Bringing energy all around dedicated to Wire & Cable ... - Borealis

www.borealisgroup.com I www.borouge.com
Bringing energy all around
dedicated to Wire & Cable solutions

www.borealisgroup.com I www.borouge.com
About Borealis and Borouge
Borealis and Borouge, a joint venture between the Abu Dhabi National Oil Company (ADNOC)
and Borealis, are leading providers of innovative plastics solutions that create value for society.
In addition, Borealis offers a wide range of base chemicals from melamine and plant nutrients
to phenol and acetone. Building on the unique Borstar ® technology, and their experience in
polyolefins for more than 50 years, Borealis and Borouge provide innovative plastics solutions for
the infrastructure (pipe systems and power and communication cables), automotive and advanced
packaging markets. We continue to invest to ensure that our customers throughout the value chain,
and across the globe, can always rely on product quality, consistency and security of supply.
Borouge and Borealis are committed to the principles of Responsible Care ® and proactively
contribute to addressing the world’s water and sanitation challenges through their Water for the
World initiative. Borealis is owned 64% by the International Petroleum Investment Company
(IPIC) of Abu Dhabi and 36% by OMV, Central Europe’s leading oil and natural gas group. With
EUR 4,714 million revenue in sales in 2009 and 5,200 employees, the company is headquartered
in Vienna and has manufacturing operations in Austria, Belgium, Finland, Germany and Sweden. It
also has special compounding units in Brazil, Italy and the United States.
The company’s main products are polyolefins and base chemicals. Polyolefins are the collective
name for polyethylene and polypropylene. Base chemicals comprise feedstocks and olefins,
phenol and aromatics as well as melamine and plant nutrients.
Borouge is a joint venture established in 1998 between Borealis and the Abu Dhabi National Oil
Company (ADNOC), one of the world’s leading oil companies. Headquartered in Abu Dhabi, the
United Arab Emirates, its state-of-the-art world-scale petrochemical complex is located at Ruwais,
where it is currently implementing a multi-billion-dollar expansion. The project, called Borouge 2,
is due for completion in 2010 and will triple the
company’s polyolefin production capacity.
For more information:
www.borealisgroup.com
www.borouge.com

Contents
02 Extra High Voltage power cables
06 High Voltage power cables
08 Medium Voltage power cables
09 Low Voltage energy cables
10 Building energy cables
11 Communication cables
12 Summary
1

2
Bringing energy all around
Extra High Voltage power cables
The leading supplier with a long proven track record
AC Cables
In close co-operation with the cable industry globally, Borealis has been at the
forefront of XLPE development. Superclean XLPE insulation was introduced
by 1973 for the first XLPE 84 kV submarine cable. Now it has advanced
to Extra High Voltage (EHV) cables up to and including 525 kV. Working in
partnership with customers and targeting developments that directly respond
to their needs, Borealis has established the dedicated technology for the
production and supply of compounds that enable the manufacture of EHV
cables to withstand the higher field stresses. By establishing the Borlink
technology, Borealis and Borouge have elevated their total network of support
to a new level by helping to facilitate the linking of different grids and energy
sources together both regionally and globally.
Together with the correct design and manufacturing care, high-quality, clean
XLPE compounds make or break cable system reliability. Contaminants reduce
the insulation performance and increase the risk of system failure. That’s why
Borlink Superclean XLPE compounds are produced in a dedicated clean
production system. After production, the cleanliness of the compound is
preserved thanks to the Borealis EHV Octabin System. To supplement Borlink
Superclean, Borealis and Borouge developed Borlink Supersmooth
semiconductive compounds. Extruded in conjunction with Superclean XLPE
insulation, Borlink Supersmooth provides very smooth and even surfaces.
Together with the best protective Borstar ® jacket, we offer the most reliable
system solution for EHV cables.

