From the Sector

• ADNOC and Borealis confirm final investment agreement to build Borouge 4 in Ruwais, United Arab Emirates (UAE), which will produce 1.4 million tons of polyethylene per annum
• Expansion project includes construction of a 1.5 million tonnes ethane cracker, two state-of-the-art Borstar® polyethylene plants and a cross-linked polyethylene plant
• Borouge 4 will meet growing customer demand across the Middle East, Africa and Asia with differentiated polyolefin solutions in energy, infrastructure, and advanced packaging
• New facility will benefit from industry-leading technologies to significantly improve energy efficiency and lower emissions, with carbon capture study underway
• Upon expansion, Borouge will be the world's largest single-site polyolefin complex and will supply feedstock to TA'ZIZ Industrial Chemicals Zone Body

ADNOC and Borealis AG signed an USD 6.2 billion investment agreement to build the fourth Borouge facility – Borouge 4 – at the polyolefin manufacturing complex in Ruwais, United Arab Emirates (UAE).

The world-scale expansion confirms both partners’ commitment to the growth of Borouge and to support chemical production, and advanced manufacturing and industry in Ruwais, a key pillar of Abu Dhabi and the UAE’s technology, innovation and industrial development strategy. Borouge produces crucial industrial raw materials, which are exported to customers globally and used by local companies, boosting local industrial supply chains and enhancing In-Country Value.

Borouge 4 will capitalize on the projected growth in customer demand for polyolefins, driven by their use in manufactured products in the Middle East, Africa and Asia. The facility will also enable the next phase of growth at the Ruwais Industrial Complex by supplying feedstock to the TA’ZIZ Industrial Chemicals Zone.

Borouge 4 will have an industry-leading focus on sustainability leveraging the capabilities of both shareholders. The facility will utilize Borealis’ proprietary Borstar technology, to produce a product portfolio focused on durable applications for energy, infrastructure, advanced packaging, and agriculture sectors. This unique technology, in combination with hexene co-monomer, will enable the production of advanced packaging grades with up to 50% recycled polyethylene content.

Subject to an in-depth study, a Carbon Capture unit that would reduce CO2 emissions by 80% could also be operational in time for Borouge 4’s start-up. The facility is also designed to capitalize on ADNOC’s recent initiatives on clean energy, decarbonizing its power supply through access to Abu Dhabi’s clean power sources. These initiatives are aligned with the UAE Net Zero by 2050 Strategic Initiative.

The first Borouge facility, producing 450,000 tons of polyethylene per annum was commissioned in 2001. Borouge 2 and Borouge 3 took capacity to 2 million tons and 4.5 million tons of polyethylene and polypropylene per annum in 2010 and 2014 respectively.  Borouge 4 will boost the company’s annual polyolefin production to 6.4 million tons, making Borouge one of the world’s largest single-site polyolefin facilities.

The new Borouge 4 facility will comprise:

• An ethane cracker, with 1.5 million tons ethylene output per annum, which will be the fourth cracker in Borouge’s integrated petrochemical complex in Ruwais
• Two additional Borstar® polyethylene (PE) plants, each with 700 thousand tons per annum capacity, using state-of-the-art Borealis Borstar third generation (3G) technology
• A cross-linked PE (XLPE) plant of 100 thousand tons per annum capacity.
• A hexene-1 unit, which will produce co-monomers for certain grades of polyethylene.

The Swedish textile recycling company, Renewcell, has chosen AFRY as partner in order to digitalize production operations in their plants in Kristinehamn and Sundsvall, Sweden. AFRY will deliver an Industrial IT solution, containing AFRY MES and AFRY ProTAK, to manage production information and secure both high quality, as well as high overall efficiency in the production. The delivered solution will serve as a hub for all production process information.

Renewcell is a multi-award-winning textile recycling company based in Sweden. With the technology they have developed, the company has succeeded in recycling and regenerating textile fiber from old clothes to turn it back into fiber pulp. Renewcell has had a production site in Kristinehamn since 2017 and is now scaling up the production in their new production plant in Sundsvall. The new plant is expected to be operating during the first half of 2022. “Modern production and logistics require a high level of digitalization to meet the demands for, e.g., traceability, and therefore the systems and experience from AFRY will be very important to us,” says Ylva Stjernquist, Supply Chain Manager and Project Leader at Renewcell.

