technology challenges of bimodal polyethylene markets: the innovene™ s solution jean chabardes...
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Technology Challenges of Bimodal Polyethylene Markets: The Innovene™ S solution
Jean Chabardes
Innovene™ S Proposal Manager
February 29th 2012
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Presentation Outline
• HDPE Bimodal Markets
• Innovene S Industrial Solutions for Bimodal PE production
• Innovene S Bimodal Product Solutions
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1Innovene S Technologyto date 1HDPE Bimodal
Markets
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Bimodal HDPE : applications perspective
Pipe & conduits market in 2015: World 6.4 MtBimodal 3 Mt
56%
44%
Monomodal Bimodal
Film market in 2015: World 11.1 MtBimodal 6 Mt
45%
55%
Cr Bimodal Ziegler
Blow Molding market in 2015: World 10.9 MtBimodal 1.2 Mt 89%
11%
Cr Ziegler Bimodal
Film27%
Blow Molding25%
Injection Molding19%
Pipe & conduits16%
Other Extrusion4%
Textile5%
Rotomolding1%
Others3%
Based on Nexant 2010 dataBased on Nexant 2010 data
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Bimodal HDPE :Production capacities growth
• Today, installed HDPE bimodal capacity exceeds monomodal capacity
• Bimodal HDPE capacities shows fast growth rate
• All new capacities with bimodal capability
Nexant ChemSystems dataNexant ChemSystems data
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Future of PE…
• Commoditization is ahead of us
– Enormous pressure on production cost
– Need for differentiation
• More “green” is likely to be the standard
• Current and future trends
– Downgauging, light-weighting (mLL and bimodal HDPE)
– Only a few new niche markets/applications
– Green PE, biodegradable PE
– Recycling solutions
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Downgauging = win-win-win
Monomodal Bimodal
Film
Monomodal Bimodal
Pipe
• WIN : for the converter who buys less material
• WIN : for the producer whose margin is higher
• WIN : for the environment
Use less for the same serviceUse less for the same service
Monomodal Bimodal
Blow moulding
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Challenges of plastics consumer ? Waste…
Bimodal Products last longer (PE100)Bimodal Replaces other material
Bimodal allows to use less material
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Bimodal HDPE :US/Canada vs China
0
500
1000
1500
2000
2500
3000
Film BM IM Pipe Otherextrusion
Textile Others
2015
dem
and
fo
reca
st (
kt)
BimodalMonomodal
0
500
1000
1500
2000
2500
3000
Film BM IM Pipe Extrusion Textile Others
2015
dem
and
fo
reca
st (
kt)
BimodalMonomodal
• US + Canada– 2015 bimodal market
share of 15 %
• China– 2015 bimodal market
share of 30 %
Room for more bimodal HDPE in North America !
Based on Nexant 2010 dataBased on Nexant 2010 data
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ReducedimpactStrength,fumes
ESCR and creep resistanceMatrixProcessability,
stiffnessMechanical
strength
Melt
strength
during
extrusion
Molecular weight (= polymer chain length)
%
Challenges ofmaking bimodal HDPE resins
Bubblestability
Area to populate for maximising product properties
Nosagging
Comonomer
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1Innovene S Technologyto date 2
Innovene S Industrial Solutions for Bimodal
production
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The Foundation of Innovene S Slurry Loop Technology
Innovene™ SThe Leading HDPE Technology
• Unique Swing Ziegler/ Chromium/ Bimodal operations at all our customers
• Dual Loop reactors deliver bimodal process with accurate control and broad differentiation
• Leading products for all HDPE Monomodal and Bimodal market segments
• Low Variable and Investment costs
Innovene S: The Leading HDPE Technology
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Innovene S Process Technology
Catalyst feeding system
Intermediate TreatmentMonomer
Co- Monomer
Light DiluentMonomer
Co- Monomer
Light Diluent
Innovene S : two reactors with independent control
and process conditions
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Benefits of Innovene S dual reactors design
Molecular weight distribution tuned by the process = infinite flexibility in the molecular design
Intermediate Treatment
Each reactor controlled independently in terms of:
• MI
• Density at least 5 degrees of
freedom
• Relative production
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Innovene S Bimodal operations
• Use of modern INcatTM Ziegler
catalyst
• Easy and independent control
of each reactor:
Temperature
Composition
• Fast process and product
transition with minimised
transition polymerUNIQUE and routine operations in monomodal and bimodal
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Innovene™ S : Technology flexibility
HD / C4 or C6Mono- & bimodalZiegler catalyst
INcat MT platform
HD C6Cr catalyst
• High Activity catalyst
• Excellent activity profile: natural access to bimodal products and to high productivity performance
• Same Ziegler catalyst gives access to a wide product mix covering Monomodal and Bimodal grades
• Use C4 or C6 comonomer
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• Based on third party 2010 data
Innovene S: Low CAPEX Polyethylene Technology
• Innovene S dual reactor capex close to leading single reactor design
Innovene™ S CAPEX Benchmark for Bimodal processes
•ISBL cost of a 400 kt/yr line in Gulf Coast
48%
47%
27%
0%
6%
0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
Competitor #1 Competitor #2 Competitor #3 Competitor #4 InnoveneS
CAPEX BIMODAL
Based on Nexant 2011 dataBased on Nexant 2011 data
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Innovene S: OPEX cost leader
Innovene™ S OPEX Benchmark for Bimodal processes
17
43
2322
0
0
5
10
15
20
25
30
35
40
45
$ /
t P
E
Competitor #1 Competitor #2 Competitor #3 Competitor #4 InnoveneS
OPEX BIMODAL •Based on third party 2011 data
•Efficient recycling system
•Standard Zeigler catalyst
•Competitive process guarantees
Based on Nexant 2011 dataBased on Nexant 2011 data
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3Innovene™S Product Solutions
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Innovene™ SHDPE Product Coverage
Application TypeInnovene™
SFilm HDPE
Bimodal HDPE
Blow Molding Medium Mw Cr
High Mw Cr
Bimodal
Injection Molding Monomodal
Bimodal
Pipe & Conduits Non pressure
PE80
PE100 bimodal
Textile Monofilament
Tape
Bimodal
Others W&C
Geomembrane
Rotomolding
A complete HDPE offer covering all applications
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Pipe and PE100 example
Pressure Pipe Market is very demanding and technical.Main applications : gas and liquid transportation
Special requirements for:• Resistance to pressure• Resistance to temperature• Resistance to crack propagation• Aging : long lasting applications
PE100
PEX
SPCOnly Bimodal grades comply with ISO PE100 requirements
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• INEOS Bimodal process and catalysts advantage– Improved rheological behaviour of products
• Bubble stability , die swell , melt strength , extrudability
– Increased flexibility in bimodal architecture
PIPE
PE100+ low sag
Large diameter pipe
FILM
Enhanced toughness and processability
Thin film
Small Blow Moulding
Enhanced impact and ESCR
Light weighting
Injection moulding
Enhanced ESCR
Light weighting
Innovene™ SBimodal Strength
Full Bimodal product Range with high Performance
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4Conclusions
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Conclusions
Innovene™ S : THE leading industrial technology for developing PE Bimodal markets worldwide
• Bimodal HDPE demand is increasing and represents a solution towards sustainable developments.
• Innovene™ S is the leading Technology to manufacture and develop bimodal products due to:– product design flexibility– easy operations– leading economics– extended bimodal products coverage– Proven technology transfer