Our recommended solutions
Production
characteristics
Normal viscosity
High viscosity
(Low sag)
Borealis and Borouge are the leading suppliers of XLPE compounds to the
world’s largest EHV power distribution projects.
Reference projects
Borlink
semiconductive
Supersmooth
LE0500/LE0500EHV
Supersmooth
LE0500/LE0500EHV
Project name Conductor size
[mm²]
Borlink
insulation
Superclean
LE4201EHV
Superclean
LE4244EHV
Voltage
[kV]
Jacket
Borstar ®
HE6062 / HE6063
Casico – Flame retardant
FR6082
Cable length
[km]
Entered
in service
PUB, Russia 1,000 220 168 1995
Powergrid, Singapore 2,000 245 58 1997
Copenhagen 1 & 2, Denmark 1,600 400 108 1997 & 1999
Berlin 1 & 2, Germany 1,600 400 63 1998 & 2000
Dublin, Ireland 1,600 220 40 2000
Madrid, Spain 2,000 220 8 2001
Dachaoshan, China 800 525 7 2001
Taiwan 2,500 345 64 2003
Seoul, South Korea 2,000 345 66 2003
London Project, UK 2,500 400 60 2004
Madrid Airport, Spain 2,500 400 90 2004
Aarhus-Arlborg, Denmark 1,200 400 15 2004
Rotterdam, The Netherlands 1,600 400 12 2005
Zhengzhou City, China 800 220 8 2005
Bureyskaya, Russia 800 500 2.5 2005
Vienna, Austria 1,200 380 32 2006
Milan, Italy 2,000 400 13 2006
Istanbul, Turkey 2,000 380 27.9 2008
Porce III Columbia 800 500 5.4 2010
Tamil Nandu,Chennai, India 1,200 230 135 2010
Changjiang Tunnel-Bridge China 1,200 220 132 2010
3

4
Bringing energy all around
DC Cables
Polymeric DC insulation materials were developed in the 1990’s in parallel
with the development of voltage source converter technology. Borealis was
at the forefront in developing the polymeric insulation and semicon materials
used in the first commercial polymeric DC cables. And, in 2007, the Estlink
interconnection between the Nordic and Baltic countries marked 10 years
of Borealis’ experience and successes in the development and commercial
application of its polymeric materials for DC cables.
Borealis Borlink Superclean LE4253DC cross-linked polyethylene is
produced in a contamination-free environment. It is delivered in Borlink
Superclean octabins that are filled and emptied under clean room
conditions. That cleanliness directly benefits the cable maker. Scorch safety is
significantly better, lowering the risk of insulation defects and making longer
production runs possible. Less degassing time is required.
Combined with Borlink Superclean LE4253DC, Borlink Supersmooth
LE0550DC semicon has been designed to provide minimum space charge
accumulation. It is super-smooth and provides both conductor and insulation
shielding with the even surfaces that reduce electrical stresses. Designed
for both underground and subsea operating environments, Borlink
Superclean XLPE insulated cable assures power distributors of a fast
installation and a low environmental impact.
Benefits of our Borlink HVDC concept solution:
• minimum space charge accumulation
• high DC breakdown strength and high reliability
• enhanced scorch safety
• lower degassing burden

Our recommended solutions
Borlink conductor
screen
Reference projects
Borlink insulation Borlink insulation
screen
Supersmooth LE0550DC Superclean LE4253DC Supersmooth LE0550DC
Project Power
MW
Voltage
kV
Jacket
Borstar ® HE6062/HE6063
Casico FR6082
Cable
lenght km
Entered in Service
Gotland, Sweden 60 80 140 1998
Tjœreborg, Denmark 8 9 9 2000
Directlink, Australia 180 84 390 2000
Cross Sound, USA 330 150 84 2002
Murraylink, Australia 200 150 360 2002
Troll A, Norway 80 60 68 2004
Estlink, Finland-Estonia 350 150 105 2006
Borkum 2, Germany 400 150 390 2009
Trans-bay, USA 400 200 85 2010
Eirgrid, Ireland-UK 500 200 512 2012
Helwin, Germany 576 250 260 2013
Borwin 2, Germany 800 300 400 2013
Dorwin, Germany 800 320 330 2013
Sylwin 1, Germany 900 320 410 2013
France-Spain 1000 320 504 2014
Helwin 2, Germany 690 320 260 2014
Gotland – Sweden Troll A – Norway Transenergie – Australia
Connecting wind farms Subsea cables Long distance land cables
5

