Document SP-02 · Decision Authorities LOCKED WITH WARNINGS

Feedstock Study

Yanbu Industrial City — Phase Initial · Registry: registry-yanbu-v1

Yanbu Industrial City generates an estimated 400 TPD across nine material streams — including 80 TPD of polymer production waste unique to YANSAB's petrochemical complex and 60 TPD of high-vanadium petcoke ash from YASREF's 400,000 bpd heavy crude refinery. Phase Initial targets 300 TPD across three ACM modules, delivering Saudi Arabia's first industrial-scale circular polymer-to-advanced-materials manufacturing.

Surge Capacity Design Basis

SURGE CAPACITY — P90 Design Basis

Yanbu ACM is designed for P90 waste volume, not average. Each 100 TPD module carries 15% surge headroom. Total facility is surge-rated, not baseline-rated.

Baseline TPD 400 TPD ESTIMATED
Surge TPD (P90) 500 TPD ESTIMATED
Surge factor 1.25× ESTIMATED — WARN-05
Surge driver Refinery turnaround and planned maintenance cycles; industrial production ramp-up
Phase Initial capacity 300 TPD (3 modules × 100 TPD base) LOCKED

Nine-Stream Volume Table All ESTIMATED

Stream TPD Annual (tpy) Originator Access Phase Primary ACM Output
MSW residuals 40 14,000 GEMS Yanbu / RCJY IMMEDIATE Initial Carbon Black RC2–RC3, Graphite RC3
End-of-Life Tires 30 10,500 ELT aggregators / SIRC mandate IMMEDIATE Initial Carbon Black RC2–RC3, Aromatics RC3, Steel RC1
Wastewater sludge 40 14,000 GEMS Yanbu / Marafiq CONDITIONAL Initial Pozzolanic SCM RC2, Metals RC2
Petcoke / refinery ash — YASREF + SAMREF 60 21,000 YASREF (Aramco/Sinopec JV) · SAMREF ACCESSIBLE Initial V₂O₅ (primary) · Ni · Ga · Mo
Polymer waste — YANSAB 80 28,000 YANSAB (SABIC 51%) ACCESSIBLE Initial Carbon Fiber Precursor RC4, Graphite RC3, Aromatics RC3
Contaminated recycling 30 10,500 RCJY recycling centers IMMEDIATE Initial Carbon Black RC2, Aromatics RC3
ASR 20 7,000 ELECTA (SIRC) IMMEDIATE Initial Carbon Fiber Precursor RC4, Aromatics RC3
Commercial waste 50 17,500 SEEC / private IMMEDIATE Initial Carbon Black RC2, Graphite RC3
C&D fluff 50 17,500 Akam (SIRC) / contractors IMMEDIATE Initial Mineral Aggregate RC1, Carbon RC2
Total Addressable 400 140,000 ESTIMATED
Phase Initial 300 105,000 LOCKED

No WtE ash stream at Yanbu Phase Initial — no confirmed WtE facility as of May 2026. REE suite absent; V₂O₅ from petcoke ash is the primary critical mineral output.

Polymer Waste Stream — YANSAB (Unique to Yanbu)

YANBU UNIQUE — no equivalent stream in any other KSA region

YANSAB (4M tpy petrochemical complex, SABIC 51%) generates ~80 TPD of polymer production waste: HDPE rejects, LLDPE off-specification outputs, PP process waste. These are high-carbon-content feedstocks that ACM converts to RC3–RC4 carbon materials. SABIC is the natural in-country off-take buyer for polymer-derived outputs.

Feedstock type Primary ACM output RevCon Key application
HDPE rejects High-Purity Graphite CRB-008 RC3 Battery anode, lubricants
LLDPE off-spec Carbon Black CRB-007 RC2–RC3 Rubber reinforcement, pigments
PP process waste Aromatics (BTX) ARM-003–005 RC3 Chemical feedstock, fuels
Mixed polymer rejects Carbon Fiber Precursor CRB-009 RC4 Aerospace, automotive composites

The YANSAB-SABIC circular loop: YANSAB (SABIC 51%) generates polymer waste → ACM converts to RC3/RC4 carbon materials → SABIC procures output for downstream polymer and chemical applications. SABIC is both the feedstock originator's parent and the natural off-take buyer — a closed-loop alignment unique to Yanbu.

Petcoke / Refinery Ash — YASREF + SAMREF

YASREF (400,000 bpd Aramco/Sinopec JV) processes heavy, high-sulphur Arab Heavy crude — known for elevated vanadium content. Petcoke combustion concentrates vanadium from crude oil to commercially recoverable levels in fly ash. At 400,000 bpd input, YASREF generates significantly greater petcoke volumes than Jubail, making Yanbu a primary V₂O₅ production site nationally.

⚠ WARN-01

Petcoke ash at Yanbu carries potential hazardous premium above standard SAR 290/ton FWDC. Petrochemical-heavy streams require NCEC classification confirmation at Feasibility Study.

Product RevCon Source In-country buyer (CANDIDATE)
Vanadium Pentoxide V₂O₅ Outside RevCon Ref. YASREF + SAMREF petcoke combustion Saudi Aramco VRFB supply chain
Nickel RC2–RC3 MTL-011 Co-concentrated with vanadium in heavy crude Ma'aden / industrial
Gallium RC4 MTL-042 Industrial ash semiconductor precursor NEOM OXAGON
Molybdenum RC3 Refinery catalyst residues in ash Industrial / metals market

Key Operators — Yanbu Industrial City

Operator Scale Feedstock contribution
YASREF 400,000 bpd heavy crude (Aramco/Sinopec JV) High-vanadium petcoke ash — primary V₂O₅ feedstock
YANSAB 4M tpy petrochemical complex (SABIC 51%) 80 TPD polymer production waste — unique stream
SAMREF ExxonMobil JV refinery Additional petcoke ash — V₂O₅ contribution
GEMS Yanbu SIRC industrial division — operational MSW residuals, wastewater sludge, hazardous streams

Scale Gap

SCALE GAP

Phase Initial processes 105,000 tpy at 300 TPD — addressing MWAN mandate while initiating Saudi Arabia's first large-scale circular polymer-to-advanced-materials conversion. YASREF alone generates more petcoke ash than the entire Jubail petcoke stream. The polymer waste gap (YANSAB 80 TPD with no incumbent circular processor) is exclusive to Yanbu.

80 TPD Polymer waste — no incumbent circular processor
3× Petcoke ash vs Jubail (YASREF scale)
105,000 tpy toward MWAN 2035 mandate

Infrastructure Map

Map initialising — requires Google Maps API key

GEMS Yanbu / SIRC facilities
YASREF / SAMREF — petcoke ash source
YANSAB — polymer waste source
Priority ACM site — RCJY Yanbu IC

Sources: SIRC.sa · RCJY.gov.sa · Marafiq.com.sa · MWAN.gov.sa · Verification: May 2026

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