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Headquartered in Vienna, Austria, Borealis is one of the largest polyolefin producers in the world. Its core business revolves around the production of polyethylene (PE) and polypropylene (PP), used in the manufacture of wire and cables, pipes, automotive components and advanced packaging materials. IPIC has a majority stake (64%) and OMV a minority stake (36%) in Borealis, which has established the Borouge petrochemical joint venture in Abu Dhabi in conjunction with ADNOC, the Abu Dhabi National Oil Company.
Through Borouge, the Borealis footprint reaches out to the Middle East, Asia Pacific, the Indian sub-continent and Africa. Established in 1998, Borouge has customers in more than 50 countries and its headquarters are in Abu Dhabi and Singapore.
Borealis produces base chemicals, including melamine, phenol, acetone, ethylene and propylene, for a wide range of industries. Borouge and Borealis together will produce approximately 6 million tonnes of base chemicals in 2014. The Borouge plant expansion in Abu Dhabi will be fully operational by mid-2014 with an annual capacity of 4.5 million tonnes, giving Borealis and Borouge 8 million tonnes of polyolefin capacity. Borealis also produces a large portfolio of fertilizers for the agricultural industry, distributing 2.1 million tonnes per year.
Borealis operates 17 production facilities in 11 countries in order to be close to key markets and to support its customers within Europe, South America, North America, the Middle East and Asia. Each of these production sites has a long heritage in polyolefin and base chemicals production.
Austria is home to the company headquarters, its Innovation Headquarters and Borealis Agrolinz Melamine GmbH in Linz, as well as a production site in Schwechat, close to Vienna.
In Belgium, Borealis has produced chemicals for more than 30 years, operating now from three production sites in Beringen, Kallo and Zwijndrecht. Two of the facilities are part of one of the world’s largest chemical industry complexes in the Port of Antwerp, providing a strong transportation hub. In Zwijndrecht, Speciality Polymers Antwerp is a joint venture between Borealis (33%) and DuPont (67%) to manufacture polyethylene.
Borealis Brasil SA is a joint venture between Borealis (80%) and the Brazilian company Braskem (20%). The company, formed in 1999, has taken over OPP’s compounding business and assets in Brazil and serves customers in the automotive and home appliances industries across South America. It has two production sites in Itatiba and Triunfo, close to São Paulo and Porto Alegre.
In France, Borealis Ottmarsheim (Borealis PEC-Rhin SAS) produces ammonia and nitric acid, part of which is used internally as raw material for manufacturing fertiliser. Part of the ammonia and nitric acid is sold as industrial agents for use in the manufacture of synthetic fibres for adhesives and carpets and high-performance technical plastics for automotive parts, rollers and IT and hi-fi equipment.
Borealis has had production facilities in Porvoo, Finland, for the past 35 years. The fully integrated petrochemical complex consists of five plants: a cracker for olefins production; a phenol and aromatics plant; two PE plants; and one PP plant. Around 70% of production is exported. The Porvoo output is used mainly to produce pipes, extrusion coating for steel pipes and packaging, as well as wire and cable sheathings. Borealis also has an Innovation Centre in Finland for catalyst and process research, featuring catalyst scale-up facilities and fully integrated Borstar PE and PP semi-commercial pilot plant lines.
In Germany, the company has production sites in Burghausen, near Munich, and Piesteritz. The Burghausen plant has a polyolefin production facility adjacent to OMV’s refining and petrochemical complex. Ethylene and propylene feedstocks are mainly supplied by pipeline from the OMV refinery ethylene plant. Borealis has invested €200 million in a 330,000 t/y expansion of its PP facilities in Burghausen, based on its proprietary Borstar technology, to satisfy the growing market demand for plastics for advanced packaging solutions and making Burghausen the third-largest PP production site in Europe. The Piesteritz facility manufactures melamine, which is used for coatings, compounds for housewares, concrete liquefiers, paint resins, fibreboard binders, special resins for textile and paper finishing, and fire-blockers. Borealis is currently the melamine market leader in Europe.
Borealis has a compounding production unit and a customer service centre at Monza in Italy. The compounding unit produces specific PP compounds mainly for the automotive and appliances markets.
The production facility in The Netherlands is situated in the Chemelot industry park, in Sittard-Geleen. Borealis Plastomers VOF was acquired and integrated into the Borealis Group in 2013. The site produces metallocene plastomers and speciality Ziegler-Natta linear low-density polyethylenes.
In Sweden, Borealis is the only polyethylene (PE) producer. The plant is located in Stenungsund, near Gothenburg, and is focused mainly on wire and cable and pipe manufacturing. Borealis in Sweden supports customers with speciality plastics for some of the largest energy supply, oil and water pipeline projects in the world. The cracker plant in Stenungsund is one of the most flexible in Europe, producing ethylene and propylene, which are used to make high-density polyethylene (HDPE), low-density polyethylene (LDPE), and Borstar® PE products. Borealis' operations in Sweden also include an Innovation Centre focused on polymer design, scientific services, and R&D for infrastructure industry solutions. The company completed a €400 million investment in 2010 in a new 350,000 t/y high-pressure LDPE plant, enhancing its capability to provide advanced materials for wire and cable applications.
Borealis Compounds Inc has been providing specifically designed and compounded polyolefins and technical support to its customers in North and South America since 1994. Its facility in Rockport, New Jersey, also produces and exports products to the Asia-Pacific, Middle Eastern, European and African markets through the Borealis and Borouge sales network. A second facility, located in Port Murray, New Jersey, is dedicated to wire and cable production and specialises in medium- and high-voltage insulations, semi-conductive and automotive cable grades.
In the UAE, through its Borouge joint venture, Borealis is expanding in the rapidly growing Asian and Middle Eastern markets. Borouge is adding 2.5 million tonnes per year of polyolefin capacity at its Ruwais plant by mid-2014, boosting production capacity to 4.5 million tonnes. This will enable Borouge to meet the growing demand for PE and PP in the Middle East and Asia, supported by a recently completed Innovation Centre in Abu Dhabi.
The addition of LDPE will also help Borouge expand its wire and cable infrastructure market. Borouge is expanding its sales and marketing efforts by establishing logistics hubs in Shanghai and Guangzhou in China. Additional investment in China, which is on track to become the world’s largest polyolefins market, includes a new 50,000 tonnes-per-year compound manufacturing plant in Guangzhou and an Application Centre at the Shanghai manufacturing plant.