grace latest advanced catalyst innovations for...
TRANSCRIPT
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
Company Confidential
Outline
2 INDIAN Petrochem - 2014
About Grace
Global PP market trends and presentation objectives
Technology drives
Showcases
Summary
Company Confidential
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
Company Confidential
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
INDIAN Petrochem - 2014
Company Confidential
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
Company Confidential
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
INDIAN Petrochem - 2014
Company Confidential
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
7 7 INDIAN Petrochem - 2014
Company Confidential
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
INDIAN Petrochem - 2014
Company Confidential
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
9 9 INDIAN Petrochem - 2014
Company Confidential
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
10 10 INDIAN Petrochem - 2014
Company Confidential
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
11 11 INDIAN Petrochem - 2014
Company Confidential
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
12 12 INDIAN Petrochem - 2014
Company Confidential
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
13 13 INDIAN Petrochem - 2014
Company Confidential
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)
14 14 INDIAN Petrochem - 2014
Company Confidential
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
15 15 INDIAN Petrochem - 2014
Company Confidential
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
16 16 INDIAN Petrochem - 2014
Company Confidential
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.
INDIAN Petrochem - 2014
Company Confidential
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]