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TRANSCRIPT
ByVivek Mehta
PADC, Panipat
Bulk Pack International Conference, Hyderabad8th April, 2010
ContentsContents
Company Profile
IOCL in Petrochemical Business
FIBC Experience & Expectation
Polymer Plants
Technology strengths & Product Attributes
Important Grades & Properties
Technical Support
Company Profile
Indian Oil Indian Oil -- An OverviewAn Overview
18th largest petroleum company in the World18th largest petroleum company in the World
Fortune 500 Global company, ranked at 105Fortune 500 Global company, ranked at 105thth position in 2009position in 2009
Sales turnover in 2008 Sales turnover in 2008 –– 09 : 2,85,337 Cr (US $ 63 09 : 2,85,337 Cr (US $ 63 bnbn))
Diversified, Transnational, Integrated energy companyDiversified, Transnational, Integrated energy company
Marketing
Refinery R & D
Business Development
Owns 10 out of 19 Refineries in India Refining Capacity – 60.20 MMTPA
17,600 RO’s, 5000 LPG Distributors, 101 AFSs, 90 Bottling Plants, 200 Bulk storage terminals & depots
Bio-fuels & Gas Marketing Prod & Mktg : LAB, PTA, Polymers
3 overseas subsidiaries in SL, Mauritius & Dubai
2100 Lube formulations 140 PatentsCountry’s largest network of nearly 10,000 KM.
Pipelines
Indian Oil Indian Oil -- An OverviewAn Overview
IOCL in Petrochemical Business
Indian Oil in PetrochemicalsIndian Oil in Petrochemicals
Linear Alkyl Benzene at Gujarat Refinery
Capacity – 120 KTA LAB, UOP Detal Process
Largest grass root single train capacity in World
Commissioned August 2004
Successfully operating at over 100% capacity
PX/PTA at Panipat
Capacity 553 KTA PTA (Invista T 10 Technology)
/370 KTA PX, UOP Technology
Commissioned in June 2006
Successfully Operating at 100% capacity
Robust logistics network from landlocked location
FIBC End User Experience
FIBC End User ExperienceFIBC End User Experience
End Use : PTA packaging
Product Form : Powder
Package Size : 1050 kg
Handling : Fork Lifts
Movement : Trucks & Rail
Bag Weight : ~3000 gms (with liner)
Dimension : 1050 X 900 X 900 mm
Bag material : PP FIBC
Liner : LDPE/LLDPE
Type : Single Trip (1:5)
Standards : EN 1898:2000 & BIS 14738
FIBC End User ExperienceFIBC End User Experience
Frequently observed problems:Stitching Opened
Breakages of stitching threads
Discoloration of bags
Cuts in fabric
Inner liner off-set
In-consistency in bag & liner size
Battery operated fork lifts
Advantages:Suitable for free flowing Powder
Automation
Economical packaging
Suitable for different mode of
transportation.
Reduced Wastage
FIBC End User ExpectationFIBC End User Expectation
UV Stabilization
Right grade of UV Stabilizer
Optimum dosage
Performance Evaluation
Anti-Fibrillation
Optimum Dosage
Right grade of CaCo3
Performance Evaluation
Handling Practices
Economical
Safe
Pilfer-proof
Polymer Plants & Technology
IOCL Polymer Plants & TechnologyIOCL Polymer Plants & Technology
Sr. No Plant No. of Lines Capacity per Line (KTA) Technology/ Licensor
1 Polypropylene 2 300 Spheripol – Basell
2 Dedicated HDPE 1 300 Hostalen – Basell
3 HDPE / LLDPE Swing 1 350 Sclairtech - Nova
Polypropylene PlantPolypropylene Plant Dedicated HDPE PlantDedicated HDPE Plant Swing PlantSwing Plant
SpheripolSpheripol HostalenHostalen SclairtechSclairtech
With 1.25 Million MT capacity, IOCL will be the second largest PWith 1.25 Million MT capacity, IOCL will be the second largest Polyolefin producer in Indiaolyolefin producer in India
Spheripol Technology : Process CapabilitySpheripol Technology : Process Capability
MFR: 0.3 - > 1600 g/10min
Xylene Insoluble: 90 – 99 (wt)%
Flexural Modulus 500 – 2200 MPa
Izod Impact Strength upto 750 J/m
Low Ash Content / Low Odour
Compliance to FDA
High Yield High Selectivity CatalystHigh Yield High Selectivity Catalyst
Bimodal gradesBimodal grades
Polypropylene
Spheripol Technology Share : 45% (100 lines)
Global PP Capacity ~ 48 MMTA
Global PP Consumption ~ 46.5 MMTA
Site Photo : Spheripol Line of IOCL, Panipat
Hostalen Technology : Process capabilityHostalen Technology : Process capability
Dedicated HDPE
Product Density - 0.94 – 0.965 gm/cc
MFR - 2.2 (I21) to 60.0 (I5) dg/min
Conversion rate up to 99.5 % for Ethylene.
