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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Providing Solutions in Polyolefins
Infrastructure
Automotive Advanced Packaging
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Industrial water pipeline applications
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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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The ‘new’ alternative materials - polyethylene and polypropylene
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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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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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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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Examples of large diameter PE and PP industrial water pipelines
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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 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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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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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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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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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 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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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