Who we are

Customer references: Petrochemicals

Fast and integrated plant upgrade

Borealis Polymers produces olefin (ethylene, propylene, butadiene), phenol, polyethylene, polypropylene and Borstar polyethylene in its five production units at Kilpilahti in Finland. The polyethylene and polypropylene made by Borealis are mainly used in pipe products, steel pipe coatings, packaging and cable products. Borealis Polymers is a subsidiary of Borealis, a leading provider of innovative solutions in the fields of polyolefins, base chemicals and fertilizers. Founded in 1994, it has its headquarters in Vienna, Austria, and operates in over 120 countries.

In 2013, Borealis Polymers wanted to introduce new polyolefin technology to upgrade their polyethylene production plant. It would require extensive modifications to the existing facility, with a major redesign. The output had to be high in value and consistently reliable. One of the most important issues was the critical time schedule, as the project had to be completed before a planned turnaround, two years hence.

Neste Engineering Solutions had done work on the Borealis plant before, so they knew exactly how to proceed. A team of very experienced, highly-skilled experts in polymerization technology, who were already familiar with the current equipment, started on the project. They were able to optimise the new technology for both safety and production volume. Their integrated approach, from the basic engineering phase, all the way to the complete EPCM service, ensured all steps of the project were finished on schedule, and it was successfully completed before the turnaround in 2015.

To achieve these results, Neste Engineering Solutions delivered:

  • A new design for the unit
  • Basic engineering
  • Full EPCM services

Key customer benefits

  • Successful upgrade
  • All project targets met
  • Project delivered on schedule

Keeping costs and environmental impact down

Borealis Polymers produces olefin (ethylene, propylene, butadiene), phenol, polyethylene, polypropylene and Borstar polyethylene in its five production units at Kilpilahti, Finland. The polyethylene and polypropylene made by Borealis are mainly used in pipe products, steel pipe coatings, packaging and cable products. Borealis Polymers is a subsidiary of Borealis, a leading provider of innovative solutions in the fields of polyolefins, base chemicals and fertilizers. Founded in 1994, it has its headquarters in Vienna, Austria, and operates in over 120 countries.

In 2016, Borealis Polymers wanted to reduce both their operating costs and their environmental impact by increasing the energy efficiency of their Finnish plants and they needed a reliable partner to conduct an energy analysis to assess what it could be. The Borealis facility was already benchmarked at a high level of process integration and energy efficiency, but both Neste Engineering Solutions and Borealis believed there was even more untapped capacity.

To answer the challenge, Neste Engineering Solutions put together a team of highly-skilled and experienced experts in olefin processes and polymerization technology to conduct an energy analysis and identify the energy savings potential. A careful interpretation of the analysis allowed them to develop ideas to improve the plant and realize those savings. They then wrote an action plan to produce those improvements. Pinch analysis, a process technology and configuration review, a process control and operations review, and best technology gap analysis were all used in the project.

To achieve these results, Neste Engineering Solutions delivered:

  • Energy analysis
  • Action plan for energy improvement

Key customer benefits

  • Better understanding of their plant
  • Significant reduction of energy use
  • Considerable lowering of operating cost