Sadara Corporate Awareness

CORPORATE
AWARENESS
Corporate awareness. Learn more about Sadara
www.sadara.com
What we do and how we do it.

Contents
1 Introduction +
2 Map +
3
Feed Stock +
Raw material required for
an industrial process.
Product +
The product that emerges at the
end of a manufacturing process;
Sadara Products.
5
6
Process +
Insights on the mechanisms and
technologies Sadara implements
to produce intermediate goods
and Sadara Products.
4
Intermediate +
An intermediate good is a good that
is used in the eventual production
of a final good, or finished product.
CONTENTS MAP FEED STOCK INTERMEDIATE PRODUCT PROCESS GLOSSARYINTRO

Introduction
Sadara is a joint venture developed by the Saudi Arabian Oil Company (Saudi Aramco)
and The Dow Chemical Company. With a total investment of about $20 billion,
Sadara is building a world scale chemical complex in Jubail Industrial City II in Saudi
Arabia’s Eastern Province.
Comprising 26 world scale manufacturing units, the Sadara complex is the world’s
largest to be built in a single phase and will be the first in the Middle East to use
refinery liquids, such as naphtha, as feedstock. Sadara will enable many industries
that either currently do not exist in Saudi Arabia or only exist through imports of raw
materials.
The adjacent PlasChem Park, a unique collaboration between Sadara and the Royal
Commission for Jubail and Yanbu, will create more value downstream, generating
unprecedented investment, innovation, economic growth and thousands of jobs.
The company name derives from the Arabic word for “at the forefront” or “leading”.
More information about Sadara can be found at www.sadara.com
START
BASICS
WITH
THE
CONTENTS INTRO MAP FEED STOCK INTERMEDIATE PRODUCT PROCESS GLOSSARY

Saudi Aramco, a fully integrated, global petroleum and chemicals enterprise, is
the state-owned oil company of the Kingdom of Saudi Arabia.
Saudi Aramco has became a world leader in hydrocarbons exploration,
production, refining, distribution, shipping and marketing, and the world’s top
exporter of crude oil and natural gas liquids (NGLs).
More information about Saudi Aramco can be found at www.saudiaramco.com
Introduction
START
BASICS
WITH
THE

Introduction
Dow combines the power of science and technology to passionately innovate what is
essential to human progress. The Company is driving innovations that extract value from
the intersection of chemical, physical and biological sciences to help address many of
the world’s most challenging problems such as the need for clean water, clean energy
generation and conservation, and increasing agricultural productivity.
Dow’s integrated, market-driven, industry-leading portfolio of specialty chemical,
advanced materials, agrosciences and plastics businesses delivers a broad range of
technology-based products and solutions to customers in approximately 180 countries
and in high growth sectors such as packaging, electronics, water, coatings and
agriculture. In 2013, Dow had annual sales of more than $57 billion and employed
approximately 53,000 people worldwide.
The Company’s more than 6,000 products are manufactured at 201 sites in 36 countries
across the globe.
More information about Dow can be found at www.dow.com.
START
BASICS
WITH
THE

H2
FEED STOCK INTERMEDIATE PRODUCT PROCESS
ANILINE
PG
MDI
LLDPE X2
LDPE
BUTANOL
H2O2
BGE
EAE
HCI Cl2
TDIDNT TDA
ETHYLENE
ETHANE
NAPHTHA
MeOH
HCl
C4S
PYGAS
NH3
NaOH2
NaCl
BENZENE MNB
PO
Cl2 NaOH
POLYOLS
EO
ELASTOMERS
NH3
AROMATICS
HYDROGENATION
& EXTRACTION
PROPYLENE
TOLUENE
HNO3
Interact with the chart below:
IMPORTED TOLUENE
IMPORTED BENZENE
EOA
CO
NH3
MIXED FEED
CRACKER
FORMALIN
CONTENTS MAP FEED STOCK INTERMEDIATE PRODUCT PROCESS GLOSSARYINTRO

Feed Stock
Ethane +
Naphtha +
Butanol +
Hydrogen Peroxide +
Nitric Acid +
Ammonia +
Formalin +
Raw material required for an industrial process.
Feed
Stock
Feed
Stock
Feed
Stock
CONTENTS FEED STOCKMAP INTERMEDIATE PRODUCT PROCESS GLOSSARYINTRO