Excellent Quality & Product consistency.
Excellent combination of processability & final
product performance in bimodal grades.
Global HDPE Capacity ~ 33 MMTA
Global Consumption ~ 30.3 MMTA
Product range – HD & HM grades
7 MMTA of HDPE Produced by Hostalen Technology (36 lines)
Site Photo : Hostalen Line of IOCL, Panipat
SclairtechSclairtech Technology : Process CapabilityTechnology : Process Capability
Swing Unit (HD/LLDPE)
Density – 0.905-0.965gm/cc
MFI – 0.3 – 150 gm/10min
High ethylene conversion > 98%
Short residence time in the reactor
Low gel level, lot-to-lot consistency
Capability to produce C4, C8 & terpolymers
Excellent Dart Impact & Sealing Properties
Sclairtech Capacity : 3.5 MMTA (11 lines)
Global PE Capacity – 77 MMTA
Global PE Consumption – 73.1 MMTA
Site Photo : Sclairtech Line of IOCL, Panipat
IOCL Polymer Grade PortfolioIOCL Polymer Grade Portfolio
Polyethylene
• LLDPE – 11 Grades – 0.9 MFI to 50 MFI (Butene & Octene)
• HDPE - 22 Grades – 0.1 MFI to 18 MFI (Unimodal & Bimodal)All PE Grades will meet the requirements of IS : 10146-1982 for food contact applications, IS:10141-1982positive list of constituents & US FDA: CFR Title 21,177.1520
Polypropylene
• Homo Polymer – 14 Grades – 2 MFI to 35 MFI
• Random Copolymers – 5 Grades - 1.8 MFI to 45 MFI (Clarified & GP)
• Impact Copolymers – 8 Grades – 3 MFI to 50 MFI (Medium & Super Impact)All PP Grades will meet the requirements of IS : 10910 for food contact applications, IS:10909 positive listof constituents & US FDA: CFR Title 21,177.1520
Important Grades & Properties
PP PP -- Grades for Woven SacksGrades for Woven Sacks
Raffia grades of IOCL are designed to offers:
Good processability.
Good balance of tenacity & elongation.
Consistency in MI & XS gives excellent thickness control.
Tailored additive package for low water carry over.
Grades are designed to give tenacity >5gpd & % elongation @ break ~20%
Isotactic Index > 95%, with Flexural Modulus >1450 MPa.
Exact replica of Basell’s grades Moplen HP456J (3.4 MI), HP456H (1.8 MI) is also possible.
• MFI : 3 (g/10 min)• Good Processability• Suitable for Woven sacks, FIBC, Fabric, Leno bags
PP PP -- Woven Sacks (Homo Polymers)Woven Sacks (Homo Polymers)
• MFI : 2 (g/10 min)• UV stabilized• Suitable for FIBC, Heavy duty sacks.
• MFI : 25 (g/10 min)• Excellent Flow & Processability• Low Neck-in• Gives stiffer, transparent & Glossy coating.
• Excellent bonding to substrate
PP PP -- Extrusion Coating GradesExtrusion Coating Grades
• MFI : 25 (g/10 min)• Excellent Flow & Processability• Low Neck-in• Gives softer,slightly hazy coating.• Excellent bonding to substrate
• MFI / Density : 0.90 / 0.952• Low Gels• Lot to lot consistency• Good tenacity/Elongation balance• Low die lip built-up• Suitable for woven sacks, tarpaulin & wrapping fabrics
HDPE HDPE –– Raffia GradesRaffia Grades
• MFI / Density : 1.0 / 0.956• Low Gels• Lot to lot consistency• Better Elongation• Low die lip built-up• Suitable for monofilaments & low denier fabrics.
LLDPE Grades for flexible films / linersLLDPE Grades for flexible films / liners
LLDPE Film grades of IOCL are designed to offer :
Excellent processability, low gelsGood mechanicals & sealing properties.Excellent clarity & GlossGood openability & desired COF Consistent dart impactGood performance on FFS machines (SIT, Hot Tack)Lot to lot consistencyHigh slip & no slip versions
IOCL LLDPE grades for Flexible Packaging Segment
Co Monomer Grade MFI (I2) Density, g/cc Applications
010F18S
010F18A
020F18S 2.0 0.918 General purpose fillms. Blending resinButene
020F18A 2.0 0.918 Lamination films. Cast films. Stretch cling
8010F18S 0.9 0.918 Heavy duty liquid pckg, with superior seal
8010F18A 0.9 0.918 Lamination films with superior sealOctene
0.9 0.918 Liquid Packaging, multi-layer films.
