Worley Wins FEED for Dow's Net-Zero Ethylene Complex

Worley has been awarded the front-end engineering design (FEED) contract for the cogeneration component of Dow's Path2Zero project in Fort Saskatchewan, Alberta. This contract is the engineering mobilization phase of the world's first net-zero Scope 1 and Scope 2 emissions integrated ethylene cracker and derivatives site. The cogeneration facility and integrated post-combustion carbon capture unit are targeted for operations by late 2030.

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What "World's First" Actually Means

Scope 1 emissions are direct greenhouse gas releases from site operations. Scope 2 emissions come from purchased energy. Eliminating both simultaneously in a high-throughput petrochemical complex has not been done before at commercial scale. That is the specific claim Path2Zero is engineered to prove.

The new cogeneration plant will replace aging assets at Fort Saskatchewan. At up to 466 MW, it will provide reliable steam and power to the ethylene complex. Integrated post-combustion carbon capture will strip CO2 from the cogen's flue gas before release. That captured CO2 travels offsite through Wolf Midstream's Alberta Carbon Trunk Line. The ACTL is a 240 km CO2 pipeline operational since 2020, with capacity for up to 14.6 million metric tonnes per year.

Why the FEED Award Is the Real Signal

FEED is the phase where a project becomes a buildable facility. Every equipment specification, piping layout, and integration point is locked in before construction begins. Once FEED is awarded, procurement and construction follow directly.

Dow approved the $6.5 billion FID in November 2023 and began construction in 2024. The project is phased. An initial capacity addition targets startup around 2027. A second phase follows around 2029. The cogeneration and carbon capture unit, now in Worley's hands, targets operations by late 2030. Worley's contract is structured as an EPCM framework, with FEED delivered by Worley's Canada and India-based Global Integrated Delivery team.

How Path2Zero Decarbonizes at Petrochemical Scale

Dow layers three integrated technologies. Linde's air separation and autothermal reformer technology converts cracker off-gas into hydrogen, which fuels the site's furnaces as a clean fuel. The new cogeneration plant delivers low-carbon power and steam. Post-combustion carbon capture at the cogen unit then moves CO2 offsite via the ACTL for permanent underground storage.

These technologies are designed to eliminate approximately 1 million metric tonnes of CO2 equivalent per year, per Dow's November 2023 FID announcement. At full run rates, Fort Saskatchewan will produce 3.2 million metric tonnes of certified low- to zero-carbon polyethylene and derivatives annually. Path2Zero will decarbonize 20% of Dow's global ethylene capacity.

>> RELATED: Alberta's First CCS Hub Just Started Injecting CO2

Path2Zero Component	Technology / Partner	Function
Hydrogen-fueled furnaces	Linde autothermal reformer	Converts cracker off-gas to clean hydrogen for site furnaces
Cogeneration plant (up to 466 MW)	Worley FEED/EPCM	Low-carbon power and steam across the complex
Post-combustion carbon capture	Integrated with cogen (Worley FEED)	Captures CO2 from cogen flue gas before atmospheric release
CO2 transport and storage	Wolf Midstream ACTL (240 km)	Permanent underground sequestration of captured CO2

Alberta's CCS Infrastructure Makes Fort Saskatchewan the Right Site

Fort Saskatchewan sits inside Alberta's Industrial Heartland, a designated industrial zone northeast of Edmonton with more than 40 heavy-industry facilities. The ACTL currently operates at around 10% of its stated capacity, per Alberta's Industrial Heartland Association. Path2Zero can connect to existing CO2 transport infrastructure without new pipeline construction.

Alberta's Industrial Heartland subsurface is designated for up to six CCUS storage hubs. The first phase of the Atlas Carbon Storage Hub, a Shell and ATCO joint venture, is under construction and expected to be operational by 2028. Total Path2Zero investment reached approximately $8.9 billion, including an Alberta Petrochemicals Incentive Program contribution of approximately $1.8 billion and third-party contributions from partners including Linde, per the November 2023 government announcement.

Path2Zero Sets the Template for Petrochemical Decarbonization

Ethylene production requires sustained high-heat combustion. Integrating carbon capture with a live cogeneration system on an operating brownfield site is engineering the industry has not executed at this scale before.

If Dow and Worley execute it correctly, Fort Saskatchewan becomes the reference design for verified Scope 1 and Scope 2 elimination in a large petrochemical complex. The 3.2 million metric tonnes per year of certified low- to zero-carbon polyethylene gives buyers across packaging, automotive, and industrial markets a verified supply source at scale. That commercial pull creates the incentive for others to replicate the model. The engineering phase is now formally underway.

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