Application Source
• Ethane can be used as a fuel.
• In Sadara, Ethane is fed into a steam
cracker to produce Ethylene.
• Ethane is the second-largest component
of natural gas.
• Sadara gets the Ethane by pipeline from
the Saudi Aramco Ethane grid.
• Ethane will be fed into Mixed Feed
Cracker
Ethane is a hydrocarbon compound
that exists in nature as an odorless
and colorless gas at standard
temperature and pressure.
Ethane is isolated on an industrial
scale from natural gas, and as a
byproduct of petroleum refining.
C2H6
Ethane

• Naphtha is produced from crude oil.
• Sadara gets the Naphtha by pipeline
from SASREF.
• Naphtha is used primarily as feed stock
for producing Ethylene and Propylene.
Naphtha is a hydrocarbon. It is a
colorless to reddish-brown volatile
aromatic liquid, very similar to
gasoline.
Naphtha
Application Source

• Sadara gets Butanol by pipeline
from the Saudi Butanol Company.
• The primary uses of Butanol are as a
solvent; as an intermediate in chemical
synthesis; and as a fuel.
• In Sadara, Butanol is used as a raw material
to produce BGE, Butyl Glycol Ether.
Butanol is a colorless, toxic liquid.
C4H9OH
Butanol
Application Source

• Sadara gets Hydrogen Peroxide by pipeline
from the Jubail Hydrogen Peroxide plant.
• Hydrogen peroxide is often used as
a bleach or cleaning agent.
• In Sadara H2O2 is used to produce
Propylene Oxide (PO).
Hydrogen Peroxide is a clear liquid,
which is slightly more viscous than
water. It is also a strong oxidizer.
H2O2
Application Source
Hydrogen Peroxide

• Sadara gets Ammonia from Linde
(on-site plant).
• Sadara will use Ammonia, Carbon
Monoxide, and Hydrogen primarily for
the production of Isocyanates (MDI
and TDI) and Amines.
NH3
Ammonia
Application Source
Ammonia is a colorless gas with
a characteristically pungent smell.

Nitric Acid (HNO3), is also known
as aqua fortis and spirit of niter,
it is a highly corrosive and strong
mineral acid. The pure compound is
colorless.
• Sadara gets Nitric Acid from the supply of
Ammonia which comes from the on-site
Linde Plant.
• HNO3 is produced in the Nitric Acid
Plant.
• Nitric Acid is used to produce
Mono Nitro Benzene (MNB)
and Di Nitro Toluene (DNT) for
manufacturing TDI and MDI.
HNO3
Nitric Acid
Application Source

Application
• Formalin is a common precursor to more
complex compounds and materials. In
Sadara it is used to produce Methylene
Diphenyl Diisocyanate (MDI).
CH2O
Source
• Sadara gets Formalin from the Methanol
(MeOH) that comes from SABIC.
• Formalin is produced in the
Formalin plant.
Formalin is a clear, colorless,
aqueous solution of 40%
formaldehyde, 8% methyl
alcohol and 52% water.
It is an organic compound, and
has a characteristically pungent,
irritating odor. It is an important
precursor to many other materials
and chemical compounds. It is
commonly used in nail hardeners
and nail varnish.
It is made in the Formalin unit.
Formalin

An intermediate is a substance that is used in the eventual
production of a finished product.
Ethylene + Aniline +
Propylene+ Di Nitro Toluene +
Benzene + Toluene Di Amine +
Toluene + Chlorine +
Ethylene Oxide + Hydrochloric Acid +
Propylene Oxide + Sodium Hydroxide +
Mono Nitro Benzene +
Intermediate
CONTENTS INTERMEDIATEMAP FEED STOCK PRODUCT PROCESS GLOSSARYINTRO

Ethylene (H2C=CH2) is a colorless,
flammable gas with a faint ‘sweet
and musky’ odor when pure.
H2C=CH2
Ethylene
Application Source
• Ethylene is produced in the petrochemical
industry by cracking (Process of breaking
large hydrocarbon molecules into smaller
molecules). Sadara uses a Mixed Feed
Cracker to crack Naphtha and Ethane
to get Ethylene.
• In petrochemicals, it’s used in
manufacturing Polyethylene plastics,
such as LLDPE and LDPE.

Propylene (C2H6) is also known as
Propene. At room temperature and
atmospheric pressure, Propylene
is a colorless gas with a weak but
unpleasant smell.
C2H6
Propylene
Application Source
• Propylene is produced in the
petrochemical industry by cracking.
Sadara uses a Mixed Feed Cracker
to crack Naphtha and Ethane to
get Propylene.
• Essentially all of the Propylene produced
for chemical purposes is consumed as a
chemical intermediate in other chemical
manufacturing processes.
• In Sadara Propylene is used to produce
Propylene Oxide (PO).

