INEOS has taken delivery of the first of the final two giant modules for its landmark Project ONE cracker at the Port of Antwerp, marking a major milestone in the construction of one of Europe’s most ambitious industrial projects.

 

The arrival of the 6,920-tonne module completes another critical phase of the project after months of disruption caused by geopolitical tensions and the blockade of the Strait of Hormuz.

 

Built in Abu Dhabi, the final modules faced an uncertain journey to Belgium after the two vessels transporting them were delayed for months. The ships eventually passed safely through the Strait during a one-week ceasefire in mid-June, before continuing their journey via the Suez Canal and arriving in Antwerp six weeks later.

 

The newly arrived module stands 55 metres high and weighs 6,920 tonnes — combining the weight of almost the entire steel structure of the Eiffel Tower with the height of a medium-sized skyscraper.

 

The structure is among the most impressive pieces of project cargo delivered to the Port of Antwerp in recent years and even surpasses the weight of the Project ONE furnaces that arrived at the port last year.

 

The final module, weighing 7,200 tonnes, is expected to arrive shortly, completing the delivery of the major components needed to finish construction of the cracker.

 

Before installation, the vessel will remain at the quay while protective steel structures used during overseas transport are removed. The module will then be lifted into position at the heart of the plant.

 

John McNally, CEO of INEOS Project ONE, said: “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.”

 

INEOS chose a modular construction approach for Project ONE to overcome space constraints at the Antwerp site, reduce disruption and save time.

 

While process modules, crackers and pipe racks were being manufactured and assembled overseas, civil engineering works and foundation construction progressed simultaneously in Antwerp. With the Abu Dhabi construction phase completed in the first quarter of this year, activity is now fully focused on final installation work in Belgium.

 

Thousands of workers drive final construction phase

 

Around 2,500 workers from approximately 80 contractors are currently active at the Antwerp site, with more than 14 million man-hours already completed.

 

With civil engineering works finished and final modules being installed, the project has entered the mechanical, electrical and instrumentation phase.

 

Teams are currently laying 1,250 kilometres of instrumentation and electrical cables, carrying out leak tests and completing key buildings including the administrative headquarters, control room and warehouses.

 

The site was permanently connected to power earlier this year following the commissioning of the 380 kV main substation — a crucial step ahead of commissioning activities.

 

Commissioning will involve extensive testing of every subsystem to ensure the installation operates safely, reliably and in line with design and quality requirements. The process will take place in stages as each subsystem reaches mechanical completion.

 

Mechanical completion of the entire site is scheduled for next summer, with INEOS aiming to begin operations at the cracker in the second half of 2027.

 

Project ONE is designed to become Europe’s most sustainable ethane cracker, with carbon emissions expected to be significantly lower than those of existing European facilities.

 

The plant will use the best available technologies to maximise energy efficiency and reduce emissions, including low-NOx burners and SCR deNOx systems across its furnaces and steam generators, achieving a 71% reduction in NOx emissions.

 

The investment represents the first major European chemical industry project of this scale in 25 years and is expected to strengthen Antwerp’s position as a leading petrochemical hub while supporting the region’s industrial future.

 

INEOS Olefins Belgium is also creating 450 direct high-quality jobs, with thousands of additional roles supported indirectly.

 

The Project ONE cracker will produce ethylene, a key building block used in products ranging from everyday materials to technologies supporting the energy transition, including wind turbines, solar panels and insulation.