Borealis Sirius catalyst

technology – enabling factor for

sustainable growth

Dr. Nora Vaarne

Catalyst Scale-Up and

Production Manager

Borealis at a glance

2 |

EUR 7.5billion

sales revenuein 2017

(>EUR 9 billionwith Borouge)

Operates in over 120 countries

on 5 continents

Head officein Vienna,

Austria

EUR 1.095

million

net profitfor 2017

Production and sales of polyolefins,

base chemicalsand fertilizers

Ownership structure

Mubadala, UAEOMV, Austria

2nd largest polyolefin producer

in Europe

Borouge operates world’s largest

integrated PO site in Ruwais, UAE

6,600employees

+3,500 in Borouge

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

3 |

We strive for zero incidents

in health and safety

We consider our local and

global responsibility for the

environment in our decisions

We do business according

to high ethical standards

and lead by example

We trust and involve people

and communicate openly,

respectfully and in a timely

manner

We collaborate, support and

help each other to develop

for the best of Borealis

We build on diversity for

better results as “One

Company”

Our values guide our business decisions and drive

every action we take

Responsible Respect Exceed Nimblicity™

We win through Excellence

and deliver beyond

expectations

We commit to making joint

decisions and follow through

We give feedback and make

“Connect–Learn–Implement”

and “Continuous

Improvement” a natural way

of working

We are fit, fast and flexible

and seek smart and simple

solutions

We encourage decisions on

all levels of the organisation

to increase ownership and

speed to realisation

We welcome change and

manage it to shape our

future

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

World class safety standards

16,3

14,8

10,19,5

8,36,9

4,0 3,82,4

1,7 1,7 1,7 1,6 0,7 1,0 1,6 1,5 1,5 1,3 1,4 0,9 1,1

9,9

8,3

7,47,0

3,03,1

2,5 2,5 1,8

1,21,4

2,5 2,11,7

2,2 2,4

1,3 1,3

0

2

4

6

8

10

12

14

16

18

1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

TRI total TRI Own TRI Contractors

Note: TRI being defined as total recordable incidents per million hours worked

TRI frequency - Own vs. Contractors 1996 – 2017

Our Core Values drive our Actions

4 | Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

Borstar process

Multimodality of Borstar® PP

Key feature to tailor end product properties

5 |

− Borstar® process gives freedom in molecular design resulting in highly differentiated PP

− Multimodality for advanced properties (e.g.: strength and processability, clarity and toughness)

− Stiffness control through MWD design, Borealis nucleation technology and catalyst

− High EPR incorporation (RTPO’s)

