AS the mist cleared in the Port of Antwerp, the scale of INEOS’ once-in-a-generation investment in a new cracker also became clear. For years Project ONE has been talked about. Now it is fast becoming a reality. On board COSCO Shipping’s vessel were two gigantic furnaces needed to provide the heat to convert ethane to ethylene – one of the most important building blocks in the chemical industry, and a vital raw material used in everything from packaging and car parts to wind turbines and water pipes.
For the crew of the Zhi Yuan Kou, it had been a long, overseas journey, rerouted around the southern tip of Africa to avoid possible Houthi attacks in the Red Sea. 12,500 nautical miles. 55 days. John McNally, CEO Project ONE, saw the ship arrive, but it would take another day or two before it could be safely docked at the quaywall due to the mist. He described it as one of the largest and most spectacular industrial ship transports ever in the Port of Antwerp.
The 200ft furnaces – the same height as Antwerp’s Museum aan de Stroom and forming part of a larger module weighing around 6,000 tonnes – had been reinforced with steel and welded to the ship to prevent them from toppling into the sea during the journey from Thailand to Belgium.
“The overseas transit of the furnaces was actually considered to be one of the most critical moments during the lifetime of the furnaces,” said John.
After docking, the ship spent a further nine days in the port to allow Flemish contractor Sarens to off-load the €150 million module with furnaces and pipe racks. From there, they were transported via self-propelled vehicles to the construction site at Lillo where they were slotted together like pieces of Lego.
“That was a huge endeavour due to the enormous dimensions of the plant units,” he said.
Jacques Vandermeiren, CEO Port of AntwerpBruges, described INEOS’ multi-billion investment as ‘pioneering’ and said it would strengthen Antwerp’s role as a strategic, international hub.
“The arrival of the furnaces is an important step towards building a forward-thinking, sustainable industry,” he said.
The furnaces for INEOS’ €4 billion cracker were manufactured by engineering contractor Technip Energies in Thailand.
“There were only a limited number of construction yards around the world that were adequately equipped and accessible to ocean-going vessels for this purpose,” said John.
There was also not enough space at the construction site in Belgium to store the materials and build the colossal modules while the site was being prepared.
Up to 2,500 people are expected to be working on the site this year to ensure the cracker becomes operational in early 2027.The furnaces are equipped with burners and combustion air preheaters to reduce emissions of nitrogen dioxide and improve energy efficiency.
They have also been designed so they can be fully fuelled with low-carbon hydrogen instead of natural gas as soon as it becomes available.
Once operational, 450 permanent staff will be needed to run the cracker, which will have the lowest carbon footprint of all European crackers.
- 200FT - THE LARGEST FURNACE IS 200FT HIGH
- 6,000 Tonnes - THE ENTIRE MODULE HAD A COMBINED WEIGHT OF 6,000 TONNES
- Antwerp Port - IT TOOK NINE DAYS TO OFF-LOAD THE FURNACE BEFORE BEING TRANSPORTED TO THE LILLO SITE
- Welded - THE FURNACES WERE WELDED TO THE SHIP TO STOP THEM TOPPLING INTO THE SEA