Borouge: AI-driven process optimization to expand across international production sites

Borouge International is expanding the use of artificial intelligence (AI) and digital technologies across its manufacturing and business operations. Formed in 2026 through the combination of Borouge, Borealis and Nova Chemicals, the polyolefins producer plans to roll out applications developed at individual plants to additional sites. The initiative covers production, research and development, supply chain management, logistics and customer engagement. According to the company, the measures are expected to deliver USD 100 million in value by 2027.

At ADIPEC 2026, Borouge International and its subsidiaries signed cooperation agreements with Microsoft, Emerson, Immensa and Cognite. The partners will support the deployment of digital solutions and their implementation across multiple sites. The company did not disclose specific investment figures or indicate how much each project is expected to contribute to the overall value target.

Advert

Real-time optimization across three ethane crackers
In the United Arab Emirates, Borouge International has deployed a real-time optimization (RTO) system across three large-scale ethane crackers comprising a total of 20 furnaces. The AI-powered system analyzes more than 2,500 process parameters per minute, enabling faster adjustments to operating conditions. The company expects the technology to improve productivity while reducing energy consumption and emissions.

Borouge International plans to extend the technology to additional production sites, including facilities in North America. By sharing proven optimization methods across its operations, the group aims to reduce implementation costs and shorten development times at individual sites.

AI-powered autonomous plant operations tested in Ruwais
Working with Honeywell, Borouge International completed a proof of concept for AI-powered autonomous plant operations under live production conditions at its Ruwais site in the United Arab Emirates in 2026. According to the company, the trials demonstrated the potential to improve operational efficiency by up to 20%, reduce unplanned downtime by 20% and cut operating costs by up to 15%. The technology is also expected to enhance process safety and reduce energy consumption and emissions.

These figures reflect potential improvements identified during the proof of concept rather than savings already achieved in routine operations. In the longer term, the company aims to establish an AI-powered control room capable of managing petrochemical plant operations comprehensively and in real time.

Digital twins and additive manufacturing
Other applications include machine learning to improve forecasting accuracy, digital twins for predictive maintenance and industrial 3D printing to support supply chain operations. The company plans to follow a standardized approach, developing and testing applications at individual sites before rolling them out to other facilities.

The expansion of the program coincides with the integration of the manufacturing, technology and sales operations of Borouge, Borealis and Nova Chemicals across Europe, the Middle East and North America. The group aims to leverage this combined expertise by sharing technologies, processes and operational know-how across its international production network.

More information: www.borougeinternational.com

Borouge Group International AG, Vienna, Austria

back to news list