Lynx Technology for Advanced PP Performance - Dr. Roger Ceustermans Business Manager Process Technologies
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Dr. Roger Ceustermans Business Manager Process Technologies Lynx® Technology for Advanced PP Performance
Agenda Engelhard – Who are we Market Trends in the Polypropylene market The Engelhard approach -- Lynx® 1000 Series Specific performance of the Lynx® 1000 Series in the major process currently in use in the Arabian Peninsula In Summary
Who is Engelhard?
A Fortune 500 company dedicated to advancing technologies to
improve customers’ products and processes.
Printing Cosmetics
Delivering Textiles Consumer
significant Automotive Paper
Petroleum
value to Electronics
Packaging
customers Chemicals
in a broad Agriculture
Glass & Ceramics
array of Power
end Architectural Materials Generation
markets Aerospace
Electronics Plastics
Industrial
EquipmentOur Focus Technology-based solutions based on the diverse markets we serve. Leveraging core competencies in surface and materials science. Multi-dimensional relationships with customers that will: Enhance productivity. Increase environmental performance. And, improve functionality.
Current Trends in the PP Market
PP applications are rapidly expanding with continued
intermaterial substitutions against ABS, Polycarbonates,
Nylon, Polyester and Steel.
Catalyst innovations play a critical role:
Improved throughput and lower fixed cost.
Activity for lower variable cost and product properties.
Product property improvements for specialty capability and
commodity “edge”.
The Polyolefins market continues to get more technology
oriented.
“Companies that are technologically lethargic face exclusion.”
Chemical WeekWorld PP Capacity Mid 2001 Total capacity of 37-38 MM ton North America: 8-9 MM ton Latin America: 2 MM ton Japan: 3 MM ton Asia: 11-12 MM ton Europe: 10-11 MM ton MEA: 2 MM ton PP catalyst market 1200-1300 ton HA catalyst Approximately 500 MM $
Major Process Licensors Basell Loop/GP 13-14 MM ton Dow/UCC Vertical Fluidized Bed GP 5-6 MM ton NTH Vertical Stirred GP 4-4.5 MM ton BP Horizontal Stirred GP 2 MM ton Hypol I Stirred Autoclave 2 MM ton Liquid Pool Processes have largest share. Share of Gas Phase Processes is extending and catching up.
PP Market on the Arabian Peninsula Producer Country Technology Capacity Cat Manuf Status Ibn Zahr Saudi Dow/UCC 640 000 Sabic R&T Operating Yanbu Saudi Dow/UCC 320 000 Sabic R&T Operating PIC Kuwait Dow/UCC 120 000 Dow/UCC Operating NIC Saudi NTH 450 000 Engelhard Q1, 2004 Sohar Ref Oman NTH 330 000 Engelhard H2, 2005
PP Market in Saudi Arabia By end of 2005, installed PP capacity on the Arabian Peninsula will reach 1 860 000 mt: By Q1, 2004 in Al Jubail area, NIC will have 450 000 mt installed capacity based on the NTH Process and having Engelhard Catalyst Economics and Product Quality. By Q4, 2005, 780 000 mt PP will be produced on the Peninsula based on Engelhard Catalyst. Several other projects under negociation but not concluded yet.
Our Focus in the Polyolefins Market
Engelhard’s two primary objectives:
1. Continue to deliver leading catalyst and donor
technology to the broader PP industry.
2. Leverage our technology position to provide
enhanced polymer attributes to the various process
segments.Lynx® 1000 Series: Milestones
PP Produced with Lynx
Bulk Commercial Gas Commercial
Slurry Commercial
1000 (KT)
Lynx 1000
Commercial Plant
Lynx 1000
Development, Testing,
Scale-up & Engineering
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
Successful Application in 40 plants
Worldwide in all ProcessesOperability with Lynx®
Activity High Good economics and low catalyst residue.
Round and Good reactor operability and powder
Morphology
Controllable transfer.
Isotacticity Controllable Dial in desired polymer properties.
High and very random
Broad random and impact copolymer
Copolymer comonomer
capabilities.
incorporation
Dial in desired catalyst/polymer size to fit
Particle Size Controllable
process requirement.
Finished Polymer Improved Attributes Enhanced market position.Lynx® 1000 Series Product Capabilities
Lynx® 1000 Lynx® 1010 Lynx® 1020 Lynx® 1030
Stiffer Polymer Softer Polymer
General Purpose
HCPP
Random
Impact Film BOPP
copolymer Fiber
Tape
XS = 0.5 XS = 4.5
Decreasing IsotacticityLynx® 1000 Series: Morphology
Lynx® -1000 Morphology
Morphology Particle size
Tightly fused Narrower particle size
agglomerates. distribution.