AFRY has a long experience in Industrial IT and will now deliver the two leading, closely integrated digital solutions for production management to Renewcell. The AFRY MES (Manufacturing Execution System) is a highly advanced digital information system that connects, monitors, and controls the complex production systems and data flows of the production processes. AFRY ProTAK is a digital tool that measures the effectiveness of a plant’s production machine performance. The system gathers information from different sources (e.g., DCS, MES, Maintenance) and combines that with the operators’ notes to calculate or present Overall Equipment Efficiency (OEE), which will lead to optimized production and increased profitability.

Together these tools will improve traceability and secure a high production efficiency by integrating data from all production systems and equipment. “We are focusing on improving sustainability within process industries, and it is therefore an honor to be part of Renewcell’s textile recycling through a full-scale digitalized solution. Our modern and competitive digital solution will definitely bring added value to these types of processes,” says David Andersson, Business Segment Manager Digitalization, AFRY Process Industries Sweden.  

AFRY MES and AFRY ProTAK will be installed to both Kristinehamn and Sundsvall plants. The installation is planned to be up and running during Q2 2022.

The Beitlich Family Foundation, owner of the CHT Group, has appointed Elke Katz as an additional member of the Foundation's Board of Directors, which includes the function of Supervisory Board, on 1 September 2021. Elke Katz is currently CEO of ratioform Verpackungen GmbH, a company of the Haniel Group, based in Munich.

She has extensive, cross-industry experience in strategic and operational corporate management at companies such as BMW and Telefonica. She holds a degree in business engineering and has extensive know-how in customer experience management, digital business and business development.

Johan de Ruiter, Chairman of the Board of the Beitlich Family Foundation: "We aligned ourselves with the UN's 17 Sustainable Development Goals several years ago and defined sustainability, digitalisation and diversity as important strategic components for the CHT Group. We are therefore delighted to have gained a proven digitisation expert for our board. We are certain that Elke Katz will give us further impetus on this path so that we continue to be a leading, modern and innovative company.”

The Beitlich Family Foundation consists of 5 members, in addition to Elke Katz and Johan de Ruiter, Prof. Dr.-Ing. Götz Gresser (Vice Chairman), Dr. Antje von Dewitz and Prof. Dr. Klaus Müller.

Indorama Ventures Public Company Limited issued a THB 10 billion triple-tranche Sustainability-Linked Bond, showcasing the company’s long-standing commitment to sustainable growth. It is the largest SLB issued in Thailand and the first offered to both institutions and high-net-worth investors.

The bond is part of IVL’s financing strategy across a range of instruments linked to the company’s sustainability targets. It is aligned with internationally accepted standards including International Capital Markets Association’s (ICMA) Sustainability-Linked Bond Principles and the Loan Market Association’s (LMA) Sustainability Linked Loan Principles.

The SLB is linked to IVL’s performance of reducing GHG emissions intensity by 10% by 2025 (from a 2020 base), increasing recycling of PET bale input to 750,000 tons per year by 2025, and achieving 25% renewable electricity consumption in 2030.

The triple-tranche structure includes 5-, 7-, and 10.5-year tenors, offering coupons of 2.48%, 3.00% and 3.60% per year respectively, targeting asset managers, commercial banks, insurance companies, cooperatives and high-net-worth individuals. With the orderbook peaking at over THB 17.8 billion due to strong interest in the sustainability-linked instrument, oversubscription was around 3x over the planned issuance amount of THB 6 billion with a green shoe option of THB 4 billion. In view of the strong orderbook from the investors, the company decided to exercise the green shoe option and increased the issuance to THB 10 billion, setting a new benchmark as the largest SLB transaction in Thailand. IVL appointed Bangkok Bank, Kasikorn Bank, Krungthai Bank, Siam Commercial Bank, and The Hongkong and Shanghai Banking Corporation Limited, Bangkok Branch as arrangers and bookrunners for the transaction.

