Baystar Initiates Operations at Polyethylene Production Unit

Baystar has ushered in a new era of high-performance polyethylene (PE) production and enhanced sustainability with the commencement of operations at its groundbreaking Bay 3 polyethylene unit. This innovative unit represents a first-of-its-kind installation in North America, leveraging proprietary Borstar technology from Borealis to significantly boost Baystar's production capacity at its facility in Pasadena, Texas.

The introduction of Borstar technology heralds a transformative shift in production flexibility, offering manufacturers and converters the capability to craft a diverse range of highly customized products. These products are characterized by being lighter, more durable, more flexible, and more efficient, contributing to the evolution of plastics in numerous applications. Notably, Borstar products are free from per- and polyfluoroalkyl substances (PFAS) and have the potential to incorporate more than 50% post-consumer recycled material into some end products. With a broad molecular weight distribution, Borstar PE boasts superior physical properties, eliminating the need for additional process aids or additives.

Chamberlain highlighted that Borstar technology empowers Baystar's teams, including technical, production, and sales, to collaborate in the creation of highly tailored products that align with customer needs while enhancing competitiveness and meeting consumer demands. This project reflects a substantial investment that commenced in 2019, exemplifying the determination, innovation, and unwavering commitment to safety exhibited by Baystar's team and partners.

Baystar achieved full integration as a polyethylene manufacturer in 2022 with the commissioning of its ethane cracker unit in Port Arthur, Texas, boasting an annual capacity of 1 million tons. This facility supplies essential ethylene feedstock to Baystar's three PE production units, solidifying the company's position in the industry. The construction of the Bay 3 unit represented a massive project with a substantial investment surpassing $1.4 billion. It engaged a workforce of more than 1,900 individuals on-site during the development stage and generated permanent employment for an extra 50 highly skilled workers in the Pasadena area.

Leesman highlighted Baystar's unique position, being both sizable enough to introduce cutting-edge technologies and agile enough to provide highly responsive solutions on behalf of its customers. He expressed anticipation for the industry's reaction to Baystar's innovative approach.

Established in 2018 as a joint venture between Novealis and TotalEnergies, Baystar operates independently as an integrated producer. The state-of-the-art Borstar technology employed by Baystar is licensed from Borealis, reinforcing the company's commitment to technological excellence and sustainability.

In summary, the launch of the Bay 3 polyethylene unit by Bayport Polymers LLC marks a pivotal moment in the realm of high-performance polyethylene production and sustainability. Utilizing Borstar technology, this first-of-its-kind unit in North America empowers Baystar to meet evolving customer demands with highly customized, sustainable, and efficient products. With a robust investment, a dedicated workforce, and a commitment to innovation, Baystar continues to redefine possibilities in the PE industry, cementing its position as a leader in the field.