grace latest advanced catalyst innovations for...

Company Confidential

GRACE Latest Advanced Catalyst

Innovations for Polypropylene

Production

Yogesh Mishra

Business Manager

South, SE Asia & ANZ

16th International Conference

INDIAN Petrochem - 2014

Mumbai, India


Outline

2 INDIAN Petrochem - 2014

About Grace

Global PP market trends and presentation objectives

Technology drives

Showcases

Summary


24%

6%

6%

21%

12%

31%

33%

27%

40%

Grace Fast Facts (NYSE: GRA)

True Speciality chemicals business High value product portfolio

Strong franchises in large, global markets

Global leadership positions Number 1 or 2 in over 70% of 2013 sales

2013 Grace Sales

2013 Grace Sales by Region

$3.1 billion

$3.1 billion

Catalysts

Technologies

Construction

Products

Materials

Technologies

North

America

Western

Europe

Eastern Europe

Middle East &

Africa

Asia Pacific

Latin America

Catalysts Technologies #1 in FCC catalysts

#1 in resid hydroprocessing catalysts

#1 in independent polyethylene catalysts

#1 in independent polypropylene catalysts

Materials Technologies #1 in Speciality silica gel

#1 in can sealants

Construction Products #1 in cement additives

#2 in concrete admixtures

3 INDIAN Petrochem - 2014


Grace® Polyethylene Catalyst Portfolio

MAGNAPORE® and Cr-based catalysts

Industry-leading pipe resin catalyst

Strong history of performance in loop process

New products for gas phase processes

Ziegler-Natta PE Catalysts

HD and LLDPE technologies

Commercial offerings for loop, gas phase, and CSTR

processes

Customer-specific catalysts

Single Site Catalysts

Integrated solutions provider

Finished supported catalysts

Metallocenes, ligands and borate co-catalysts

Silica supports



Grace Polypropylene Catalyst Recent History

2002 Purchased catalyst manufacturing

assets in Finland to advance

production of polypropylene and

polyethylene catalysts

2006 Purchased additional custom catalyst

assets in New Jersey

2009 Expanded manufacturing capacity in

Germany to meet demand for

polypropylene catalysts

2010 Purchased facility in Oregon for

production of specialty single site and

polypropylene catalysts

2013 Acquired UNIPOL® PP Licensing and

Catalyst business from Dow

5 5 INDIAN Petrochem - 2014


Grace® Polypropylene Catalyst Portfolio

POLYTRAK®

Catalyst

4th generation

technology

Used in bulk

and gas phase

polymerization

processes

Homo- and

co-polymer

capability

HYAMPP ®

Catalyst

6th generation

technology;

high yield

Offerings for

bulk (liquid)

polymerization

processes

Non-phthalate,

with improved

resin performance

SHAC ®

Catalyst and

Donors

Industry leading

catalysts for gas

phase processes

Homo- and co-

polymer capability

CONSISTA®

Catalyst and

Donors

6th generation

technology;

high yield

Offerings for

gas phase

polymerization

processes

Non-phthalate with

improved resin

performance

Custom

Polypropylene

Catalysts

Vast experience in

scale-up and supply

of customer-specific

Polypropylene

catalyst products



Global Trends

Aging population in Europe and NA

Population growth and middle class

expansion in Asia and Latin America

Time is a luxury

Climate change

Globalization of retailers

E-commerce

Trend

Health products and medical

needs

Automobiles

Consumer goods

Non-food packaging

Packed foods, snacks and pre-

cooked meals

Technology focus on performance

and cost and environmental

impact

Results in increasing



Polypropylene Market trends since 2005

Lighter Faster

Cleaner Clearer Cleaner

Less catalyst

residuals

Lower VOC

Lower taste and

odor by avoiding

peroxide cracking

Non-Phthalate

based



GRACE advanced catalyst systems are designed to address market trends

Major Technology Drivers in Asia Pacific

CASE 1: Higher modulus to enable

down-gauging of BOPP films

CASE 2: Faster heat sealing processing

CASE 3: Cleaner high MFR TPO’s

GRACE Showcases Inter-material substitution

Faster processing

Down-gauging to decrease part weight

Cleaner products – less taste and odor,

less metal residuals

Technology drivers



XS / w%

3 5 7

3.5

4.5

5.5

MW

D (P

DI)