Smooth catalyst No fines.
surface.Advanced Donor System
Donor that gives the best performance with Lynx®
1000 Series.
Di-isopropyl
Di-isopropyl Dimethoxy
Dimethoxy Silane
Silane
[P-donor]
[P-donor]
License from BP to use with Lynx® 1000 Series
Catalyst.
Has been used commercially with success.
Good hydrogen response
Good product properties
Good catalyst activity and II controlNext Generation Catalyst Performance
CE
New generation
catalyst family
MWD Lynx® 1000
family % XS
MFROur Commitment to PP Applications
Engelhard has PP Pilot Plant Contracts covering the
various process segments:
Bulk Autoclave
Fluidized Gas
Bulk Loop
Slurry Autoclave
Polymer & Catalyst Testing Laboratory:
Polymer Institute Brno [PIB] PP Technical Alliance
Functions as our own department
Market-Technology Focus – Improving Your PP ResinsPolypropylene Structure – Properties Relationship
Structure Properties
Physical
PhysicalProperties
Properties
Micro
MicroProperties
Properties Macro Properties ••Impact
Impact
••Tacticity
Tacticity • Rubber Dispersion ••Stiffness
Stiffness
••Molecular
MolecularWeight
Weight • Spherulite Structure ••Gloss
Gloss
••MWD
MWD • Skin Orientation & ••FDA
FDA
••Rubber
RubberContent
Content Thickness ••Tear
TearStrength
Strength
••Rubber Composition
Rubber Composition • Crystallinity % ••HDT
HDT
••Rubber
RubberMw Mw ••Tensile
TensileStrength
Strength
••Blush Resistance
Blush Resistance
Catalyst
Catalyst Synthesis
Synthesis&&
&&
Processing
ProcessingConditions
Conditions
Synthesis
SynthesisConditions
ConditionsImpact Stiffness Balance
50
Impact (FWI, - 20°C)
40
30 C
D
20 P
10
0
900 1000 1100 1200 1300
Stiffness (Flex Modulus, MPa)
Stirred Bulk/Gas pilot plant, 70 °C, 6 - 10 MFR, C2 ~ 8%Hydrogen Response
10000
Hydrogen, PPM
1000
100
0 5 10 15 20 25 30
Melt Flow
C D P
Loop pilot plant, 70 °CProduct Improvement Attributes possible with
Lynx® Technology
Product Application) Polymer Attributes with Lynx
better flowability, better color dispersion, richer color, better
Injection Molding
gloss and improved stiffness
Better processability
Yarn
Good color appearance, more glossy
Better processability
CPP
Better tensile strength and better stiffness
Improved processability during extrusion
Fiber
Improved stiffness and color appearance
Faster line speed
BOPP Better (whiter) color
Better transparencyGeneral Resin Product Properties Lynx® vs major catalyst used on Peninsula Low ash content of powder. Broad range of XS from low (
Examples of Product Range Extension with Lynx®
1000 Series vs major catalyst used on Peninsula
TWIM with XS < 2.0 %.
BOPP with XS > 4 %.
Film with higher XS in general exhibits better transparancy and
better Processability.
C2 incorporation in random copolymers will be more
random and level can be increased.
Products with better transparancy and lower Tm.
Impact copolymers with improved FlexMod and Impact
Strength.
Improved FlexMod due to capability of low XS in the homopolymer
phase.
Improved Impact Strength due to better C2 distribution in EPR.Examples of Product Improvement with Lynx 1000
Series vs major catalyst used on Peninsula
Injection Molding Grades:
All IM grades will exhibit rich color.
For all IM grades, FlexMod and HDT can both be increased
resulting in Added Value via downgauging (less weight per item to
achieve same rigidity).
No smell or taste transfer due to very low oligomers.
Amount of nucleating agent can be reduced for nucleated grades.
Amount of clarifier can be reduced to obtain same clarity.
For Visc Breaking grades, less MFI variation due to more uniform
peroxide distribution.Examples of Product Improvement with Lynx®
1000 Series vs major catalyst used on Peninsula
Fiber Grades
Low ash content will result in richer color and less fiber breaking
during spinning.
Ideal XS values in 2.5-3.0 % range can easily be achieved.
For visc broken grades, MFI variations will be decreased due to a
more uniform peroxide distribution.
TG and Cast Film
Slip and Antiblock additives will be more equally dispersed due to
narow PSD of powder.
End colour greatly improved.Economics of Lynx® 1000 Series Substantial throughput improvement in the range of 10-15% over current due to: Low polymer fines. Excellent powder flowability. High powder density. Engelhard technology.
In Summary
PP Process
Application
& Optimization
Lynx®
PP Product Technology
Innovation End Use
Catalyst and
Donor System
Requirements
Developments Fabricators,
Compounders
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