The chemical and petrochemical industries are currently undergoing profound transformations. There are many challenges: existing infrastructure must be used intelligently and efficiently, emissions must be reduced, and new value must be created. As a long-standing partner of Shell, Kraftanlagen Energies & Services supports this transition from planning to implementation.
A project at the Shell Energy and Chemicals Park Rheinland in Wesseling shows that transformation can succeed in the real world. Kraftanlagen Energies & Services, the general contractor, is building a Base Oil Distillation Unit (BODU) that will enable the production of high-quality base oils, including those that meet the Medical White Oil purity standard, for applications such as medical and cosmetic products, as well as sustainable lubricants.
The project objective:
The project aims to upgrade the existing refinery infrastructure to ensure its future viability and facilitate industrial value creation amid the energy transition. The base oil distillation unit allows for continued use of the hydrocracker in producing high-quality base oils and significantly contributes to decarbonization via innovative electric process technology.
In November 2024, the Shell Energy and Chemicals Park Rheinland handed over the construction site for the new crude oil distillation plant to Kraftanlagen Energies & Services in the presence of Wesseling Mayor Ralph Manzke and Bernhard Ripp, Deputy District Administrator for the Rhein-Erft district. / © Shell Deutschland GmbH
Our services:
Kraftanlagen Energies & Services is serving as the general contractor for the project’s full implementation.
In collaboration with our subsidiary ECM, we oversee the planning, project management, construction, and installation of the entire facility.
A key component is integrating the electric process furnace as the heart of the plant. The E-Heater replaces conventional, natural gas-fired heating systems and runs entirely on electricity from renewable sources.
Milestones of the project:
November 2024:
Handover of the construction site to Kraftanlagen Energies & Services
Februar 2025:
Delivery and installation of the stripper and vacuum columns
The successful delivery and installation of the 37-meter-tall stripper column and the 54-meter-tall vacuum column marked a major milestone in the project. Despite significant logistical and technical challenges, manufacturing, heavy lifting, maritime transport, foundation preparation, and assembly were all precisely coordinated and completed on schedule.
©Shell Deutschland GmbH
”"We have been working with Kraftanlagen for many years. In awarding the contract for the R3 Base Oilproject, we were particularly impressed by the industrial services provider's expertise in the field of decarbonisation and its geographical proximity. With Kraftanlagen as a partner, we can be sure that we will have experienced specialists and qualified installation personnel on site at all times, both during the planning phase and at the end of the project.”`
Amu ArenjaProjektleiter bei Shell
©Shell Deutschland GmbH
September 2025:
Delivery of the E-Heater
Construction of the Base Oil Distillation Unit (BODU) at the Shell Energy and Chemicals Park Rhineland continued according to schedule with the delivery of the first components for the electric process furnace. As the general contractor, Kraftanlagen Energies & Services is responsible for integrating the E-Heater, an electrically powered component, into the overall plant. Kraftanlagen is also overseeing the engineering, delivery, and installation of the E-Heater. The E-Heater replaces conventional natural gas heating systems, which requires more careful planning and integration into the process. With the start of the installation phase, the project is moving into the next EPC construction phase.
”"The e-heater is the heart of the entire plant,” explains Christian Wanghofer, head of the BODU project at Kraftanlagen Energies & Services. “It generates sustainable, CO₂-free heat, making it the first of its kind in this performance range for the petrochemical industry. Now that the delivery has been completed successfully, the assembly phase can begin. Despite facing a few challenges, we are still fully on schedule."
Christian WanghoferProjektleiter der Business Unit Industrie bei Kraftanlagen Energies & Services
April 2026:
Completion of steel construction and completion of the analysis building
The completion of the steel framework for the Base Oil Distillation Unit is another key milestone. Standing approximately 55 meters tall, the steel framework forms the structural backbone of the plant and provides the load-bearing foundation for installing the process equipment. Additionally, completing this phase ensures safe and efficient operations during subsequent project phases.
Additionally, the analysis facility has been completed and will be responsible for continuous process and quality monitoring. The next visible step will be constructing the pipe bridge between the electric process furnace and the BODU plant.
©Shell Deutschland GmbH
”“I am delighted that we have now reached this milestone in this highly complex project. I am particularly proud that there were no safety-critical incidents. This demonstrates the focus on quality and the dedicated, proper execution by the contracted companies, who have worked together consistently and constructively.”
Amu ArenjaProjektleiter bei Shell
