TotalEnergies, Borealis double production capacity at Baystar JV with new polyethylene unit

TotalEnergies and Borealis are celebrating a significant milestone in their partnership with the start-up of the new 625,000 metric ton-per-year Borstar polyethylene (PE) unit at their Baystar joint venture (JV) in Bayport, Texas. This state-of-the-art unit, referred to as Bay 3, not only more than doubles the current production capacity but also utilizes the innovative Borstar 3G technology, making its North American debut. This technology allows for the creation of advanced, sustainable polymers with a focus on light-weighting and incorporating post-consumer recycled materials into a range of products, benefiting industries such as energy, infrastructure, and consumer goods.

With a substantial investment of USD 1.4 billion, the Bay 3 unit is a crucial addition to the integrated petrochemical venture established by TotalEnergies and Borealis. This venture includes the expansion of the Bayport PE facility and the ethane cracker at the TotalEnergies Platform in Port Arthur, Texas. In total, the Baystar site will now produce over one million tons per year, encompassing the output from two existing polyethylene production units.

This achievement follows the inauguration of the ethane cracker unit in Port Arthur last year, marking the second significant milestone for this joint venture. Bernard Pinatel, President of Refining & Chemicals at TotalEnergies, noted, “The fruition of this venture also advances TotalEnergies’ ambition to grow in the United States.”

Borealis CEO Thomas Gangl added, “The arrival of Borealis’ proprietary Borstar technology in North America through Baystar is a crucial step in becoming a global leader in advanced and sustainable chemicals and material solutions. Expanding and deepening our footprint through Baystar enables us to better serve customers and partners by offering improved access to Borstar-based products produced right here in North America.”

This development not only solidifies the Baystar joint venture’s position in the U.S. petrochemical industry but also contributes to TotalEnergies and Borealis’ shared vision of providing advanced and sustainable solutions to meet evolving market demands.