SAPCO Super Absorbent Polymer Plant

Client: SAPCO

Location: Jubail, Saudi Arabia

Map showing the location of SAPCO Super Absorbent Polymer Plant

Executive Summary

SAPCO has a propriety process to produce state-of-the-art super absorbent polymer, used in diapers and incontinency products to capture and retain liquid. Worldwide demand for these products is increasing, and the new plant supports demand by serving the Middle East market.

To build the production facilities, SAPCO required a partner with extensive experience in executing projects in the specialty chemicals industry and in the Kingdom of Saudi Arabia. Fluor, which had managed projects in the Kingdom for more than 40 years, was responsible for basic engineering of the plant as well as engineering, procurement and construction of the facilities.

In 2014, the Super Absorbent Polymer project was selected by ENR magazine as the Global Best Project in the Manufacturing category.

Client's Challenge

Evonik Industries AG produces a wide range of specialty chemicals that support the health and nutrition industry as well as providers of resource efficiency and specialty materials. Through its Baby Care business line, Evonik is one of the world's leading producers of super absorbent polymer.

To address the increasing demand, Evonik, the technology licensor, established a joint venture, SAPCO, with SAAC, itself a joint venture of Tasnee and Sahara. Tasnee produces titanium dioxide, lead, chlorine and derivative products; and with Sahara, polyolefins.

SAAC, together with Dow Chemical as the joint venture SAMCO, owns a state-of-the-art production facility for glacial acrylic acid, the key ingredient of super absorbent polymer.

The SAPCO joint venture invested in a new facility for full grassroots production of super absorbent polymer. The building, on Tasnee property, and fully integrated in its existing facilities in Jubail, is 80 meters (260 feet) long, 50 meters (165 feet) wide and 60 meters (200 feet) high.

Fluor's Solution

To build the production facilities, SAPCO required a partner with extensive experience executing projects in the specialty chemicals industry and in the Kingdom of Saudi Arabia.

Fluor, having managed projects in the Kingdom for more than 40 years, was responsible for basic engineering of the plant as well as engineering, procurement and construction of the facilities.

Evonik and Tasnee staffs, who were assigned to the project from day one, worked with Fluor to develop the scope of work for producing the super absorbent polymer and to integrate the plant's design with the existing facilities in Jubail.

We completed the engineering effort (in collaboration with SAPCO), purchased production equipment and materials, hired construction contractors and executed construction of the entire plant.

Conclusion

The SAPCO/Fluor venture resulted in a modern production facility that not only produces state-of-the-art super absorbent polymer but also is esthetically pleasing.

Fluor's flexible approach to scope development and the integration of Evonik and Tasnee personnel with the project team helped SAPCO (and its joint venture partners, the Evonik and Tasnee companies) to improve its competitive position in the market and to boost its long-term business success.

The project was completed in 2013.