Polyolefin Plants

In June 2005 SHARQ, a joint venture between SABIC and a Japanese consortium headed by Mitsubishi, awarded an EPC contract for the construction of a polyethylene plant based on UNIPOL PE technology (licensed by SABIC) to Linde.

The contract included the construction of a HDPE unit (high-density polyethylene) and a LLDPE (linear low-density polyethylene) unit in separate reactor lines each with a capacity of 400 kta (kilo tons per annum) with two extrusion lines per reactors system.  

Beside the licensed technology scope of plant consisting of purification, reaction and finishing section, large product handling facilities were engineered and constructed by Linde where the pelleted product from the four extrusion lines is conveyed to an intermediate storage of large aluminium silos before final routing product shipment. In this plant section, the following facilities were installed by Linde for this purpose: 

- 6 automatic bagging and palletizing lines for 25 kg bags

- 4 big bags bagging lines with a weight of over 1,000 kg per bag

- 8 truck filling station for sea bulk containers

During the engineering phase, the joint team consisting of SHARQ’s project management and Linde’s project management team worked in Linde’s Dresden office. At the end of the detail engineering phase of the project, both groups moved to Al-Jubail, Saudi Arabia, jobsite to complete the project. 

Comprising of a multi-national and multi-cultural workforce, the project management team worked diligently to ensure that all team members are well aligned towards achieving the common goal of completing the projects safely, within budget, and on schedule.

All in all, over 80,000 m³ of concrete had to be poured for the foundations and buildings. The size of the construction site was approximately 500 by 250 metres. The erected steel construction now rises 93 meters above ground. The workforce peaked at more than 5,000 direct and indirect labor onsite.

Despite of the difficulties during the construction phase due to the severe shortage of qualified personnel on the overheated Arabian labour market in 2007 and 2008, Linde’s performance was rated very positively by SHARQ. SHARQ had already taken over the entire plant area in September 2009. The goals of the contractual completion schedules/incentive plans were fully achieved.

With the successful handing over of the polyethylene plant to SHARQ, Linde strengthened its position as one of the most important EPC contractors for polyolefin plants world-wide.

A great deal of specific project experience was acquired during the project execution, which in turn will be utilized for optimization measures on future projects. Key improvements and knowledge were gained in processes like:

- Improvement and consolidation of our understanding of the Arabian-Islamic business culture

- Engineering and construction of plants in accordance with special SABIC standards

- Management of all construction activities for large-scale projects staffed with more than 5000 people during peak

- Cooperation with local partners for erection and construction in Saudi Arabia

- Implementation of a newly developed turnover system for effective hand over of plant units from the construction phase to commissioning

- Improving work safety measures during the construction phase by the application of a strict HSE management system