity to store up to 400 kilograms of clean hydrogen on site.
(Source: Pixabay)

March 27 – Invenergy, the largest privately held developer, owner, and operator of clean energy solutions, recently announced that its first clean hydrogen project, the 5-acre Sauk Valley Hydrogen (Sauk Valley) facility in Rock Falls, Illinois, has reached commercial operations.

Utilizing power from Invenergy’s co-located solar facility and Ohmium International’s electrolyzer technology, Sauk Valley can produce up to 40 metric tons of clean hydrogen annually with the capacity to store up to 400 kilograms (kg) of clean hydrogen on site.

Sauk Valley’s initial hydrogen supply has been used as a turbine generator cooling agent at the adjacent Nelson Energy Center, Invenergy’s 980-megawatt natural gas facility. The loading capability at Sauk Valley also enables hydrogen to be shipped and used offsite. Sauk Valley’s first offsite order will be delivered by Certarus to an Aether Fuels project.

“Invenergy’s significant renewables portfolio allows our team to produce clean hydrogen for ‘hard-to-abate’ sectors of the economy across the country at scale, especially large hydrogen consumers such as liquid fuels and chemicals plants. We are excited to supply Aether with hydrogen from Sauk Valley, demonstrating our unique market capabilities and strong partnerships,” said Jon Horek, Vice President, Hydrogen at Invenergy.

Sauk Valley Hydrogen is Invenergy’s 22nd clean energy project to have completed development in Illinois. The facility builds upon Invenergy’s robust investment in Illinois and reflects a commitment to supporting the state’s clean energy economy.

Total Energies, Equinor, Shell Begin Phase 2 of Northern Lights CCS Project

The second phase announced recently represents an investment of NOK 7.5 billion (~700 million dollars) and leverages existing onshore and offshore infrastructures.(Source:  Pixabay)
The second phase announced recently represents an investment of NOK 7.5 billion (~700 million dollars) and leverages existing onshore and offshore infrastructures.
(Source: Pixabay)

March 29 – Total Energies and its partners, Equinor and Shell, have recently announced the Final Investment Decision (FID) of the second phase of the Northern Lights development, which will increase the project transport and storage capacity from 1.5 million to more than 5 million tons of CO2 per year from 2028.

The first phase of Northern Lights is completed and ready to receive CO2 from industrial emitters. Operations are expected to start this summer, with the first CO2 transportation by ship from Heidelberg Materials’ cement factory in Brevik, Norway and its injection and permanent storage into a reservoir 2,600 meters below the seabed, off the coast of Øygarden, western Norway.

The second phase announced recently represents an investment of NOK 7.5 billion (~700 million dollars) and leverages existing onshore and offshore infrastructures. This expansion includes new onshore storage tanks, pumps, a jetty, injection wells and transport vessels - which are all expected to be completed for a start-up by the second half of 2028.

This FID of this second phase follows the signing of a 15-year commercial agreement between Northern Lights and the Swedish district energy provider, Stockholm Exergi, for the cross-border transport and storage of 900,000 tons of biogenic CO2 emissions annually, starting in 2028. Stockholm Exergi is the 5th company to commit with Northern Lights for transport and storage of its CO2 emissions, after Heidelberg Materials and Celsio in Norway, Yara in the Netherlands and Ørsted in Denmark. In addition, Northern Lights is in advanced discussions with several large European industrial customers to market the remaining storage capacity.

BASF Starts Up Plant for Recycled Polyamide 6

Integrated into the polyamide-6 facility at the Caojing site in Shanghai: the new loopamid plant.(Source:  BASF)
Integrated into the polyamide-6 facility at the Caojing site in Shanghai: the new loopamid plant.
(Source: BASF)

March 29 – BASF has recently announced the start-up of the world’s first commercial loopamid plant. The production facility at the Caojing site in Shanghai, China, has an annual capacity of 500 metric tons and marks an important step in the supply of sustainable products for the textile industry.

loopamid is a recycled polyamide 6 that is entirely based on textile waste. The new production facility supports the growing demand for sustainable polyamide 6 fibers in the textile industry.

The plant as well as the quantities of loopamid produced are certified according to the Global Recycled Standard (GRS). This certification guarantees to consumers and textile manufacturers that loopamid is made from recycled materials and that the production processes comply with specific environmental and social criteria. In addition, first yarn manufacturers are successfully using loopamid.

To produce loopamid in its new plant, BASF currently utilizes industrial textile waste from textile manufacturing and will gradually increase the share of post-consumer waste. This feedstock includes cutting scraps, defective cuts, offcuts and other production textile waste from the textile industry. These materials are collected and provided to BASF by customers and partners.

End-of-life garments made from polyamide 6 and other textile products can also be utilized for the production of loopamid. All these waste materials are challenging to recycle because they typically consist of a mixture of different fibers and materials as well as dyes and additives. Additionally, for post-consumer waste recycling, buttons, zippers and accessories must be removed in advance. BASF works closely with partners and customers to accelerate the development of collection and sorting systems.

(ID:50379017)