Success Stories

NOVA Chemicals Joffre

Polyethylene 1 Plant Expansion

NOVA Chemicals Corporation (“NOVA Chemicals”), a leading supplier of polyethylene in the Americas, completed the start-up of its new world-scale linear low-density polyethylene (LLDPE) gas phase reactor at its Joffre, Alberta site. The new reactor started up in December 2016. The plant has operated within expectations since startup.

This was the first new LLDPE reactor in the Americas in over a decade. The new capacity allows NOVA Chemicals to meet the growing demand for flexible films used in food packaging, heavy-duty sack and can liners.

The addition of this reactor increases NOVA Chemicals’ LLDPE production capacity by close to one billion pounds, giving the company total polyethylene production capacity of approximately 5 billion pounds. NOVA Chemicals’ butene LLDPE is known in the industry for a range of benefits including excellent balance of physical properties, product uniformity and consistency, and best-in-class gel performance.

The project received final investment decision in February 2013, construction started in June 2013 with Mechanical Completion occurring in August 2016, followed by a successful startup in December 2016. During peak construction activities, there were 750 craft resources, and management and staff of 200 people for a total peak site resource level of 950 people.

Scope of the project included the main plant including the reactor, extruder, rail loading facilities, plus the addition of a 500-car rail storage yard, and modifications to the existing Polyethylene plant for feed, catalyst manufacturing and utilities.

The project was completed under budget with a successful schedule to be online over a year ahead of the first wave of North America Polyethylene expansion. The project success was a result of the collaborative relationship and common goals with our talented Engineering, Vendor, and Construction partners. There were many challenges that were resolved in a timely fashion due to these relationships.

“The new supply of LLDPE from our PE1 Expansion Project will enhance NOVA Chemicals’ position as a leading polyethylene supplier in the Americas, helping our customers grow and succeed in their businesses,” said Senior Vice President, Polyethylene Business Chris Bezaire.

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