Benzene (C6H6) is a colorless and
highly flammable liquid with a
sweet smell. It evaporates quickly
when exposed to air.
C6H6
Benzene
Application Source
• Benzene comes in a non-purified form
through a pipeline from SASREF. It will go
under a process within the Aromatics fa-
cility ** (Aromatics are a group of organic
compounds which include Benzene) to
be converted into a very high-purity Ben-
zene and used as feed stock by the Isocy-
anates production unit.
• Benzene is used mainly as a feedstock to
make other chemicals. It has been used
in, or used to manufacture, a wide variety
of chemical products. In Sadara Benzene
is used to produce Mono Nitro Benzene
(MNB).

Toluene (C7H8) is a clear,
water-insoluble liquid with the
typical smell of paint thinners.
C7H8
Toluene
Application Source
• Toluene comes from Ras Tanura. It will
go under a process within Aromatics
to be converted into a very high-purity
Toluene and used as feed stock by the
Isocyanates production unit.
• Toluene is an aromatic hydrocarbon
that is widely used as an industrial
feed stock to produce Toluene
Diisocyanate (used in the manufacture
of polyurethane foam).

Ethylene Oxide (C2H4O) is a
colorless, flammable gas at room
temperature, with a faintly sweet
odor.
C2H4O
Ethylene Oxide
Application Source
• Ethylene Oxide is manufactured by the
direct oxidation of Ethylene with high-
purity oxygen.
• Ethylene Oxide is used as an Intermediate
product to produce Butyl Glycol Ether
(BGE), Ethanolamine, Ethyleneamine,
and Polyols.

Propylene Oxide (PO) is a highly
reactive, colorless, highly flammable,
liquefied organic compound.
Propylene Oxide
Application Source
• The industrial production of Propylene
Oxide comes from the oxidation of
Propylene.
• PO is made by a technology jointly owned
by BASF and Dow.
• Propylene Oxide is used for the
production of Polyether Polyols for
making polyurethane plastics. It is also
used to produce Propylene Glycol (PG).
CH3CHCH2O

Mono Nitro Benzene (MNB) is
produced by the nitration of
Benzene, which minimizes the
formation of Nitrophenols and
Dinitrobenzene byproducts.
MNB will be made by
NORAM technology.
Mono Nitro Benzene
Source
• Mono Nitro Benzene, obtained from
Benzene and Nitric Acid in the presence
of Sulphuric Acid by the adiabatic
process, is the starting material for
Aniline, which is a valuable raw material
for the plastics chemistry, MDI.
Application
• Mono Nitro Benzene is converted to
Aniline, which is subsequently used
to produce Methylene Diphenyl
Diisocyanate (MDI). MDI is
copolymerized with various Polyols
to form polyurethane.
C6H5NO2

• Aniline is manufactured by hydrogenating
Mono Nitro Benzene.
• It will be produced in the Aniline Plant.
• Aniline is used to produce Methylene
Diphenyl Diisocyanate (MDI). MDI is
copolymerized with various Polyols to
form polyurethane.
C6H5NH2
Aniline (C6H5NH2), also known as
Phyeylamine or Aminobenzene, is
a colorless, oily and slighty water-
soluble liquid. It is toxic and, like
most volatile amines, possesses
the odor of “rotten fish”. It ignites
readily, burning with a smoky flame
that is characteristic of aromatic
compounds.
Application Source
Aniline

Di Nitro Toluene (DNT) is a pale
yellow crystalline solid.
Di Nitro Toluene
Application Source
• DNT is produced in the DNT plant that
mixes Toluene with Nitric Acid.
• Di Nitro Toluene is well known as a
precursor to Trinitrotoluene (TNT) but
is mainly produced as a precursor to
Toluene Diisocyanate (TDI).
C7H6N2O4

Toluene Di Amine (TDA) is a
colorless solid that tends to darken
on storage and exposure to air.
Nearly all of the TDA produced is
used as part of a mixture for the
production of TDI.
Toluene Di Amine
Application Source
• TDA is manufactured by Dow Technology
by nitrating Toluene to produce Di
Nitro Toluene, which is then catalytically
reduced to TDA.
• TDA is used to manufacture TDI by
the reaction with Carbonyl Chloride
(Phosgene).

