Borouge 2012

Sustainable Polyolefin

Piping Systems

A step change in industrial application

Khalfan Al Muhairi

MEDW & PETCHEM ARABIA – Abu Dhabi

14 May 2013

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Agenda

Overview on Borouge

Examples of large diameter PE and PP

industrial water pipelines

Industrial water pipeline applications

The ‘new’ alternative materials

- Polyethylene & Polypropylene

Conclusion Remark

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Borouge 2012

Overview on Borouge

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Borouge…. A successful joint venture combining

resources, feedstock and technology leadership

40% 60%

35% 65%

50% 50%

ADP (Production Co.)

PTE (Marketing & Sales Co.)

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Who we are

Established in 1998; first production in 2001

Leading provider of innovative, value creating polyethylene and

polypropylene plastics solutions

Based on proprietary Borstar® technology

Focus on infrastructure, automotive and advanced packaging

markets of the Middle East, Asia-Pacific, Indian sub-continent

and Africa

Manufacturing capacity of 2 M tonnes per year

Expansion to 4.5 M tonnes (Borouge 3 start up by end of 2013)

Customers in more than 50 countries

Founding member of the Gulf Petrochemicals and Chemicals

Association (GPCA)

Signatory of the Responsible Care® Global Charter

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Borouge 2012

Borealis customer service centre

Borealis Head Office

Borealis production

Innovation Centre

Borouge Production Head Office

Borouge Sales & Marketing Head Office

Borouge production

Borouge sales offices

Borouge representative office

Borouge – a leading force in the

international plastics market

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‘Commodity’ path

Feedstock Olefins Polyolefins Converters End users Consumers

‘Value Creation’ path

Feedstock Olefins Polyolefins Converters End users Consumers Re-use Recycle Recover

Our mission:

“Value Creation through Innovation”

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Borouge 2012

Providing Solutions in Polyolefins

Infrastructure

Automotive Advanced Packaging

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Borouge 2012

Industrial water pipeline applications

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Borouge 2012

Typical properties required by industrial

pipework and pipelines

Property Why is it required?

Tensile strength Hoop stress in pressure pipelines

Abrasion resistance Resist abrasion of the pipe inner surface cause by

particles carried in the flow

Chemical resistance Resist attack by fluid being carried by the pipe

Corrosion resistance Corrosion caused by the fluid being carried by the

pipe and / or the surrounding environment

Elastic modulus Resist deformation and / or buckling of the pipe

due to external loads

High integrity joints Structural integrity + prevent leakage or infiltration

High durability Minimise maintenance, repair and replacement

Flexibility Reduce risk of failure and allow easier installation

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Borouge 2012

Typical Industrial Pipeline Applications

Seawater / industrial cooling

Fire mains

Oil and gas water injection mains

Water & oil mixture flow lines

Industrial process water

Power Plant Piping

Slurry transportation

Chemical transportation

District cooling /Heating

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Borouge 2012

The ‘new’ alternative materials - polyethylene and polypropylene

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Borouge 2012

Comparison of PE, PP, GRP and steel pipe

properties required by industrial pipes

TensileStrength

ElasticModulus

AbrasionResistance

ChemicalResistance

CorrosionResistance

JointIntegrity

Durability Flexibility

PE PP-HM GRP Steel PP-HM = PP-High Modulus

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Borouge 2012

The European use of these ‘new’

materials is well established

PE and PP have a similar structure

comprising of macro-molecules and both

belong to a family called thermoplastics

PE pipes were first used in the mid

1950’s and undersea pipelines have

been used for different applications

including industrial intakes, outfalls and

undersea crossings since 1960

PP is principally used for gravity or low

pressure applications and has been in

use since the mid 1980s. It’s use in

industrial applications dates from the

early 1990’s when higher elastic

modulus PP-HM became available

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Borouge 2012

Why are these ‘new’ materials now

becoming available in the Middle East?

Raw material availability

PE100 and PP-HM the pipe grade

material is now produced by Borouge in

the UAE.

Regional pipe production & welding

10 Yrs ago, PE100 pipes produced in the

ME were limited to 800 mm OD. Local

companies now produce and weld up to

2,000 mm dia. in PE100 and 3,500 mm in

PP-HM

PE pipes can be towed long distances

Companies in Europe can produce pipes

of up to 2,200 mm straight in to the sea

for towing all over the world.