0.9 0.918 Lamination films, cling films
HDPE Film grades of IOCL are designed to offer :
Bimodal grades
Excellent processability, Low gels.
Good Mechanical Properties.
Excellent stiffness and good barrier properties.
IOCL HDPE grades for Flexible Packaging Segment
Grade MFI (I5) Density, g/cc Applications
003DF49
002DF50
003F46 0.30 0.946 Co-extrusion films & Liners
0.28 0.949 Carry Bags, Co-extrusion, Dart ~ 12 g/µm
0.22 0.950 Carry Bags, Co-extrusion, Dart ~ 14 g/µm
HD / HM Grades for flexible films / linersHD / HM Grades for flexible films / liners
Technical Support
PADC is being set up at Panipat (Haryana) near
Panipat Naphtha cracker Project (PNCP).
PADCPADC
PLANTPLANT
MARKETINGMARKETING
CUSTOMERSCUSTOMERS
New Grade development
Knowledge Management
Customer Relation
Management
Technical Support to Customers
New Applicationdevelopment
PADCPADC
PADC is an interface between Plant, Marketing & CustomersState of Art Technology Centre with sophisticated Plastic
Processing & Characterisation equipments
Product Applications & Development Centre Product Applications & Development Centre -- PADCPADC
Customer Benefits with IOCL EntryCustomer Benefits with IOCL Entry
• Reduced import dependency for niche PP & PE grades.
• Wider PP product portfolio due to 2 Spheripol lines.
• Plants incorporating latest developments & most sophisticated control systems for superior lot to lot consistency.
• Sizable plant capacities will help in stream-lining supply & pricing fluctuations which are frequently experienced in Indian market.
• Due to better plant capability, fast grade transition – better control over grade basket.
• IT Enablement – E Commerce module – Transparency and ease of transaction
• Business opportunity with company trusted by Indians for over 50 years.
FIBC Industry : Challenges & OpportunitiesFIBC Industry : Challenges & Opportunities
Challenges:
• Move up the value chain ladder in FIBC manufacturing with wider product
portfolio (type A,B,C & D bags)
• Create global economics of scale – Benchmark with Turkey
• Follow JIT approach – Establish offices & Warehouses near demand centers
• Match quality expectations of international customers
• Cost effective alternate handling systems for FIBC
Opportunities:
• Ample & easy availability of raw material locally
• Projected CARG over next 5 years : ~17% (source: ICRA report)
• Agriculture & food processing sectors can open up huge growth opportunity.
• Packaging of food grain/Sugar in FIBC is yet to arrive in India.
Thank youThank you
“Looking forward for a long lasting business relation with you”
Back - Up
FIBC StandardsFIBC Standards
• IS : 14738 (Part – 1) 1999 : Definitions Related to FlBC
• IS : 14738 (Part – 2) 1999 : Specifications, Requirements, Certification and Marking
• IS : 14738 (Part – 3) 1999 : Test Methods – Cyclic Top Lift Test
• IS : 14738 (Part – 4) 1999 : Test Methods – Compression / Stacking Test
• IS : 14738 (Part – 5) 1999 : Test Methods – UV Resistant Test
• IS : 14738 (Part – 6) 1999 : Regulations on Selection and Use of FIBCs
PADC / Tech Service Group : Skills & ExpertisePADC / Tech Service Group : Skills & Expertise
• A team of 24 Graduate/Post graduate Plastics engineers & technologists fromleading educational institutes (PADC, Panipat:10, Field TS:11 & CO:3)
• Relevant industrial experience ranging from 2 yrs to 17 years
• Product development/Technical services experience in India & Abroad withleading petrochemical companies like Reliance, Haldia, LG Polymers, SABIC,Supreme, Unilever
• Skill & Knowledge set with PADC team:
− Product & Application development in Polyolefin− Diversified experience in polymer processing− Technical services & Customer complaint handling− Expertise in grade development & additives recipe optimizations− Testing of Plastics
Indian FIBC IndustryIndian FIBC Industry
• FIBC production in India in 2008 : 92 KT
• Projected CARG over next 5 years : ~17% (source: ICRA report)
• Agriculture & food processing sectors can open up huge growth opportunity
• Packaging of food grain in FIBC is yet to arrive in India
Source : Industry Estimate