Chlorine (Cl2) is a chemical element
with the symbol Cl and atomic
number 17 (Atomic number Equal
to the number of protons in a given
element).
At standard temperature and
pressure, two Chlorine atoms form
the diatomic molecule Cl2 (Diatomic:
Molecule composed of two atoms).
Chlorine is a yellow-green gas that is
highly toxic when exposed to directly.
Chlorine
Application Source
• Sadara gets Cl2 from the Chlorine plant.• Chlorine is used in the production of a
wide range of industrial and consumer
products. In Sadara it is used to produce
MDI (Methylene Diphenyl Diisocyanate)
and TDI (Toluene Di Amine).
Cl2

Hydrochloric Acid is a clear,
colorless solution of Hydrogen
Chloride (HCl) in water. It is a
highly corrosive, strong mineral
acid with many industrial uses.
Hydrochloric Acid
Application Source
• Hydrochloric Acid is used in the chemical
industry as a chemical reagent in the
large-scale production of MDI/TDI for
polyurethane.
• HCI is produced as a byproduct from
PMDI (Polymeric Methylene Diphenyl
Diisocyanate) and TDI then recycled back
to the HCl plant to produce Chlorine
(Cl2).

Application
Sodium Hydroxide (NaOH), is also
known as lye or caustic soda. It
is a highly caustic metallic base
and alkaline salt. It is a white solid
available in pellets.
NaOH
Source
Sodium Hydroxide
• Sodium Hydroxide is the principal strong
base used in the chemical industry.
In Sadara’s production line it is used to
produce MNB (Mono Nitro Benzene) and
MDI.
• NaOH is provided by the Chlor-Alkali
unit.

These are the final Sadara products that emerge at the
end of the manufacturing processes.
Linear Low-Density Polyethylene + Propylene Glycol +
Low-Density Polyethylene +
Elastomers + Toluene Diisocyanate +
Butyl Glycol Ether + Ethanolamin +
Polyols + Ethyleneamine +
Product
Polymeric Methylene Diphenyl Diisocyanate +
CONTENTS PRODUCTMAP FEED STOCK INTERMEDIATE PROCESS GLOSSARYINTRO

Application Source
• LLDPE is used for plastic bags and sheets
(where it allows using lower thickness
than comparable LDPE), plastic wrap,
stretch wrap, pouches, toys, covers, lids,
pipes, buckets and containers, covering
of cables, and flexible tubing.
• LLDPE is produced by copolymerization
of Ethylene with alpha-olefins such as
Butene, Hexene, or Octene.
Linear Low-Density Polyethylene
(LLDPE) is a substantially linear
polymer (polyethylene), with
significant numbers of short
branches.
Sadara capacity is 750 KTA.
SINGLE MIXED FEED CRACKER ETHYLENE LLDPE
Linear Low-Density Polyethylene

Application Source
• LDPE is widely used for manufacturing
various containers, dispensing bottles,
wash bottles, tubing, plastic bags for
computer components, and various
molded laboratory equipment. LDPE’s
most common use is in plastic bags.
• LPDE is made by a high-pressure process
via free radical polymerization of
Ethylene.
Low-Density Polyethylene (LDPE)
is a thermoplastic made from the
monomer Ethylene. It is the first
grade of polyethylene.
SINGLE MIXED FEED CRACKER ETHYLENE LDPE
Low-Density Polyethylene

Application
• Sadara will have different grades of
elastomers, each for use in different
markets and applications. These include:
- Adhesives
- Consumer solutions
- Health hygiene
- Building construction
- Footwear
- Automotive.
Elastomers are a formation of a
thermoplastic or thermoset that
can stretch and then return to its
original shape without permanent
deformation. Elastomers are only
slightly cross-linked.
Sadara capacity is 220 to 270 KTA.
SINGLE MIXED FEED CRACKER ETHYLENE ELASTOMERS
Source
• Elastomers are made by a high-pressure
process via free radical polymerization of
Ethylene.
Elastomers

Application
Butyl Glycol Ether (BGE) is a
colorless, mild-smelling liquid with
a high boiling point.
Source
SINGLE MIXED FEED CRACKER ETHYLENE EO BGE 3RD PARTY BUTANOL
Butyl Glycol Ether
• Glycol Ethers are used as solvents for
resins, lacquers, paints, varnishes, gum,
perfumes, dyes, inks, as a constituent of
paints and pastes, cleaning compounds,
liquid soaps, cosmetics, and hydraulic
fluids.
• Glycol Ether products are produced in the
BGE unit through continuous processes
of selectively reacting an alcohol and
Ethylene Oxide.

