Expansions: Covestro expands production of PC in US; Vioneo opts for Honeywell methanol-to-olefins tech for Belgian green polymers plant

German materials firm Covestro says it will invest a low triple-digit million Euro amount to expand its site in Hebron, Ohio, US. It will construct multiple new production lines and infrastructure to manufacture customised polycarbonate (PC) compounds and blends and significantly expand its capacity in the Solutions & Specialties business for the American market. Construction of the new production lines is scheduled to begin in 2025, with operations starting by the end of 2026, though it did not reveal the capacity expansion.

It adds that the capacity expansion is an important step to meet the growing demand for high-quality materials for the automotive, electronics, and healthcare industries in North America.

Covestro already has an established R&D centre in Pittsburgh and is now doubling down on its US-based compounding capability. In the future, both facilities will work even more closely together to drive the technology transfer from lab to industrial production to support major transformation processes, such as the electrification and automation of mobility, sustainable developments and digitalisation.

"To be successful in these markets, you need the right portfolio, consistent quality, and supply reliability, as well as solution-oriented technical expertise,” says Lily Wang, head of the Engineering Plastics Business Entity. "The expanded production capacity for differentiated polycarbonates enables us to better serve our customers' complex needs for high-quality, high-tech materials with individualised properties.”

“This investment, which follows our recent announcement of an almost 40 million Euro investment in our R&D capabilities in Pittsburgh, underscores how critical our US sites and the US market are to Covestro’s global strategy,” says Samir Hifri, Chairman/President of Covestro LLC. “

In other news, Belgian firm Vioneo and US company Honeywell have announced that Honeywell’s technology will be used by Vioneo as part of its plans to produce plastics using green methanol, at a new EUR1.5 billion facility to be built in Antwerp, Belgium. Vioneo will use Honeywell’s methanol-to-olefin (MTO) conversion technology to produce feedstock for output of combined 300,000 tonnes/year of PE/PP at the plant in Belgium, with operations to start in 2028.

This facility will use green methanol from renewable energy-based hydrogen and biomaterials and will be powered by renewable electricity.

Vioneo will also deploy Honeywell’s light olefins recovery process (LORP) and olefins cracking process (OCP) to ensure high-purity ethylene and propylene output while capturing and reusing byproducts. This approach minimises waste, saves energy, reduces costs and maximises yield.

Planned development of the Antwerp-based plant will proceed in phases, starting with a Front-End Engineering Design (FEED) in the fourth quarter of 2024 and potential Final Investment Decision (FID) in 2025. Commercial operations are anticipated to begin in 2028.

Honeywell's advanced MTO technology will enable Vioneo to use green methanol, containing only biogenic carbon dioxide, in place of coal and crude oil in its plastic production processes. This can avoid the high carbon emissions associated with fossil fuel-derived plastic, while still supporting the production of propylene and ethylene – essential components used in various everyday items such as medical equipment, food packaging, automotive parts, personal care products and toys.

“Vioneo aims to help transition the plastics industry by demonstrating that large-scale, cleaner production is economically viable using green methanol as an alternative to fossil fuel. This initiative offers Europe a chance to lead the EUR5 trillion chemicals and materials sector's defossilisation movement. Our collaboration with Honeywell for our Antwerp production facility marks a key step in our plans to support this transition,” said Alex Hogan, CEO of Vioneo..

“Vioneo’s Antwerp plant has the potential to significantly decrease greenhouse gas emissions, and help position Europe as a leader in lower emissions industrial innovation. We are delighted to be a critical technology partner to this initiative,” said Rajesh Gattupalli, president of Honeywell UOP. “Our MTO technology helps support the industry's commitment to reducing emissions and the European Union's ambitious climate goals. This technology will play a crucial role in helping transform the production of olefins, helping advance the shift away from plastics made from fossil-derived feedstocks and supporting a path to a net-zero emissions future for the region.”

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