No.6 Naphtha Cracker ComplexMagnitude & Facilities

Magnitude & Facilities

1. Civil works

pipeline end of land reclamation

• Land reclamation : 109.15 million cubic meters of sand were poured to create land, sufficient in volume to construct a three story tall, eight-lane wide building along the 373 km-long stretch of freeway from Keelung to Kaohsiung. The total area of reclaimed land is 2,255 hectares, about 8% the size of Taipei City (27,180 hectares) and 14.7% the size of Kaohsiung City (15,359 hectares), or equal to 0.062% of Taiwan's land area.
• Engineering foundation : The total length of piles driven amounted to 4.7 million meters and the total amount of concrete used reached 8.64 million cubic meters (approximately 1.88 million tons).
• Plant construction: Fifty three plants were built within a single complex, including oil refineries, naphtha cracking plants, cogeneration plants, power plants, heavy machinery plants, boiler plants, wafer fabrication plants and petrochemical-related plants. Piping inside the plant area alone extends for 3,000 km.
• Complex area : The area of the entire complex totals 2,603 hectares, more than four times the total of the Linyuan (403ha), Dashe (109 ha), and Toufen (95 ha) petrochemical industrial zones.

2. Mailiao Port

The Project's Mailiao Port occupies an area of 476 hectares. With a water depth of 24 meters during mid- tide, the Port can accommodate 300,000 ton vessels. Therefore, it is Taiwan's deepest port and the first privately funded industrial port. The Mailiao Port has the ability to handle up to 70 million tons of cargo a year, second only to Kaohsiung Harbor. Although Mailiao Port was constructed for industrial purposes, its operations in Yunlin County incorporates the vast adjacent hinterland area into the port zone. Consequently, the access to convenient marine transportation promotes development of local industry.

3. Independent power plant

Independent power plant

The Project includes a large thermal power plant equipped with three power generation units that each generates 600,000 kW of electricity, for a total generating capacity of 1.8 million kW. Since commercial operation of these units officially commenced in June 1999, September 1999 and September 2000, respectively, all electricity generated has been sold to the Taiwan Power Company and incorporated into the national power grid. This contribution has helped ease Taiwan's power shortage.

4. Oil refinery

The oil refinery’s capacity increased from 450,000 to 540,000 barrels/day upon the completion of the Phase IV expansion. Meanwhile, the naphtha capacity increased to 4 million tons/year, which is sufficient to supply for the entire Mailiao Complex. Other petroleum products, including gasoline, diesel, kerosene and Liquefied Petroleum Gas (LPG) are exported to overseas markets.

Oil Refinery

5. Naphtha cracking plant

Naphtha Cracking Plant

Machinery shop

There are three naphtha cracking plants (NCP). Upon the completion of the NCP1 debottlenecking project, ethylene capacity will increase from 0.45 million tons/year to 0.7 million tons/year; the NCP2 unit’s ethylene capacity is 1 million tons/year. The NCP3 unit, with a capacity of 1.2 million ton/year, was completed in 2007, bringing the total combined ethylene capacity to 2.9 million tons/year.

6. Co-generation plant

The plant is designated to generate electricity, steam, and water for industrial use, as well as produce hyper pure water, nitrogen, oxygen, and compressed air for use by plants within the complex. The largest co-generation plant in Taiwan, it has 16 generation sets with a total capacity of 2.82 million kW. After supplying onsite manufacturing needs, excess electricity is sold to Taiwan Power Company to ease Taiwan's power shortage.

7. Machinery Shop and Boiler Shop

The machinery shop primarily engages in the design, manufacture, installation, and construction of oil refining and petrochemical process equipment such as reactors, towers, pressure containers, earth covered tanks, etc. It has the capability of producing very large vessels – up to 10 meters in diameter, 100 meters in length and 1,000 tons in weight. During the project, the shop participated in the planning, design, manufacture, installation, and construction of the 50-150 MW co-generation power plant and the 600 MW independent power plant. Today, it produces large vessels for external commercial sale.

8. Wafer fabrication plant

Wafer Fabrication Plant

This wafer plant is a joint venture owned by Formosa Plastics, Asia-Pacific Investment and Japan's SUMCO TECHXIV CORPORATION for the production of silicon wafers used in semiconductor, with an annual capacity of 3.84 million pieces for 8-inch and 2.88 million pieces for 12-inch, planning to expand 12-inch annual capacity to 3.6 million in 2Q 2013. The plant was qualified by ISO-9001:2000 in December 2002, ISO-14001 in March 2001, QS9000 in March 2003, and TS16949/OHSAS18001 in April 2005. In December 2006, the plant further received the “TPM Excellence Award” from Japan Institute of Plant Maintenance (JIPM) and in August 2007 it also received the “Golden Merchant Award.” Furthermore, the plant was qualified by TOSHMS in May 2010 and received the “TPM Excellence Consistent Award” in January 2012.

9. Formosa Asahi Spandex Co. Ltd.

Spandex Co. Ltd.

Formosa Asahi Spandex Co. Ltd., with an annual capacity of 5,600 MT for spandex and 21,000 MT for polytetramethylene ether glycol (PTMG), is a joint venture between Formosa Plastics and Asahi Kasei Fibers of Japan. The plant was qualified by ISO-14001:2004 certification in March 2013,OHSAS 18001:2007 in March 2013, and ISO- 9001:2008 in September 2010.