Application
Polyol is an alcohol with more
than two reactive hydroxyl
groups per molecule.
Source
SINGLE MIXED FEED CRACKER PROPYLENE PO POLYOLS
Polyols
• By mixing Polyol with TDI or MDI in
the presence of suitable catalysts and
additives, we can get polyurethane.
• Polyurethane applications include:
- Flexible foams
- Rigid foams
- Non-foamed products.
• Polyols products are produced through
batch processes of selectivity reacting
Propylene Oxide and Ethylene oxide.
• Butyl Glycol Ethers unit.

SINGLE MIXED FEED CRACKER PROPYLENE PO PG
Application
• 45% of Propylene Glycol produced is
used as chemical feed stock for the
production of unsaturated polyester
resins, which can be used in the following
markets and applications:
- Pharmaceutical
- Pet food
- Food and flavorings
- Paint and coatings
- Urethanes
- Aircraft deicing fluid
- Heat transfer fluid / thermal fluids
- Hydraulic and brake fluid
- Coolants and antifreeze
- Unsaturated polyester
- Fragrance and Personal Care.
Propylene Glycol (PG) is a colorless,
nearly odorless, viscous liquid
with a faintly sweet taste, and
is hygroscopic and miscible with
water, acetone, and chloroform.
Source
• Propylene Glycol is produced from
Propylene Oxide.
• The new PG facility will use Dow’s
proprietary technology.
Propylene Glycol

Application
• Rigid polyurethanes such as sandwich
panels and cold stores.
Polymeric Methylene Diphenyl
Diisocyanate (PMDI) is the
predominant Isocyanate used in
rigid polyurethane manufacture.
Otherwise standard mixtures of
MDI/PMDI are used in urethane
production and essentially all MDI/
PMDI is used in the manufacture of
normal polyurethanes.
Source
• The first step of the production of PMDI
is the reaction of Aniline and Formalin,
using Hydrochloric Acid as a catalyst.
• PMDI unit.
AROMATICS HYDROGENATION EXTRACTION BENZENE MNB ANILINE PMDI FORMALIN
Polymeric Methylene Diphenyl Diisocyanate

Application
• By mixing Polyol with Toluene
Diisocyanate (TDI), we can get flexible
foams which can be used in mattresses
and furniture.
Toluene Diisocyanate (TDI) is an
organic compound produced
in large scale production for
Polyurethane. It is a colorless,
yellow, or dark liquid with a sharp,
pungent odor.
Source
• TDI is manufactured by the reaction of
TDA Clarion gas.
• TDI is made by Dow Phosgenation
Technology.
AROMATICS HYDROGENATION EXTRACTION TOLUENE DNT TDA TDI
Toluene Diisocyanate

Application
• It is used in aqueous solutions for
scrubbing certain acidic gases. It is
used as feed stock in the production
of detergents, emulsifiers, polishes,
pharmaceuticals, corrosion inhibitors, and
chemical intermediates.
Ethanolamine (EOA) is a toxic,
flammable, corrosive, colorless,
viscous liquid with an odor similar to
that of Ammonia.
Source
• Ethanolamine is produced in the
(EOA) unit by reacting Ethylene Oxide
with aqueous Ammonia.
ETHYLENE EO ETHANOLAMINE NH3SINGLE MIXED FEED CRACKER
Ethanolamine

Application
• Ethyleneamine is used for:
- Asphalt additives
- Corrosion inhibitor
- Elastomeric fibers
- Fabric softeners
- Pharmaceuticals
- Plastic lubricants
- Rubber processing additives
- Lube oil and fuel additives.
Ethyleneamine (EAE) is a colorless
and highly corrosive liquid. it mixes
well with organic solvents and
water.
Sadara capacity is 45 KTA
• Ethyleneamine is produced in the
(EOA) unit by reacting Ethylene Oxide
with aqueous Ammonia.
ETHYLENE EO ETHYLENEAMINE NH3SINGLE MIXED FEED CRACKER
Ethyleneamine
Source

MAP FEED STOCK INTERMEDIATE PRODUCT GLOSSARYINTRO
Mixed Feed Cracker +
Aromatics +
Process
Insights on the mechanisms and technologies Sadara implements
to produce intermediate goods and Sadara Products.
Isocyanates +
Mono Nitro Benzene +
Hydrochloric Acid +
Di Nitro Toluene +
Chlor-Alkali +
Nitric Acid +
Aniline +
Toluene Di Amine +
Formalin +
Polymeric Methylene Diphenyl Diisocyanate +
Chemicals +
Ethylene Oxide +
Ethanolamine and +
Ethyleneamine
Butyl Glycol Ethers +
Propylene Oxide +
Propylene Glycol +
Polyols +
Plastics +
Polyethylene Trains +
1,2 4
HP-LDPE Train 3 +
Toluene Diisocyanate +
CONTENTS PROCESS

