NOVA Chemicals' Beaver Valley plant is located at Monaca, Pennsylvania, approximately 25 miles (40 kilometers) northwest of Pittsburgh. The facility manufactures expandable polystyrene (EPS) resins, and ARCEL® advanced foam resin. This site also houses a Styrenics Technology Center, which was inaugurated in 1998 and contains an applications lab, along with a pilot plant, for testing and customer demonstrations.
Beaver Valley was built by the U.S. government in 1942 as part of the United States Synthetic Rubber Program during World War II and was used for producing synthetic rubber raw materials. In 1955, the site began production of DYLITE® EPS resins. In 1983, the site began production of ARCEL advanced foam resins. Site ownership transitioned over the years through the U.S. government, Koppers Company, Sinclair Oil Company, ARCO Chemical Company, to NOVA Chemicals, which is part of the International Petroleum Investment Company (IPIC) of Abu Dhabi.
Primary raw materials include styrene and pentane. These raw materials and others are received by barge, rail, and truck.
The Beaver Valley site has the capacity to manufacture about 250 million pounds of plastic resins per year using NOVA Chemicals' proprietary product and process technologies. Products are typically packaged in 1 ton supersacks and/or 1000 pound cartons and are transported to customers via truck, rail, and sea bulk containers.
Regular and Modified grades of EPS resins are used in foam packaging and in insulation, while DYLITE EPS resin is primarily used for cups and food service containers. ARCEL resin has become a packaging resin of choice for high-end electronics and for the reduction of energy and packaging waste.
The site is ISO 9001 and ISO 14001 certified.
Approximately 200 employees work in the manufacturing, technology, and commercial areas at the Beaver Valley site.