Process enables tailoring of polyethylene

Edited by the Engineeringtalk editorial team Oct 28, 2005

Borstar PE 2G is a multi-modal process that enables the molecular tailoring of polyethylene (PE) to provide solutions that meet the exact needs of the customer.

Building on the established advantages of its Borstar bimodal process technology, Borealis has introduced a new generation of proprietary technology - Borstar PE 2G, a multi-modal process that enables the molecular tailoring of polyethylene (PE) to provide solutions that meet the exact needs of the customer.

"We are very proud to present the newest Borstar developments at a time when we are celebrating the 10th anniversary of our proprietary technology", said Henry Sperle, Executive Vice President Hydrocarbons and Projects, Borealis.

Yielding a step change in polymer design, Borstar PE 2G consists of a new catalyst system in combination with process improvements.

This results in a simplified process with fewer steps that offers even better safety, through modified catalyst handling.

Also, Borstar PE 2G provides a lower energy consumption of up to 7% per ton produced as well as increased plant capacity to bring both cost and environmental benefits.

By allowing tailoring of the molecular structure of PE to precisely match application requirements, Borstar PE 2G gives the possibility to extend Borealis' product range with more sophisticated, customer-oriented solutions that are characterised by outstanding mechanical and optical properties, such as transparency and sealability, with excellent processability.

The improvements offered by this multi-stage technology have already been tested and applied in Borealis PE production facilities in Porvoo, Finland and Stenungsund, Sweden and its benefits have been proven.

Borstar PE 2G process technology has most recently been implemented in the new Borealis PE production facility at Schwechat, Austria with a capacity of 350kt/year to capture the growing demand for linear low-density polyethylene (LLDPE) for flexible consumer packaging and industrial applications.

With Borstar PE 2G, Borealis is able to offer a versatile range of solutions for flexible packaging covering the full spectrum of linear low, medium and high density grades.

In combination, these grades offer the best film formulation to fulfil the needs of the value chain.

A typical example of this is Borealis' new PE film grade Borstar FB4370 for advanced packaging solutions.

It offers a unique spectrum of mechanical properties such as high stiffness and toughness, with easy opening and downgauging possibilities.

Together with outstanding extrusion and high productivity it is already paving the way for new packaging opportunities and efficiencies.

Another example is Borstar FB4250T, an enhanced linear low density PE film for high quality film in demanding packaging applications such as heavy duty films.

This new grade is an excellent material where higher stiffness and mechanical toughness combined with transparency are needed.

These products give the additional benefit of a downgauging potential of between 20-25%, making them an environmentally friendly solution.

Moreover due to the better flow properties of Borstar products, the convertor can achieve significant improvement in production regularity and film quality.

For PE100 pipe fittings and extrusions, Borstar PE 2G enhanced pipe grades can provide even better durability through slow crack growth, ensuring long service life and low maintenance.

Borstar PE 2G enhanced pipe grades deliver an extremely smooth surface improving water flow characteristics.

Through these enhancements, Borstar PE 2G technology underpins Borealis' strategy to aid the success of its customers by answering the challenge to deliver the high performance, value added solutions they need today and in the future.