Borealis Launches AI-Driven Borstar® Digital Twin Program
- Launched in 2023, the Borstar Digital Twin program focuses on polyethylene and polypropylene production.
- In 2025, Borealis scaled up the program globally across all Borstar units, including Baystar™ and Borouge.
- The platform enables real-time monitoring, predictive insights, and advanced simulations for production processes.
Introduction
Borealis has announced the global rollout of its Borstar® Digital Twin program, a significant step in its digital transformation journey. This program integrates AI, real-time optimization, and data analytics to enhance operational efficiency and productivity.
Program Features
The Borstar Digital Twin creates a virtual replica of the production process, allowing for real-time monitoring, predictive insights, and advanced simulations. It aims to optimize performance, enhance safety, advance sustainability, and accelerate innovation.
Implementation and Impact
Initially launched in 2023, the program focuses on Borealis' proprietary Borstar® technology for polyethylene and polypropylene production. By 2025, Borealis has successfully scaled the program globally across all Borstar units, including those operated by licensees Baystar™ and Borouge.
Operational Benefits
The Borstar Digital Twin enables plants to run at higher efficiency, achieve faster and more controlled grade transitions, and deliver consistently prime product quality. Real-time monitoring allows for early detection and mitigation of process and equipment anomalies, reducing unplanned shutdowns and increasing reliability.
Source: Borealis