6
Bringing energy all around
High Voltage power cables
Satisfying the rising demand with proven technology
In high voltage cables, Borealis can rely on a track record of more than three
times the circumference of the earth. More than 280,000 kilometres of cable
have been installed world-wide using Borealis compounds and we are on our
way to making another global lap with Borlink Supercure cross-linked
polyethylene.
Our Borlink Supercure product, Supercure LS4201S is ahead of the
field. It has a significantly improved scorch safety that lowers the risk of
insulation defects. In combination with the inherently reduced degassing time,
cable manufacturers benefit from an optimised production cycle. To guarantee
their absolute cleanliness all Borlink Supercure LS4201S insulations are
produced and packed on specifically designed lines. Our advanced equipment
and quality management system leave nothing to chance.
Utility providers can trust cabling with Borlink Supercure insulation to
deliver them long-term reliability and an improved overall safety.

Our recommended solutions
Standard
viscosity
High
viscosity
S: Superclean for HV
Jacket
Borlink
Semiconductive
Supersmooth LE0500,
LE0592S or LE0592
Supersmooth LE0500,
LE0592S or LE0592
Borstar ® HE6062 or HE6063
Casico – Flame retardant FR6082
Borlink insulation
Classic XLPE High productivity XLPE
LE4201S Supercure LS4201S
LE4244S
7

8
Bringing energy all around
Borlink conductor
screen
Medium Voltage power cables
High productivity XLPE insulation Borlink Supercure enables
increased output to achieve lowest total-cost
Keeping up with the needs of power distributors is a huge challenge for Medium
Voltage cable makers. They need to be able to raise production levels quickly
and cost-effectively without compromising cable quality or long-term reliability.
With Borealis and Borouge Borlink Supercure high productivity cross-linked
polyethylene, cable makers now hold the key to increasing their production,
while lowering their costs.
Our Borlink Supercure copolymer offering allows for cable manufacturing
10-20% faster than classic homopolymer XLPE while delivering the outstanding
electrical performance meeting the most stringent market requirements.
Our Borlink Supercure homopolymer offering allows the cable makers to
extend the production runs potentially by more than 30% than other classic
homopolymer products thanks to its superb scorch retardant property.
As a result, more kilometres of cable can be produced in the same period and
the cable makers can have the opportunities to capture more business in the
market place.
Borlink Supercure
insulation
Borlink core
screen
Jacket
Borstar ®
Increased CV line speed LE0592 LC8205R (copolymer) LE0592 HE6062/HE6063
Wider process window
- Longer production runs
Our recommended solutions
LE0592 LS4201R
LE0592
LE0520
ME6052/ME6053
LE8707/LE8706

Low Voltage energy cables
Best cost-efficiency and productivity with Visico/Ambicat
Large-scale black-outs have shown the unreliability of the existing electricity
supply. To remedy this, more and more bare and PVC-insulated overhead lines
are replaced by cross-linked polyethylene insulated low voltage cables. For
underground cables as well, XLPE and PE have proven to be a safer, more
durable, more environment-friendly and more cost-efficient insulation than PVC.
The demand for low voltage cable is high, but manufacturers are facing stricter
requirements and severe competition. Cost-efficiency and high-value solutions
are crucial to stay in business. With such high stakes, no other moisture-cured
XLPE solution gives higher productivity and output than Visico/Ambicat.
Because the Visico base material is reactor-made, the quality is high and very
consistent. Scorch performance is unrivalled, allowing production runs of up to
one month without any need for cleaning the extruder. Ambicat, the catalyst
used in combination with Visico, uses environment-friendly sulphonic acid as its
active substance, instead of harmful tin-organic additives. Moreover, it offers a
significantly faster cross-linking which facilitates curing of the insulation at room
temperature or at ambient conditions without the need of putting the reels in a
waterbath or sauna.
With its outstanding quality consistency, scorch resistance and speed, Visico/
Ambicat is ahead of the game in moisture-cured XLPE solutions, offering Cable
Makers of Low Voltage cables best cost efficiency and productivity.
Our recommended solutions
Insulation Jacket
Base Polymer:
Visico LE4423 (Natural)
Visico LE4427 (Black)
Visico ME4425 (Natural)
Catalyst masterbatch:
Ambicat LE4472 (Black)
Ambicat LE4476 (Natural)
Borstar ® HE6062/HE6063
Borstar ® ME6052/ME6053
Borstar ® LE8707/LE8706
Casico FR6082 (Black)
Flame Retardant
9