CONTENTS PROCESSMAP FEED STOCK INTERMEDIATE PRODUCT GLOSSARYINTRO
• MFC, the heart of Sadara, will utilize a Mixed Feed Cracker that is licensed from
Technip, with a designed feed rate of 85 MMSCFDM (million standard cubic feet per
day) of Ethane and 51,000 barrels per day of Naphtha. The unit will be equipped
with 12 furnaces: seven will be dedicated to Ethane (gas) and five to Naphtha
(liquid). The feed stock will be converted into 1.5 million tons per year of Ethylene
and 400,000 tons per year of Propylene. The cracker provides additional products
for the Sadara complex including Pygas. The Pygas contains Benzene and Toluene
which will be refined in the Aromatics plant. Hydrogen and Methane off-gas are
also produced and used within the Sadara site as fuel.
Mixed Feed Cracker

• The Aromatics facility comprises of two process technologies to extract the aromatics from Pygas
feed stock: The front end of the facility, which will use a Pygas Hydrogenation process (first
and second stage hydrogenation); and the back end of the facility, which will use an Extraction
Distillation process.
(Hydrogenation: A chemical reaction between hydrogen and another chemical, usually in the
presence of a catalyst.)
(Extraction Distillation: Process to extract a chemical from a mixture that, due to the chemical’s
low volatility, cannot be extracted through a simple distillation process. A solvent is added to raise
the volatility of the chemical, so that it can be extracted through distillation – check definitions)
Shaw will provide technology for the Pygas Hydrogenation process (with BASF reactor design
and catalyst) while GTC will provide technology for the Extractive Distillation process. The plant
will have a design capacity of 275,000 tons per year of Benzene and 131,000 tons per year of
Toluene. Additional Benzene and Toluene will be needed for the planned capacities of the
downstream plants such as Mono Nitro Benzene (MNB) and Di Nitro Toluene (DNT) plants
and these will be sourced from third parties.
• The Aromatics units will take the MFC-produced Pygas feed, as well as purchased chemical-grade
Benzene and Toluene, and convert them into very high-purity Toluene and Benzene for use as
feed stock by the Isocyanates production units.
Aromatics

• Plastics is a complex manufacturing unit consisting of four trains which produce Polyethylene
in a wide grade portfolio; like LLDPE, LDPE and Elastomers.
Plastics

Polyethylene Trains 1,2 4
• Polyethylene trains will use Dow’s proprietary Solution Polyethylene Most Effective
Technology. The reaction is conducted in a solvent carrier. Ethylene and another compound
such as Butene, Hexene, or Octene are fed to the reactor along with Hydrogen and the
carrier solvent. A catalyst is injected into the reactor to initiate the polymerization reaction.
Following the reaction, the catalyst is deactivated, additives are introduced and the
polyethylene is separated from the solvent. The recovered solvent is recycled back to the
reactor along with un-reacted recycled Ethylene.
The polymer is converted into pellets and forwarded to storage silos and bagging (Solution
PE trains) or directly to packaging (Elastomers). Trains 1 and 2 will have a combined design
capacity of 750 KTA of LLDPE products, while Train 4 will have a design capacity of 220–
270 KTA of Elastomer materials.
If there is a replica of a plant it is called a train. A train is used to produce the same product
as a specific plant.

HP-LDPE Train 3
• The Tubular High Pressure Polyethylene process technology is based on the free radical
polymerization at very high pressures initiated by Organic Peroxides. Telomers are used to
control polymer molecular weight. Co-monomers can be used to obtain special properties.
The process is heavily mechanical in nature. The Polymer is separated in two stage steps.
The un-reacted materials are recycled to the Compression area where they join the fresh raw
materials and a mixture is compressed back to a high-pressure reactor. The molten polymer
stream from the separators is pelletized and transferred to storage. Additives can be added
to the product. The plant capacity is highly dependent on the actual product mix and can
vary in the range of 350 KTA.
(Polymerization: Reacting simple molecules together to form long molecule chains)
(Free radicals: Atom or ions which react rapidly, sometimes forming polymer chains.)

• The Chemicals unit is a complex manufacturing unit that consists of two sections: Ethylene
Oxide Derivatives (EOD), and Propylene Oxide Derivatives (POD), with seven units to
produce a number of main products.
Chemicals

Ethylene Oxide
• Ethylene Oxide is manufactured by the direct oxidation of Ethylene with high-purity oxygen.
Ethylene and Oxygen are combined with methane and fed into a single Ethylene Oxide
reactor. The methane is added as ballast to help control the oxidation reaction. The design
for the Sadara project is a 360,000 tons per year standalone Ethylene Oxide plant.