On 23 September 2021, the bond was assigned an AA- rating and a “stable” outlook by TRIS Rating following a strong recovery of petrochemicals and derivatives and IVL’s growing profitability.

Under the terms, all tranches must purchase Energy Attribute Certificates (EAC) or voluntary carbon offsets in the event of failure to meet the sustainability performance targets (SPT). The testing dates for tenors with a maturity of 5 and 7 years are 31 December 2025, and 31 December 2030 for the 10.5-year tenor. SPT performance will be independently verified upon the testing dates.Proceeds for the issuance will be used to finance IVL’s corporate working capital and refinance existing debt.

In recent years, IVL secured loans linked to improvements in the company’s sustainability performance as a global leader in environmental, social and governance (ESG) integration. These included Thailand’s first Green Loan of USD 200 million and EUR 200 million from Japan’s Mizuho Bank, Thailand’s first cross-border Sustainability-Linked Ninja Loan worth USD 225 million from 16 institutions in Japan and a Blue Loan of USD 300 million arranged by International Finance Corporation and funded by Asian Development Bank and DEG.

Tonello presents O-Zone, a new garment finishing project developed with Candiani Denim, a leading brand in the denim industry.

O-Zone, just presented at Kingpins 24, represents a new leap in quality and an important step in the growth of Tonello'a range of ozone processes, which are born from direct experience, research and a deeper knowledge of technology.

First with ECOfree2, then with SaniCare and OBleach, now with O-Zone, Tonello are defining ozone finishing and taking it to its maximum expression in every field of application: creation of special effects, garment sanitization, cleaning and reduction of water consumption, etc.

What is O-Zone?
At first glance it is similar to a cabinet. A special cabinet, however, inside which the garments are placed and treated, through an innovative, sustainable, responsible process.

A process that is also flexible, fast, safe and fully controllable by a touch screen that allows you to easily set all the desired parameters to obtain unique and customizable aesthetics, such as localized discoloration and lightening, sun-faded looks and degradé effects.

O-Zone is designed for small productions and is ideal for doing experiments and research directly on the garment, quickly verifying the result.

INDEX™20 opened its doors, after an 18 month’ wait, delighted to welcome the nonwoven industry back to Geneva with open arms. The exhibition floor was busting with activity and anticipation at the prospect of new business.  

Over 500 exhibitors from 44 countries were present at the event, premiering their latest innovations. The resounding message was one of a positive outcome and an inspiring vision of the industry’s future across the spectrum of applications sectors.

The industry continued to evolve dramatically during the pandemic, and expectations were high as players from across the industry worldwide came together for the first time since 2017. Exhibitors said their expectations were exceeded, citing the high quality of the visitors present, converging on INDEX™ to conclude new business projects.

Over 9,300 visitor entries were recorded on-site, and over a thousand on the virtual platform. 

As the industry’s first hybrid industry event, many attendees made the most of the interactive INDEX™ virtual platform by arranging video meetings and messaging as well live exchanges. It also meant those unable to attend personally benefitted from the rich Sector Seminar programme and a wide variety Exhibitor Product Presentations.

The Innovation Lab opened its doors for the first time, demonstrating the sheer diversity of applications in which nonwovens are employed. The spotlight was on nominees of the INDEX™ Innovation Awards, and the winners presented with their coveted bronze statues designed by Belgian artist Olivier Strebelle. This initiative demonstrates the innovative properties and uses of nonwovens across a wide range of sectors, demonstrating the exciting future of the industry and its suppliers.

INDEX™23 will take place from 18 to 21 April 2023.

• DiloGroup looks forward to participating in the Techtextil India show 2021.

DiloGroup offers tailor-made production systems from one supplier and will inform at this forum in the German pavillon about its portfolio and the latest equipment developments from fibre opening to the finished felt.