10
Bringing energy all around
Building energy cables
Cost-effective ecological low smoke and zero halogen solutions
with Visico/Casico
Our homes, our schools, our companies, our public infrastructure,… we expect
our buildings to be functional and safe. Building cables for energy distribution
and communication need to address these issues. To meet the increasing
demands regarding safety and environmental issues, Borealis and Borouge
offer a unique Low Smoke and Zero Halogen flame retardant system.
Casico jackets are not only around 20% lighter than alternative plastics but
also limit smoke generation and have no toxic or corrosive gas emissions,
reducing secondary fire damage to equipment and installations. Cross-linked
Visico/Ambicat compounds offer a downsizing potential up to 40% and are
a cost-effective insulation compared to PVC. They also can boast superior
dielectric properties.
PVC
VDE 250 teil 204 NHMH
VDE 250 teil 215 New concept
0.7 mm
insulation
Figure 1: Cable downsizing
But there is more than safety at stake. And we have also kept production
performance in mind: LSZH cables can be produced on most PVC and PE
extrusion equipment.
Using less material with a lower weight than alternative plastics,
Borealis’ LSZH system also respects the environment without compromising
on performance.
Our recommended solutions
0.5 mm
insulation
Insulation Jacket
0.35 - 0.4 mm
insulation
Visico LE4423 Casico FR4803 or FR4804

Communication cables
The leading edge of technical insulation and jacketing
In today’s wired world, network providers demand cables that can carry
reliable, quality transmissions at increasingly higher frequencies offering
broader bandwidths. Borealis and Borouge compounds help meet those
requirements for copper multipair, data, coaxial and fibre optic cables.
Copper multipair: The Borealis and Borouge product range in copper
multipair cables is the broadest in the market. Our latest innovation in this area
is the Borstar HE3366 compound, produced in Ruwais (Abu Dhabi) to support
strong growth in Middle East and Asia.
Data: HE4873 is the compound of choice for physical foaming of data cables.
Offering the advantages of a full compound, it enables stable processing at
high line speed and a fine and uniform cell structure with increased crushability.
Longer production runs can be achieved due to anti plate out nucleating agent
system. HE4872 is our recommended solid insulation with improved copper
adhesion to reduce cross talk because of its improved conductor adhesion. It
can also be used as conductor and outer skin.
Coaxial: In our complete range of gas injection insulation and jacketing grades
for various types of coaxial cables, HE1106 is our most recent compound.
Ease of use and consistent processability are matched with excellent
dielectric properties. Next to this full compound, Borealis and Borouge also
offers a 2 component solution for radio frequency cables.
Fibre optic: The Borstar technology offers the broadest range of materials
to fit all jacketing requirements for fibre optic cable. Whether for linear low
density, medium density or high density, Borstar compounds show the lowest
shrink and highest environmental stress-cracking resistance.
Our recommended solutions
Coax LE6006
HE1106 (type RG)
LE1120-HE1123 (RF)
Data HE4872
HE4873
Telephone HE1344
HE3366
Insulation Jacket
Borstar ®
HE6062/HE6063
ME6052/ME6053
LE8707/LE8706
Fibre Optic Borstar ® HE6067, HE6068
11

12
Bringing energy all around
Summary
All over the world, wires and cables are transmitting and distributing
electricity, and enabling communication. Borealis and Borouge are the world’s
leading providers of innovative, value creating plastics solutions for the wire
and cable industry.
We are actively committed to investing in our customers’ continued
success.
• Leading innovator providing solutions for our customers to
differentiate their products.
• Global presence enabling customers to meet the fast growing
demand in the markets.
• Long-term reliable partner with solid industry knowledge and proven
technology, offering consistent and high-quality products.
• Investing for the future not only supported by our forward thinking on
innovation but also by our commitment to asset investments.