Ethanolamine and Ethyleneamine
• Dow will provide technology for the integrated Ethanolamines (EOA) and Ethyleneamines
(EAE) technologies. The EOA/EAE plant will have a combined design capacity of 255,000
tons per year. The EOA plant will be fed Ethylene Oxide produced on site and Ammonia
produced by the on-site third party plant. The plant will produce Monoethanolamine
(MEA), Diethanolamine (DEA), and Triethanolamine (TEA) will be produced in changeable
production ratios.
The back end integrated EAE plant will be fed MEA produced on site from the EOA plant
along with Ammonia and excess Hydrogen for the production of Ethylenediamine (EDA),
Diethylenetriamine (DETA), Piperazine (PIP), and EAE heavy products.

Butyl Glycol Ethers
• The design for the Sadara project is a 200,000 tons per year Butyl Glycol Ethers plant. The
process unit comprises two steps: (1) Glycol Ethers synthesis reaction and Butanol recovery
and (2) product refining.
The reaction step involves the reaction of Ethylene Oxide and Butanol with Sodium
Hydroxide as a catalyst to produce a range of Glycol Ether products. Fractional distillation
is then used to obtain products. (Fractional distillation: The separation of a mixture into its
component parts.) The process can produce both light and heavy mixtures of Glycol Ether
products. The light mixture maximizes Monobutoxyglycol (EB) production, which will yield
a specific EB to Dibutoxyglycol (DB) ratio. The heavy mixture maximizes production of the
heavier Glycol Ethers to yield a lower EB to DB ratio. The process can operate to produce any
mixture specification within this regime.

Propylene Oxide
• Dow plans to use its Hydrogen Peroxide-based Propylene Oxide (HPPO) technology
jointly owned by BASF and Dow for the manufacturing of Propylene Oxide as part of
the Sadara project. The plan will have a capacity of 390,000 tons per year using a single
production line. Propylene feed stock will be supplied by the Cracker unit in the same
project, while Hydrogen Peroxide (H2O2) will be supplied by the Hydrogen Peroxide plant to
be constructed adjacent to the PO plant by a Sadara–Solvay joint venture.
• Crude Hydrogen Peroxide, Methanol, polymer-grade Propylene and an aqueous buffer
are fed to the main reactor to convert H2O2 and Propylene to PO. In the intermediate PO-
removal, PO and the excess Propylene (lights) are separated by distillation to protect PO from
consecutive reactions. The bottom product consists of Methanol, water and H2O2 etc. which
is sent to a secondary epoxidation reactor, where Propylene is added to increase the H2O2
conversion.

Propylene Glycol
• The Propylene Glycol (PG) facility will use proprietary Dow technology to achieve advanced
energy reductions and throughput optimization. The design for the Sadara project is a
70,000 tons per year PG plant.
• The basic reaction is between Propylene Oxide and water. The hydration takes place
in two stages followed by dehydration and purification. The reaction between PO and
water requires a precise amount of water to favor PG production. The reaction mixture is
dehydrated by evaporation and the various Glycols (Mono Propylene Glycol or MPG, Di-
Propylene Glycol or DPG and Tri-Propylene Glycol or TPG) are separated by distillation.

Polyols
• Sadara will be using two different technologies to produce 400,000 tons per year of
Polyether Polyols. A batch process will produce 70,000 tons per year of Potassium Hydroxide
(KOH) catalyst plant for Polyols moulded (for use in rigid end-products) and a continuous
330,000 tons per year of DMC catalyst for Polyols slab (for flexible end-products) integrated
with Propylene Oxide and Ethylene Oxide feed stocks.
• In the KOH process Sadara will produce low molecular weight Polyols, which will serve
as an intermediate building block for the high molecular weight products. The reaction
goes through two separate Oxide feed and digestion cycles. The Oxide type (Propylene or
Ethylene Oxide), charge amount, reaction temperature and digestion time/temperature
depend on the specific product to be manufactured. After the digestion step, the product is
pumped to the crude Polyol rundown tank that serves as a buffer between the reaction and
purification processes.