A new, simplified elliptical needle beam drive makes Hyperpunch technology also attractive for standard application. Hyperpunch HαV allows a more uniform stitch distribution in the preneedling process especially in combination with the new needle pattern 6000X. In a complete needling line this felt homogenization process can be improved further by using the new needle pattern 8000X which is a milestone in the needle pattern development process and results in endproduct surfaces with low markings over a wide range of advances/stroke.

The “3D-Lofter” which was first presented during ITMA 2019 in Barcelona offers a wider range of nonwovens applications by exploring the third dimension. A series of single web forming units which work according to the aerodynamic web forming principle deliver defined fibre masses in varied patterns on a base needlefelt. A stress oriented production of technical formed parts resulting in fibre savings or patterned DI-LOUR or DI-LOOP felts are two examples for this technology which explores new application areas for needlefelts.

The 3D-Lofter technology may also be used “inverted” for filling up bad spots in web mats and thus achieves a better homogeneity of e. g. spunlace, thermobond or airlay products. The DiloLine 4.0 concept offer I4.0 modules which not only support the user but also facilitate quality control and maintenance by a maximum data transparency in production and control of operation. The Dilo solutions “Smart Start” for a fully automatic start of the production line or “DI-LOWATT” for energy savings are accompanied by Siemens solutions which can be selected via App or Data Cloud “MindSphere”.

With more than 370 installations delivered to the nonwovens industry worldwide, DiloGroup has the necessary know-how and the complete equipment portfolio to engineer the perfect production line for any product specification. The efficiency of Dilo production lines is the result of long-term research work and experience. Apart from machines for needling technology we offer in cooperation with partner companies also production lines including thermobonding and hydroentangling components.

The Hygiene Fibers Group of Indorama Ventures (IVL) came together at the Index Show to present an all-inclusive range of recycled and biodegradable solutions for Hygiene Fiber and Nonwoven applications.

The combination of polymers, technologies, processes and global reach supported by the Hygiene Fibers Group – one of three business segments that make up Indorama Ventures – positions it within the Hygiene industry to meet increasingly challenging market demand for innovative sustainable solutions within the hygiene sector. Across the six brands and companies that make up Hygiene Fibers Group – Auriga, Avgol, FiberVisions, Indorama Asia, Trevira and Wellman International – sustainability and supporting customers to achieve circular objectives is integral to all efforts and fundamental to the ethos of the Hygiene business segment.

At the Index Show, the Hygiene Fibers Group launched CiCLO®, a textile technology which allows polyester and other synthetic materials to biodegrade like natural materials do in wastewater treatment plant sludge, sea water and landfill conditions, reducing synthetic microfiber pollution generated during washing, and minimizing plastic accumulation in landfills caused by discarded textiles.

In line with the company’s commitment to support customers with high performance products, while also reducing the impact on the environment, several of the  Hygiene Fibers brands, including Wellman International, Trevira GMBH and Auriga, have been working closely over the last 12 months with the IAM team and the CiCLO® technology. Developments have focused on PET and rPET staple fiber and filament sustainable solutions for applications where recycling is particularly challenging, such as Hygiene, Home Textiles and Automotive applications.

Strengthening the profile of biodegradable offerings within the Hygiene Fibers Group’s sustainability portfolio, Trevira introduced a new range of bicomponent fibres based on PLA and PBS (polybutylene succinate) at the Index show. Both biopolymers offer an exceptional technological opportunity in terms of environmental care and sustainability, while delivering optimum performance. Equally to PLA, PBS is recyclable and up to 100% biodegradable under industrial conditions.

Efforts towards supporting customers to achieve circular objectives are a priority within the Hygiene Fibers Group. This is reflected in the recycled fibers expertise deployed across the segment. Four Hygiene Fibers Group brands, IVL Asia, Auriga, Trevira and Wellman International offer an extensive range of 100% recycled, accredited PET fibers, across a multitude of fiber and nonwovens applications.

