INEOS Project ONE modules escape Strait of Hormuz to reach Antwerp.
- The first of two critical modules for INEOS’ €5bn engineering project in Antwerp arrived today after being trapped in the Strait of Hormuz for months.
- The final two modules complete the Project ONE cracker, with the second and final module expected in the coming days.
- The modules weigh approximately 7,000 tonnes and stand 55 metres high.Construction activities at the ethane cracker site now reach peak levels in Antwerp with ~2,500 workers on site.
From stuck in the strait to safe in Antwerp
INEOS has today taken delivery of the first of the last two modules, at the Port of Antwerp, to complete the Project ONE cracker.
The modules were built in Abu Dhabi but their transport to Antwerp was disrupted by the war in Iran and the blockade of the Strait of Hormuz. After being trapped for months, the two ships carrying the modules managed to safely pass through the Strait, during the one- week ceasefire in mid-June, arriving in Antwerp six weeks later, via the Suez Canal.
The final pieces fall into place: two last heavyweights complete the cracker colossus
The module transported weighs 6,920 tonnes and is 55 metres high. As such it combines the weight of almost the entire steel structure of the Eiffel Tower with the height of a medium-sized skyscraper, making it one of the most impressive project cargoes to have arrived at the Port of Antwerp in recent years. The module exceeds the weight of the Project ONE furnaces which, arrived at the Port of Antwerp last year.
The second and final module, weighing 7,200 tonnes, is due to arrive shortly allowing INEOS to complete the plant.
The vessel will remain moored at the quay for a little while longer, as the steel structures protecting the module during overseas transport need to be removed. It will then be placed in position at the heart of the plant.
“We are extremely relieved that the last two modules have arrived ‘home’ in Antwerp safely. I am already looking forward to seeing them take their final positions within the overall installation so that we can complete hooking all of our modules together and start up our cracker complex. This marks a significant milestone in the realisation of this project, which is unique in Europe.” – John McNally, CEO INEOS Project ONE
Modular construction concept
INEOS deliberately opted for a modular construction of Project ONE. This approach made it possible to overcome the lack of space at the Antwerp site, minimised disruption and also resulted in significant time savings: whilst process modules, crackers and pipe racks were being assembled at overseas sites, civil engineering works and the laying of foundations could begin in Antwerp in parallel. Following the phasing out of the final site in Abu Dhabi in the first quarter of this year, the focus of all activity is now in Antwerp.
~2,500 people are working on the site
Now that the civil engineering works have been completed and the final modules are being installed, the focus at the Antwerp site is on the mechanical, electrical and instrumentation work. There are currently ~2,500 workers from some 80 contractors working on site. To date, more than 14 million man-hours have been worked.
Cable laying for a total of no less than 1,250 (!) kilometres of instrumentation and electrical cables, as well as leak tests, are currently underway. In addition, various buildings are being completed, such as the administrative headquarters, the control room and the warehouses. In the first quarter of this year, the site was also permanently supplied with power following the commissioning of the 380 kV main substation. This is a key prerequisite for starting ‘commissioning’ activities.
Commissioning is a key part of the project’s implementation, ensuring a safe and reliable start-up. During this phase, all subsystems of the installation are thoroughly tested to verify that they have been implemented safely and in accordance with the design’s quality requirements. This is carried out in stages as each subsystem is mechanically completed.
The mechanical completion of the entire site is scheduled for next summer. We aim to be able to start up the cracker in the second half of 2027.
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About INEOS Project ONE
Project ONE, the ‘renaissance’ of European basic chemicals
Chemical applications that improve our quality of life have become an integral part of everyday life. INEOS aims not only to meet this need but also to fulfil climate targets.
The ethane cracker that INEOS Olefins Belgium is building in the port of Antwerp is the most sustainable of its kind. The facts speak for themselves: the carbon emissions from the cracking plant are no less than three times lower than those of the average cracker in Europe. Compared to the top 10% of performers in Europe, the Project ONE cracker emits less than half as much. This is because the best available technologies have been chosen across the board for this plant, which translates into maximum energy efficiency.
Long before the nitrogen debate flared up, INEOS had already committed to minimising its environmental impact by incorporating the two Best Available Techniques (BAT) into the design of its facilities (6 furnaces + 2 steam generators) to limit nitrogen emissions. This involves the use of low-NOx burners on the one hand, and the implementation of SCR deNOx systems at these eight emission points on the other. This combination of techniques ensures an effective 71% reduction in NOx emissions.
It has been 25 years since an investment of this scale was made in Europe. For the future of the petrochemical cluster in Antwerp – one of the key drivers of the Flemish economy – it is now more important than ever that the sector continues to innovate. Not least to remain competitive in a global market. Just as in the automotive sector, where new, more environmentally friendly models are replacing older ones, a similar market shift will occur with the arrival of Project ONE, making the sector as a whole more sustainable.
With this investment, INEOS Olefins Belgium is also creating 450 direct, high-quality jobs in the local labour market; indirectly, there are thousands more.
The ethane cracker at Project ONE will produce ethylene, one of the most widely used basic chemicals in the world. This chemical building block is used in a wide range of applications, including those designed to facilitate the energy transition, such as wind turbines, solar panels and insulation materials. By producing this ethylene with the lowest possible carbon footprint, INEOS is meeting growing market demand.
The installation is future-proof. The path to net-zero emissions is the shortest for Project ONE, not only because of its starting point, but also because the design incorporates the necessary flexibility to harness the potential of new technologies: for example, provided there is sufficient availability of low-carbon hydrogen, it is possible to run the furnaces and steam boilers entirely on this fuel, thereby reducing emissions to virtually zero.
More info: https://project-one.ineos.com/en
Media contact
Nathalie Meert