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Borouge 2012

Other advantages of PE and PP pipes for

large diameter industrial applications

Both are homogenous materials

If there is some abrasion - no gel coat or

lining to penetrate and hence pipe

properties will be unaffected

Weighting of structured wall pipes

Spiral can be filled with high flow grout

reducing the need for weight blocks and

allowing installation after pipe laying

Very smooth pipe surface

Reduces the build up of marine growth on

the inside of intake pipelines,

Very long PE100 pipes can be installed in

a single operation @ 500+ m/hr

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Borouge 2012

Examples of large diameter PE and PP industrial water pipelines

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Borouge 2012

Borouge 2 sea water cooling system - an

early success for large dia. pipes in the ME

4 x 2.8 km 1600 mm OD inlet pipelines

4 x 2.3 km 1600 mm OD outlet pipelines

A total of 104 bends

Max. pressure was 3 bar

Pipes were SDR 26 – 6 bar

Completed in 2009 and no

problems to date

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Borouge 2012

Borouge 2 - Over 80% of fittings were

fabricated in Abu Dhabi

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Borouge 2 – butt welding of 1600 mm OD

pipes on site

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Borouge 2012

The TAKREER Ruwais Refinery 2 seawater

cooling system in the UAE

4 x 4.15 km DN 3000 mm inlet

pipelines – max. 140,000 m3/hr

8 x 2.75 km DN 2000 mm

outlet pipelines

Pipe production commenced in

Q4 2009

Pipes are produced using 4 no.

spiral wound pipe machines

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Borouge 2012

The TAKREER Ruwais Refinery 2 seawater

cooling system in the UAE

Previous large dia. PP pipelines had

extrusion welded spigot and joints

The pipe producer went for stronger

butt welded joints and had to

purchase the world’s 6 largest butt

welding machines

4 no. 6 m long pipes are welded

together for transport to site

Pipeline strings of

300 m are welded

together on site

for submarine

installation

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Borouge 2012

TAKREER - Seawater outfall

8 No. 2750 m long DN 2000mm PP-HM pipelines

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TAKREER - Seawater outfall

8 No. 2750 m long DN 2000mm PP-HM pipelines

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TAKREER – 45o segmented bends and

seawater outfall

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TAKREER - Preparation of a 300 m

x DN 3000 mm PP-HM pipe string

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Borouge 2012

TAKREER - Preparation of a 300 m x

DN 3000 mm PP-HM pipe string

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Offshore 4 x 4 km long DN 3000 mm

structured wall PP-HM

seawater intake pipes.

Design flow 178,000 m3/hr

Onshore 100 km of PE100 solid wall

pipes carrying cooling,

potable and fire fighting water

and sewage with 5300 fittings

Sizes 63 – 2000 mm OD

Pressure ratings 6 – 20 bar

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Borouge 3 - butt welding of 2000 mm OD

cooling water pipelines fittings

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Borouge 3 - cooling water pipelines and off

takes

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Borouge 3 - cooling water pipelines and off

takes

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Borouge 3 - Seawater intake showing diver

access point at the end of the 300 m string

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Borouge 2012

Borouge 3 – DN 3000 mm PP-HM seawater

intake under tow after launching

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Conclusion Remark

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Examples of Industrial Investment in MEA

2012-2016 (Projects worth 72 Billion USD)

Project Name Country

Ras Laffan Condensate Refinery Expansion Qatar

Total Petrochemicals/QP - Ras Laffan Petrochemicals Complex Qatar

QP/QAPCO - Ras Laffan Petrochemical Complex Qatar

New Refinery Project Al Zour- Kuwait Kuwait

IPIC-Duqm refinery Oman

Oman MOG - Oman Full Field Development Oman

Tacaamol - Tacaamol Aromatics Olefins and Nitrogen Chemical UAE

Jordan Red Sea Project Jordan

Source: Zawya

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Borouge 2012

Conclusion

The highly durable nature of PE and

PP pipes makes them suitable for large

diameter industrial water pipelines.

Their flexibility and ability to be welded

in to long strings makes them ideal for

undersea intake and outfall pipelines.

Borouge’s BorSafe HE3490LS (PE100)

and BorECO BA212E (PP-HM) pipe

grade materials are now produced in

Abu Dhabi.

Pipe producers can extrude solid wall

low sag PE100 pipes of up 2000mm

OD and manufacture structured wall

PP-HM pipes of up to DN 3500 mm.

Borouge 2012

THANK YOU

Borouge is committing in

Shaping the Future with Plastics