The development and evolution of sustainable technologies is central to activity across IVL’s Hygiene Fibers Group, with particular focus on sustainable polyolefin solutions. FiberVisions and ES-FIBERVISIONS, leading Polyolefin mono and bico fiber brands and sister company Avgol, have partnered with UK-based Polymateria to commercially harness the innovative ‘biotransformation’ technology pioneered by Polymateria. The patented technology alters the properties of polyolefins to make them biodegradable in a natural process.  Other polyolefin sustainable innovations within the Hygiene Fibers Group were featured at Index include biosurfactant and biocolourant developments being undertaken by the Avgol team with FiberVisons progressing sustainable design solutions, including lightweight, high performance, reduced carbon solutions.

SABIC has announced that the newly formed Hygiene & Healthcare segment of its Petrochemicals business will showcase its extensive portfolio of SABIC PURECARES™ polypropylene (PP) and polyethylene (PE) polymers for high-purity nonwovens and hygiene films at the upcoming INDEX™ Expo in Geneva, Switzerland, from October 19 through 22, 2021. The company will also present enabling solutions developed with partners to address the issue of plastic waste and support the transformation of the industry towards a circular economy with closed-loop initiatives and certified circular polymers under its TRUCIRCLE™ portfolio and services.

During INDEX, SABIC will exhibit a wide range of PP polymers targeted at these needs. Highlights on display will include dedicated PP and PE grades for lightweight nonwoven fabrics using the latest spunbond and meltblown processes, and a new ultra-high melt flow PP product engineered for meltblown fibers in nonwoven fabrics. The nonwoven focus will be complemented by industry proven polyolefins for cast and blown film applications in hygiene webs and laminates, providing desirable back and top sheet properties such as water tightness, breathability and elasticity.

In addition, SABIC will also present ISCC Plus certified fiber and film polymers based on circular and renewable PP and PE polymer technology as part of the company’s TRUCIRCLE portfolio for advancing the transformation of the plastics industry from a linear to a truly circular economy. Examples of this comprehensive initiative include collaborations with various market leaders in the field. Together with Fibertex Personal Care, one of the world’s largest manufacturers of spunbond nonwovens for the hygiene industry, SABIC is creating a range of high-purity nonwovens for the hygiene market using ISCC PLUS certified circular PP polymer derived from post-consumer plastic waste. In another project, Fraunhofer Institute, SABIC and Procter & Gamble (P&G) joined forces to develop and demonstrate the feasibility of an advanced close-loop recycling process for used nonwoven facemasks.

Knopf’s Sohn, a contract finisher of technical textiles, has installed a fully automated Montex stenter at its plant in Helmbrechts, Germany.
Knopf’s Sohn is processing technical textiles for the automotive, aerospace, home furnishings and workwear markets, based on wool, cellulose, polyamide and polyester fabrics, along with elastane blends, in weights of 80-800gsm.

The Montex machinery range is constantly being upgraded to meet evolving customer needs for greater automation, ease of operation and energy optimisation. The latest ten chamber line at Knopf’s Sohn, with a working width of up to 2.0 metres, was engineered to specific requirements in order to accelerate the company’s move to fully automatic control of its production, and high scaffolding was required for its installation.

The line benefits from two integrated ECO Booster modules to provide high energy savings. These compact, air-to-air heat exchangers, installed within the roof structure of the line, exploit energy from the exhaust gas to preheat up to 60% of the incoming fresh air entering the stenter.

The use of a single ECO Booster unit has been calculated to save up to 35% in energy costs, based on fixation processes. Fully automatic operation, set at the Monforts Qualitex control unit, ensures there is no additional burden on the machine operator.

The line is powered by Exxotherm indirect heating, which practically eliminates the yellowing which can be experienced during the treatment of certain polyamide and elastane-based fabrics, and is also equipped with a Conticlean circulating air filter system for constant high drying capacity.

Software
The latest Qualitex visualisation software offers operators reliability and easy control with its full HD multi-touch monitor and slider function, dashboard function with individual adaptation to operating states and faster access to comprehensive recipe data management.

With the Monformatic control system, the exact maintenance of the dwell time in combined treatment processes (drying and heat-setting) can be monitored. When the heat-setting point is reached, the fan speed is automatically adjusted, keeping energy consumption fully under control.