Basell Orlen on Schedule with $600 Million Twin Polys Plant - Eastern Europe's Largest Construction Project

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Researched by Industrialinfo.com (Industrial Information Resources, Incorporated; Houston, Texas). The twin polyolefins plant now under construction in Plock, Poland is claimed to be the largest of its type in the world and the largest and most complex construction project ever undertaken in Eastern Europe. The Basell Orlen Polyolefins (BOP) construction site is unique in that twin facilities, for polyethylene (PEC 82000021) and polypropylene (PEC 82000022) are being built simultaneously in the $600 million greenfield project.

When completed both factories, together with a logistical platform, will cover a surface area of 145,000 square meters. The highest structure on the site will be the 120-meter flare which when in operation will be a regional landmark.

The large-scale contract for the construction, engineering and procurement for the project was awarded to Technimont (Milan, Italy). The use of local Polish subcontractors is being maximized.

When completed the total production capacity of BOP will exceed 400,000 tpa of polypropylene, using the Spheripol process. 320,000 tpa of high-density polyethylene (HDPE) will be produced using the Hostalen process and there will also be production of 100,000 tpa of low-density polyethylene.

VOS Logistics (AB OSS, Netherlands) has been contracted to construct the logistical platform that will consist of 63 silos of 400 tons capacity each. They will allow the direct loading of polyolefins onto trucks. The design of the logistical platform has met some complex challenges to meet the specifications of the distribution of thousands of kilograms of polyolefin per hour.

The installation of the 70-meter high polymerization reactors, scheduled for May, has involved their transportation to the construction site on special barges from Gdansk to Plock down the River Vistula. Their installation will be followed by the erection of the HDPE distillation column in June and the PP loop reactors in July/August. The PP gas phase reactor erection was scheduled for completion in April. Silo construction, erection and installation should be complete in May/June.

The complex is on track for completion in mid-2005. The on site work force will peak at 2,000 people.

"Once operational, these new plants will significantly increase plastics production in the region and future plastics sector development in Poland," said Harmut Lueker, president and general director of BOP. The Plock plant is expected to expand the economic opportunities for Polish convertors and related businesses and create new investment opportunities. The local government is working to attract investment by establishing land and development incentives as well as providing supporting infrastructure to attract complementary manufacturing interests.

BOP is a 50/50 joint venture between Basell Europe Holdings BV (ZURICH:BLKD) (also Wilmington, Delaware) and PKN Orlen SA (Warsaw, Poland). Basell develops, produces and markets polypropylene and advanced polyolefin products and is a leader in their development and licensing processes and catalysts. PKN Orlen SA is one of the largest companies in Central Europe, and is Poland's largest petrochemical producer and refiner of crude oil and marketer of world-class petroleum and related products.