The first petrochemical facility in the Middle East with Borealis' proprietary Borstar Enhanced polyethylene (PE) polymerization technology, Borouge's production facility in Ruwais, Abu Dhabi, UAE started operations in 2001. According to Borouge, Borstar can produce the entire range of PE from linear low density (LLDPE) to high density PE (HDPE) in a single production campaign.
The $1.2-billion Ruwais facility produces ethylene and polyethylenefeatures a 600,000-t ethylene cracker, two 225,000-t Borstar bimodal polyethylene lines, polyethylene utilities, and product handling and distribution facilities. Alliance Bechtel / Linde (ABL) built the ethylene cracker and Tecnimont SpA constructed both Borstar PE lines.
Phase 2 Expansion
In its "Borouge 2" second-phase expansion, Borouge is tripling existing production capacity to 2 million tonnes per annum and will add polypropylene to the product mix. The joint venture expects to reach these production milestones by mid-2010.
The Borouge 2 expansion, which began in late 2007, entails constructing the following alongside existing facilities: one of the world's largest ethane crackers capable of producing 1.4 million tonnes of ethylene per annum; the largest olefins conversion unit in the world (750-kilotonne capacity); a 540,000-tonnes per annum Borstar PE plant; and two 400,000-tonne-per-annum Borstar PP plants.
Borouge has awarded Linde Engineering/CCC a US$1.3-billion contract to build the new ethylene cracker. Earlier that month, Tecnimont S.p.A. signed a US$1.855-billion contract with Borouge to build the three new Borstar polyolefins units as well as material handling facilities, laboratory facilities, and machine works. Finally, Borouge awarded a US$1.234-billion contract to Technicas Reunidas S.A. to construct the offsite and utility facilities for the expanded plant.
Phase 3 Expansion
On April 4, 2008, Borouge announced that it had launched a feasibility study to investigate adding 2.5 million tonnes per year of capacity to its polyolefins operations by 2014. The proposed expansion would bring Borouge's total production capacity to 4.5 million tonnes per year. It would be located alongside the existing Borouge 1 and Borouge 2 complex.
According to Borouge, the proposed expansion would allow the joint venture to meet growing demand in the Middle East and Asia.