GRACE Proposed

Processing Window for BOPP HPP

Increasing Stiffness

CASE 1: Higher Modulus HPP to enable Down-gauging in

BOPP films



CASE 1: CONSISTA® / HYAMPP ® Catalyst Systems (6th Gen)

HPP with 5% to 20% higher stiffness than 4th gen systems

Potential of 2% to 3% weight reduction

1200

1400

1600

1800

0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0

Flex

ura

l Mo

du

lus

/ M

Pa

Xylene Solubles / w%

CONSISTA™ C601

SHAC™ 201

6th Gen

4th Gen



0

2

4

6

8

10Line speed

Haze

Thickness Distribution

Mechanical Properties

Screen change frequency

4th Gen

6th Gen

CASE 1: BOPP Customer Trial

6th Gen CONSISTA® / HYAMPP® Catalyst Systems can meet the needs

of the resin producer and converter in the BOPP market

12 mm film

3 layers

5/90/5

Bruckner

Higher number

means better



CASE 2: Catalyst Solutions For Advanced Heat Seal Grades

Heat Seal Temperature (°C)

E-R

CP

90 130

B-R

CP

TE

RP

OLY

ME

RS

110

6th Gen advanced catalyst systems provide answers

to all heat sealing needs



CASE 2: Customer Requirements and 6th Gen Catalyst Systems

Tailored Heat seal temperature

Hexane extractables < 5.5 % (FDA)

PP Producer

Film Converter

C4

, w%

C2, w%

Linear (C4 - 9 w% XS)

Linear (C4 - 5 w% HX)

CONSISTA® / HYAMPP®

catalyst systems enable a

broad design window for

the production of

Speciality terpolymers

High productivity

High co-monomer window

Low XS (process dependent)



CASE 2: Summary of 6th Gen GRACE® Catalyst Systems

0

2

4

6

8

10Productivity

Co-monomer window

Xylene SolublesTailored Heat Seal T

Hexane Extractables

4th Gen

6th Gen

Terpolymer Technology Designed to Meet Customer Needs



0

2

4

6

8

10

Mechanical Properties

Catalyst residuals

VOC levelOperability

Taste and odor

Gen 4

Gen 6

CASE 3: Cleaner High MFR TPO’s with CONSISTA® Systems

Higher number is

better in all cases

Lower catalyst residuals from super-high productivities

High H2 response eliminates unnecessary need for rheology control

High H2 response reduces VOC generation



Summary

The PP market in Asia Pacific is

experiencing strong competition and

moderate growth. These are times to

upgrade product mix and reduce

operating cost.

Grace has responded to these market

challenges and related technology

needs with the 6th generation

CONSISTA® / HYAMPP® Catalyst

Systems. Designed to

Maximize line speeds for BOPP

Meet a broad range of heat sealing

needs

Produce cleaner TPO’s

Provide improved property balance and

higher productivities

Grace – Talent that spans the

globe. Technology leadership

in catalysts for polyolefin and

polypropylene production.

Trust built over time.



GRACE®, POLYTRAK®, HYAMPP® DAVICAT®, RANEY®, SHAC®, and CONSISTA® are trademarks, registered in the

United States and/or other countries, of W. R. Grace & Co.-Conn. TALENT | TECHNOLOGY | TRUST™ is a trademark

of W. R. Grace & Co.-Conn. UNIPOL® ® is a trademark of The Dow Chemical Company or an affiliated company of Dow.

W. R. Grace & Co.-Conn. and/or its affiliates are licensed to use the UNIPOL® trademark in the area of polypropylene.

This trademark list has been compiled using available published information as of the publication date of this brochure and

may not accurately reflect current trademark ownershTalip or status. GRACE CATALYSTS TECHNOLOGIES is a business

segment of W. R. Grace & Co.-Conn., which now include all proaduct lines formerly sold under the GRACE DAVISON brand.

© Copyright 2014 W. R. Grace & Co.-Conn. All rights reserved.

Thank You

For more information, please visit

www.grace.com or contact:

Name: Yogesh Mishra

Email: [email protected]

mailto:[email protected]

mailto:[email protected]

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