Borstar® PP – A unique technology platform

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

Catalyst

Macrostructure

Borealis Sirius catalyst technology –

Key to advanced PP products with Borstar®

6 |

− High degree of control on the catalyst nano and micro

structure allowing fine-tuning of polymer properties

− Excellent control of internal and external morphology for an

optimal polymerisation behaviour

− Versatile catalyst chemistry allowing flexibility in the choice of

modern donor technology

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

Requirements for a Catalyst used in Borstar®

Kinetics matchingprocess window

Good particle morphology & homogeneity

Good polymerstructure control

High productivity

IPRCatalyst

manufacturingHSE

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 20197 |

Borealis Sirius: Sustainable Basics

1. Borealis Proprietary Sirius technology: IPR in place

2. No phthalates – No other questionable chemicals either

3. Catalyst manufacture designed to be highly contolled for reproducibility of quality –

Still flexible enough for making several types of Borealis Sirius catalysts

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 20198 |

IPRCatalyst

manufacturingHSE

Borealis Sirius – Meeting Borstar® operability

requirements

9 |

Catalyst kinetics matching

process

Flexibility to adjust the

reactor split to get

different products

High enough catalyst productivity

Different reactors and conditions

Good morphology and

homogeneity of catalyst

and polymer

Operability in different

reactors & conditions

PP powder from Borstar®

PP plant

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

The Catalyst Value Chain

Catalyst

Design

Catalyst

Performance

Process

Development

Polymer

development

Catalyst

Pilot

Polymerisation

Pilots

Cat Scale-Up

Process

Development

Catalyst

Plant

Full Scale

Plants

PO Catalyst R&D Pilot Scale Commercial Scale

Catalyst Scale-Up

Polymerisation Scale-Up

10’s of Pilot

scale runs

100’s of lab scale tests

1 plant

test run Cost /

experiment

Probability of

discovery

Process

Development

Polymer

development

Cat Scale-Up

Process

Development

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201910 |

Catalyst scale-up from lab to plant

11 |

• Catalyst development

• Screening, DoE for conditionsLaboratory reactor

• Catalyst development

•Polymerisation, analyticsLaboratory reactor

• Scale up

• Combining chemistry with engineering practices process optimisation

Catalyst Pilot

reactors

• Catalyst production for PO plantsProduction

Sirius catalyst Plant

Batch < 1,5 g

Batch < 5 g

Batch kilograms

Batch hundreds kg

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

Polymerisation scale-up from lab to plant

12 |

• Catalyst screening

•High Throughput

Laboratory

HTE

• Catalyst Evaluation, Product Development

• Polymerisation, Polymer Analysis

Laboratory

bench reactors

• Polymer Production at Pilot Scale

• Validation, Pre-marketing testing, Operating windows, Demonstration

PolymerisationPilots

•Production Plants

• Several Borstar® in the WorldFull Scale Plants

Polymer: 300 mg – 100g

Polymer: 0,5 - 3 kg

Production Rate: 60 – 120 kg/hr

Up to 700 kt/a

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

Borealis Catalyst R&D

13 |

Parallel Catalyst Synthesis Advanced Catalyst Characterisation

High Throughput Experimentation Bench Scale Polymerisation

• Located in Finland,

Europe

• Target is to develop new

catalyst systems that

meet the PO product and

process targets

• Supported by broad

polymerisation capability

and analytical tools

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

Borealis Sirius Catalyst Technology – Mastering

polymer structure and polymerization behaviour

14 |

Intra- and inter-particle

homogeneity

Particle morphology

MgCl2 nano-crystals with

active sites

External / internal donor

chemistry

Polymer structure /

product properties

Nanostructure

ChemistryMicrostructure

Assembly of MgCl2nanoparticles

Porosity

Polymerization process

behavior

Macrostructure

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

Borealis Catalyst Pilot Plant

– Located in Finland, Europe

– Own proprietary technology

– Scope is catalyst development including Borealis Sirius

technology

– Several types of catalysts has been piloted

– High level of flexibility with a wide variety of reactors

and equipment combinations

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201915 |

Borealis Sirius Catalyst Technology – Inside the reactor

16 |

Formation of

two liquid

phases

Emulsification Solidification Final catalystWashes

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019

Borealis Sirius Catalyst Plant

– Located in Austria, Europe

– Own proprietary technology

– Start up year 2012

– Non-phthalate Ziegler-Natta PP catalyst manufature since 2014

– So far proven for different Borealis Sirius catalysts at the plant

– Broad range of particle sizes

– Different chemical compositions

– Different morphologies

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201917 |

Key messages

− Borealis’ Borstar® process gives freedom in molecular design resulting in highly

differentiated polymers

− The Borstar® process sets a variety of demands for the catalyst capability

− Borealis’ Sirius catalyst technology is fulfilling these demands and enables broad

product property capability

− Sirius is platform technology for all kind of Ziegler-Natta and Single Site catalysts

− Sirius emulsion catalyst technology allows unique possibilities in tailoring particle size

and morphology

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201918 |

Thank you

A project by Borealis AG. The ideas documented in

this presentation are the sole property of Borealis AG,

and are subject to current copyright laws.

Unauthorized use, reproduction in whole or in part, as

well as transmission to third parties is not permitted.

Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201919 |