Borealis expands XLPE production in Sweden

Together, these projects will significantly increase capacity for insulation materials used in medium, high, and extra-high voltage (MV, HV, and EHV) power cables. These cables are essential for expanding transmission and distribution networks so they can integrate more renewable energy sources, support electrification, and ultimately deliver the energy transition. These investments build on the Stenungsund site’s expertise, where research, advanced laboratories, and a skilled team have established it as a global centre for XLPE materials.

Project 1: expanding capacity for MV XLPE

The first project is the construction of a new production unit for insulation grades used in medium-voltage power distribution cables. The asset will produce a new-generation homopolymer XLPE grade that matches the proven performance of Borealis’ existing MV portfolio, including processing and productivity advantages, while delivering a lower carbon footprint through optimised production.

The expansion will improve local material availability within the EU, ensuring continuity of supply to meet MV market demand. It will also enable bulk deliveries, further reducing the cradle-to-gate carbon footprint of the product. Commercial availability is expected in 1Q27.

Project 2: expanding capacity for high-end XLPE for HV and EHV applications

The second project adds capacity for advanced XLPE grades used in high and extra-high voltage alternating current (AC) and direct current (DC) cable systems. These systems are essential for reinforcing national grids and enabling large scale power transmission. HVDC technology, in particular, is needed to bring offshore renewable power to shore and integrate it into national grids.

As part of this expansion, Borealis will further expand its closed and controlled loop (from monomer to final packaging) system to ensure best-in-class cleanliness standards and the reliability required for critical energy infrastructure.

Construction is scheduled for completion in 2026, with commercial availability expected during the course of 2027.

Building for the future

“We are continuously investing in innovation and optimising our product portfolio to meet the evolving needs of the energy industry,” says Craig Arnold, EVP Polyolefins, Circular Economy Solutions and Base Chemicals, Borealis. “This expansion at our Stenungsund site strengthens our ability to keep pace with growing demand for advanced insulation materials and enables our customers to deliver the power cables that make the energy transition possible.”

Read the article online at: https://www.hydrocarbonengineering.com/petrochemicals/14102025/borealis-expands-xlpe-production-in-sweden/