Rejlers Abu Dhabi, a subsidiary of Swedish engineering services firm Rejlers, has secured a detailed engineering job on a polyethylene production capacity expansion project of petrochemicals producer Borouge.

Borouge has undertaken the project to expand its PE4 and PE5 polyethylene production units to increase their nameplate capacity from 540,000 tonnes a year (t/y) to 700,000 t/y each.

Rejlers Abu Dhabi has secured the detailed engineering job as a sub-contract from Abu Dhabi’s Target Engineering Construction Company, the main contractor executing the engineering, procurement and construction (EPC) works on the project.

Borouge announced awarding the main EPC contract for the PE4 and PE5 polyethylene production unit expansion project to Target in late April.

EPC works on the project are expected to be completed in the first quarter of 2027, Borouge said.

The project will contribute towards Borouge’s goal of increasing its overall production capacity to 6.6 million t/y by 2028.

Borouge has also announced initiating a project to upgrade its second ethane cracker unit (EU2), adding 230,000 t/y of capacity, which is a 15% increase for the EU2 cracker.

Adnoc Gas and Adnoc Refining, subsidiaries of Abu Dhabi National Oil Company (Adnoc Group), will supply ethane feedstock for the EU2 upgrade project, with completion scheduled for 2028-end.

Borouge awarded Germany-headquartered Linde Engineering a contract to perform front-end engineering and design (feed) on the EU2 upgrade project.

Borouge expects the two output capacity expansion projects to contribute between $165m and $200m in annual earnings before interest, taxes, depreciation and amortisation (Ebitda).

Borouge entered operations in 2001, with a production capacity of 450,000 t/y of polyethylene. The Borouge 2 and Borouge 3 expansion projects took the capacity to 2 million t/y and 4.5 million t/y of polyethylene and polypropylene in 2010 and 2014, respectively.

When the under-construction Borouge 4 complex enters operations, Borouge’s overall production capacity will increase significantly from 5 million t/y to 6.4 million t/y, making it the world’s largest single-site polyolefins facility.

The upcoming Borouge 4 polyolefins complex will feature two polyethylene plants – each with a capacity of 700,000 t/y – using the third generation of Borealis Borstar technology. These plants will be supplied by an ethane cracker with a capacity of more than 1.5 million t/y of ethylene, as well as associated ethylene derivatives.

Following the signing of a final investment decision agreement worth $6.2bn by Adnoc and Borealis in November 2021, Borouge awarded the main EPC contracts for the Borouge 4 project in December of that year.

The EPC packages, the winning contractors, their estimated contract values and a brief scope of work are as follows:

• Early works (package one) – Al-Asab General Transport & Contracting (UAE) – site preparation and early civil works
• Ethane cracker (package two) – Technip Energies (France)/Target Engineering (UAE) – $1.58bn – building an ethane cracker with a manufacturing capacity of 1.5 million t/y of ethylene
• Polymers production (package three) – Tecnimont (Italy) – $1.35bn – building two new polyethylene manufacturing plants and a unit to produce 1-hexene, a component in the production of high-performance polyethylene
• Utilities and offsites (package four) – Tecnimont (Italy) – $1.5bn – constructing non-process buildings, roads, infrastructure, internal and external interfaces, tankage systems, flaring systems and utilities, as well as integration of Borouge 4 with the existing facilities
• Second cross-linkable-polyethylene (XLPE) plant (package five) – Tecnimont (Italy) – $350m – building an XLPE plant with a capacity of 100,000 t/y.

Italian contractor Maire Tecnimont executed the front-end engineering and design works for Borouge 4.

Borouge awarded France-based Axens a contract to provide licensed technologies in January 2020. This covered supplying a methyl tertiary butyl ether unit coupled with a 1-butene production unit and 1-hexene unit for the project.

The new Borouge 4 facility will cover an area equivalent to almost 500 football pitches, or more than three times the size of Al-Maryah Island in Abu Dhabi. It will produce enough polyolefins annually to make pipes to supply water to 35 million households.

Borouge Group International

Borouge is the petrochemicals-producing joint venture of Abu Dhabi National Oil Company (Adnoc) and Austrian energy company Borealis. Adnoc owns the majority 56% stake in Borouge, with Borealis holding a 34% stake. The remaining 10% of shares in Borouge trade on the Abu Dhabi Securities Exchange following an initial public offering in June 2022, from which Adnoc Group earned proceeds of $2bn.

In March, Adnoc and Austrian energy company OMV entered into a binding framework agreement to combine their shareholdings in Borouge and Borealis and take control of a greater share of the global chemicals market.

Adnoc has also entered into a share purchase agreement with Canada-based Nova Chemicals Holdings, an indirectly wholly-owned company of Abu Dhabi’s sovereign wealth institution Mubadala Investment Company, for 100% of Nova Chemicals Corporation (Nova).

Adnoc and OMV have also agreed that upon completion of the planned merger of Borouge and Borealis, the new entity – which will be known as Borouge Group International – will acquire Nova for $13.4bn including debt, further expanding its footprint in North America.

Borouge Group International is intended to be headquartered and domiciled in Austria, with regional headquarters in the UAE. In addition, Borouge Group International will hold corporate hubs in Canada’s Calgary, Pittsburgh in the US and Singapore.

The combination of Borouge and Borealis, and the acquisition of Nova, are expected to complete in the first quarter of 2026, subject to regulatory approvals and other customary conditions, Adnoc said.

The acquisition, together with the contribution of the upcoming Borouge 4 petrochemicals project in Abu Dhabi, will create a major polyolefins producer valued at over $60bn. It will be the world’s fourth-largest by nameplate production, with a potential of 13.6 million metric t/y across 62 plants globally.