technology challenges of bimodal polyethylene markets: the innovene™ s solution jean chabardes...

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


1Innovene S Technologyto date 1HDPE Bimodal

Markets


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


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


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


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


Challenges of plastics consumer ? Waste…

Bimodal Products last longer (PE100)Bimodal Replaces other material

Bimodal allows to use less material


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 !



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


1Innovene S Technologyto date 2

Innovene S Industrial Solutions for Bimodal

production


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


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


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


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


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


• 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



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



3Innovene™S Product Solutions


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


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


• 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


4Conclusions


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

Thank you !Thank you !

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technology challenges of bimodal polyethylene markets: the innovene™ s solution jean chabardes...

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