Disclaimer The information contained herein
is to our knowledge accurate and reliable
as of the date of publication. Borealis and
Borouge extend no warranties and make
no representations as to the accuracy or
completeness of the information contained
herein, and assume no responsibility regarding
the consequences of its use or for any printing
errors. It is the customer’s responsibility
to inspect and test our products in order
to satisfy himself as to the suitability of
the products for the customer’s particular
purpose. The customer is also responsible
for the appropriate, safe and legal use,
processing and handling of our products.
Nothing herein shall constitute any warranty
(express or implied, of merchantability,
fitness for a particular purpose, compliance
with performance indicators, conformity
to samples or models, non-infringement or
otherwise), nor is protection from any law
or patent to be inferred. Insofar as products
supplied by Borealis and Borouge are used in
conjunction with third-party materials, it is
the responsibility of the customer to obtain
all necessary information relating to the thirdparty
materials and ensure that Borealis and
Borouge products, when used together with
these materials, are suitable for the customer’s
particular purpose. No liability can be accepted
in respect of the use of Borealis and Borouge
products in conjunction with other materials.
The information contained herein relates
exclusively to our products when not used in
conjunction with any third-party materials.
Borstar is a registered trademark of
the Borealis group.
Borlink, Shaping the Future with Plastics,
Superclean, Supercure, Supersmooth, Casico,
Visico and Ambicat are trademarks of the
Borealis group.
Borealis and Borouge – Dedicated to Wire & Cable Solutions
Borealis and Borouge are the world’s leading providers of innovative, value creating
plastics solutions for the wire and cable industry. Our solutions are customer-driven
and designed to satisfy the industry’s continuously evolving demands for higher
technical performance. Consequently, they can be found in the most challenging EHV
and HV cable applications, as well as MV and LV energy transmission and distribution
cables, building wires, and communications cables.
In answer to the need for production, installation and cable-system lifetime
enhancements, we create the innovation links that secure world-class, step-change
solutions and benefit the whole wire and cable value chain. Through the introduction
of unique polymer technologies, which include Supercure, Visico/Ambicat,
Borcell, Borstar ® , and Casico, we continue to pioneer the development of
advanced insulation and jacketing systems for both energy and communication cables.
Built on more than 50 years experience, Borealis and Borouge have a well-established
track record in serving customers’ needs with the consistently high quality products
expected of global leaders. We are committed to extending that leadership position
and our role as reliable partners for the long-term – a commitment not only supported
by our forward thinking in innovative solutions, but also confirmed by ongoing
investments for our customers’ continued success.
Putting customers’ needs at the centre of our planning is reflected in Borealis’
largest investment in Europe to date, the new 350,000 t/y high-pressure, lowdensity
PE plant in Stenungsund, Sweden, will be inaugurated in June 2010, further
strengthening Borealis’ capabilities to meet the needs of the growing wire and
cable markets. Furthermore, Borouge’s expansion of Borstar ® capacity in the Middle
East allows us tosatisfy growing customer demand for wire and cable products in
emerging markets.
Through ongoing research and development,
investment in the future and a dedicated team
with solid industry knowledge, we aim to
remain fully responsive to our customers’ needs
throughout the world.

WC BROCH 049 GB 2012 02 BB
© 2012 Borealis AG
© 2012 Borouge Pte Ltd
For more information :
visit www.borealisgroup.com and www.borouge.com
Borealis AG I IZD Tower
Wagramer Strasse 17-19 I A-1220 Vienna I Austria
Tel +43 1 22 400 000 I Fax +43 1 22 400 333
Borouge Pte Ltd I Sales and Marketing Head Office
1 George Street 18-01 I Singapore 049145
Tel +65 6275 4100 I Fax +65 6377 1233