• Isocyanates is a complex manufacturing unit consisting of two sections with a number of
units to produce two main products: PMDI (Polymeric Methylene Diphenyl Diisocyanate)
section and TDI (Toluene Diisocyanate) section.
Isocyanates

• Uhde has been selected to provide its latest electrolysis technology for the Hydrochloric
Acid (HCl) to Chlorine process to the Sadara project.
• The plant will have a capacity of 432,000 tons per year. It will be fed by the Hydrochloric
Acid byproduct of the Isocyanate units. The pure Chlorine gas resulting from the HCl
electrolysis will be recycled to both the PMDI and TDI units.
Hydrochloric Acid

• Dow will be providing its technology for the Chlor-Alkali (Cl2-NaOH) process to the Sadara
project. The plant will have a capacity of 115,000 tons per year. It will be fed by salt
imported to the site while the Chlorine and Caustic soda products will be fed downstream
to the Polymeric Methylene Diphenyl Diisocyanate (PMDI) and Toluene Diisocyanate
(TDI) facilities.
Chlor-Alkali

• The Mono Nitro Benzene (MNB) plant is a single train continuous operating unit that will
be mainly feeding on Benzene from aromatics and Nitric Acid (65%). The MNB produced is
stored in ISBL tanks and is routed to the Aniline plant for Aniline production.
• NORAM will provide technology for the MNB process. The plant, composed of three trains,
will have a capacity of 416,000 tons per year and will be fed by the Nitric Acid and Benzene
produced on site while the MNB product will be fed into the downstream Aniline plant.
Mono Nitro Benzene

• Josef Meissner GmbH Co. KG will license its technology for the Di Nitro Toluene (DNT)
process for the Sadara project. The technology package includes the NACSAC® process.
It’s a sub-licence from Plinke, used to produce higher concentration Nitric Acid by utilizing
Sulphuric Acid. The DNT plant will have an instantaneous design capacity of 250,000 tons
per year and will be fed Toluene from the aromatics Hydrogenation and extraction unit. The
Nitric Acid will be produced in-situ along with third party sourced Sulphuric Acid, while the
DNT product will be fed downstream for Toluene Diamine (TDA) production.
Di Nitro Toluene

• The Nitric Acid plant is a single train continuous operating unit with dry Ammonia as feed
to the unit producing Nitric Acid (65%). The plant has two consumers in the Isocyanates
envelope: Mono Nitro Benzene (MNB) and Di Nitro Toluene (DNT) plants. Nitric Acid
is transferred to an ISBL tank and stored prior to consumption in MNB. Nitric Acid is
concentrated to 98%, prior to feeding the DNT plant.
• Espindesa, a subsidiary of Tecnicas Reunidas, will be licensing its dual pressure technology
for the Nitric Acid (HNO3) process. It’s to be implemented with a plant design capacity of
400,000 tons per year. The process will be fed by Ammonia to be produced from an on-
site third party Ammonia plant, while the Nitric Acid product will be fed downstream to the
Mono Nitro Benzene (MNB) and Di Nitro Toluene (DNT) plants.
Nitric Acid

• DuPont/KBR will be providing its technology for the Aniline process to the Sadara project.
The plant will have a total capacity of 300,000 tons per year and will be fed by the MNB
produced in-situ, and hydrogen will be provided from the Syngas unit.
Aniline

• The plant is to be designed with an instantaneous design rate of 160,000 tons per
year and will be fed Di Nitro Toluene (DNT) in-situ by an integrated upstream Toluene
nitration process unit, while the TDA product from the Hydrogenation process will be
fed downstream for Toluene Diisocyanate (TDI) production by Phosgenation. The TDA
technology to be implemented at the Sadara plant is based on the 60,000 tons per year. The
TDI plant is owned and operated by Dow in Camacari, Brazil.
Toluene Di Amine

• Perstorp will be providing its technology for the Formaldehyde plant to the Sadara project.
The plant will have an instantaneous design capacity of 130,000 tons per year. It will be
fed by Methanol purchased from a third party. The unit will produce a 45% solution of
formaldehyde that will be fed to the PMDI plant.
Formalin

• Diisocyanate (PMDI) process for the Sadara project. The plant will have a capacity of
400,000 tons per year and will be fed by the Aniline and Formaldehyde produced in-situ.
A Phosgene unit will also be built, CO will be provided from the Syngas unit while Chlorine
will be supplied from both the Chlor-Alkali and HCl to Chlorine units.
Polymeric Methylene Diphenyl Diisocyanate

• Dow will provide its Toluene Diisocyanate (TDI) by phosgenation technology to the Sadara
project. The plant will have an instantaneous design rate capacity of 208,000 tons per year
and will be fed in-situ by the back-integrated TDA plant. The TDI product will be purified and
collected for product export.
Toluene Diisocyanate

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