The petrochemical production plant in Ruwais, about 250 km west of Abu Dhabi City in the United Arab Emirates, is central to Borouge’s operations. Borouge invested US$1.2 billion to build the first petrochemical facility of the Middle East in Ruwais and equip it with the proprietary Borstar® technology from Borealis.
Initially the Ruwais plant had a total manufacturing capacity of 450,000 tonnes per year (t/y). By 2005, the complex consisted of an ethane cracker (EU1) built by an alliance of the companies Bechtel and Linde, and two Borstar® bimodal polyethylene units constructed by Tecnimont (PE1/PE2), each capable of producing 300,000 tonnes of bimodal polyethylene.
In 2010, under the project name of Borouge 2, we tripled the polyolefins manufacturing capacity of the Ruwais plant. Approximately US$ 5 billion was invested to enable Borouge to produce a total of 2 million tonnes of Borstar® polyolefins per year. The Borouge 2 project includes an additional ethane cracker, a third polyethylene unit, an olefins conversion unit (OCU) for converting ethylene to propylene, and two new polypropylene units, spearheading the company’s entrance into polypropylene production.
The 1.5 million t/y ethane cracker (EU2) was built by the Linde Group at a cost of US$ 1.3 billion and is considered to be the largest in the world. The first of its kind and largest OCU in the world, capable of producing 752,000 tonnes of propylene a year, was built by Samsung Engineering using APP Lummus technology worth US$ 300 million. This investment ensures the supply of 800,000 tonnes of polypropylene per year on two similar sized units. In addition, the Borouge 2 project also provided for the construction of a new polyethylene unit with an annual capacity of 540,000 t/y. The polyolefin units were constructed by Tecnimont of Italy at a cost of US$ 1.9 billion. Off-site and utility facilities were completed by Tecnicas Reunidas of Spain at US$ 1.2 billion.
Current capacity overview (2013)
- 2.1 million tonnes of ethylene per year (EU1/EU2)
- 1,140,000 tonnes of polyethylene per year (PE1 / PE2 / PE3)
- 800,000 tonnes of polypropylene per year (PP1 / PP2)
- Olefins Conversion Unit of 752,000 tonnes per year (OCU)
Borouge is expanding its petrochemical plant at Ruwais in Abu Dhabi by 2.5 million t/y to a total annual capacity of 4.5 million tonnes in 2014. The expansion project under the name of Borouge 3 includes an ethane cracker, two polyethylene units, two polypropylene units, and a low density polyethylene (LDPE) unit. The company Bechtel provides management support for the implementation of the project.
Preparation of the Borouge 3 site, which comprises some 3.6 km2 adjacent to the current Ruwais plant, was completed by Al Asab General Transportations and Contracting Establishment of Abu Dhabi. The site is located east of Borouge’s existing Ruwais facilities.
The new ethane cracker, Borouge’s third, will produce 1.5 million tonnes of ethylene per year and is being built by the Linde Group at a contract value of US$ 1.075 billion.
Two additional Borstar® polyethylene units producing 1,080,000 t/y, two additional Borstar® polypropylene units of 960,000 t/y, and a 350,000 t/y LDPE unit incorporating unique technology from Borealis for high value wire and cable applications, will be built by a joint venture between Samsung and Tecnimont, worth US$ 1.2 billion and US$ 400 million respectively.
An additional contract worth US$ 935 million for the utilities and off-site facilities for the expanded plant was awarded to Hyundai Engineering and Construction of South Korea. In 2011, a contract worth US$ 111 million was awarded to Alpine Bau Deutschland AG to construct the non-process buildings of the Borouge 3 expansion project.
A contract worth US$ 169 million was awarded to Hyundai Engineering and Construction of South Korea to build the cross-linkable polyethylene (XLPE) unit at Ruwais. With an annual capacity of 80,000 tonnes, the unit is an added-value to the LDPE unit.
Borouge 3 projected capacity overview
- 1,080,000 tonnes of polyethylene per year (PE4 / PE5)
- 960,000 tonnes of polypropylene per year (PP3 / PP4)
- 350,000 tonnes of low density polyethylene per year (LD1)
- 1.5 million tonnes of ethylene (EU3)
Borouge has invested approximately US$ 60 million in a compounding manufacturing plant in Shanghai with an annual capacity of 50,000 tonnes. The Shanghai plant compounds resins specifically for customers in the automotive markets. The plant is currently being expanded to a production volume of 90,000 t/y.
Shanghai Compounding Manufacturing Plant’s capacity overview
- 50,000 t/y compounded PP resins
- 40,000 t/y expansion planned for completion by 2015