Transcript Recent developments on Innovene S

Technology Challenges of
Bimodal Polyethylene Markets:
The Innovene™ S solution
Jean Chabardes
Innovene™ S Proposal
Manager
February 29th 2012
Presentation Outline
• HDPE Bimodal Markets
• Innovene S Industrial Solutions for Bimodal PE
production
• Innovene S Bimodal Product Solutions
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2
Innovene S Technology
1
HDPE Bimodal Markets
to date 1
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3
Bimodal HDPE : applications
perspective
Pipe & conduits
market in 2015:
44%
Monomodal
Film market in 2015:
World 11.1 Mt
Bimodal 6 Mt
World 6.4 Mt
Bimodal 3 Mt
Bimodal
56%
Cr
Other Extrusion
4%
Textile
5%
Others
3%
Bimodal Ziegler
55%
Rotomolding
1%
Film
27%
Pipe & conduits
16%
Injection Molding
19%
Blow Molding
25%
Blow Molding market
in 2015:
World 10.9 Mt
Bimodal 1.2 Mt
Based on Nexant 2010 data
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4
11%
Cr
Ziegler Bimodal
89%
45%
Bimodal HDPE :
Production capacities growth
• Today, installed HDPE
bimodal capacity exceeds
monomodal capacity
• Bimodal HDPE capacities
shows fast growth rate
Nexant ChemSystems data
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• All new capacities with
bimodal capability
5
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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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
6
Downgauging = win-win-win
Film
Monomodal
Bimodal
Pipe
Monomodal
• WIN : for the producer
whose margin is higher
Bimodal
Blow moulding
Monomodal
• WIN : for the converter
who buys less material
• WIN : for the environment
Use less for the same service
Bimodal
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commercial services UK Limited , and the information and images it contains may not be altered or
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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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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
8
Bimodal HDPE :
US/Canada vs China
• US + Canada
• China
– 2015 bimodal market share
of 15 %
– 2015 bimodal market share
of 30 %
3000
3000
Bimodal
Monomodal
Bimodal
Monomodal
2500
2015 demand forecast (kt)
2015 demand forecast (kt)
2500
2000
1500
1000
500
2000
1500
1000
500
0
0
Film
BM
IM
Pipe
Extrusion
Textile
Others
Film
BM
IM
Pipe
Other
extrusion
Based on Nexant 2010 data
Room for more bimodal HDPE in North America !
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Textile
Others
Challenges of
making bimodal HDPE resins
Area to populate for maximising product properties
%
Reduced
impact
Strength,
fumes
Processability,
stiffness
Matrix
ESCR and creep resistance
Mechanical
strength
Melt
strength
during
extrusion
Bubble
stability
No
sagging
Comonomer
Molecular weight (= polymer chain length)
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
10
Innovene
S Technology
Innovene
S Industrial 1
2
to
date
Solutions for Bimodal
production
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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The Foundation of Innovene S
Slurry Loop 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: The Leading HDPE Technology
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Innovene S
Process Technology
Catalyst
feeding system
Intermediate
Treatment
Monomer
Co- Monomer
Light Diluent
Monomer
Co- Monomer
Light Diluent
Innovene S : two reactors with independent control
and process conditions
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commercial services UK Limited , and the information and images it contains may not be altered or
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Benefits of Innovene S dual
reactors design
Each reactor controlled independently in terms of:
• MI
• Density
• Relative production
at least 5 degrees of freedom
Intermediate
Treatment
Molecular weight distribution tuned by the process
= infinite flexibility in the molecular design
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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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 polymer
UNIQUE and routine operations in monomodal and bimodal
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Innovene™ S : Technology
flexibility
• High Activity catalyst
HD / C4 or C6
Mono- & bimodal
Ziegler catalyst
INcat MT platform
HD C6
Cr 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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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Innovene™ S CAPEX Benchmark
for Bimodal processes
CAPEX BIMODAL
48%
• Based on third
party 2010 data
47%
50%
45%
40%
35%
• Innovene S dual
reactor capex close
to leading single
reactor design
27%
30%
25%
20%
15%
6%
10%
5%
0%
0%
Competitor #1
Competitor #2
Competitor #3
Competitor #4
InnoveneS
•ISBL cost of a 400 kt/yr line in Gulf Coast
Based on Nexant 2011 data
Innovene S: Low CAPEX Polyethylene Technology
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Innovene™ S OPEX Benchmark
for Bimodal processes
•Based on third party
2011 data
OPEX BIMODAL
43
45
40
•Efficient recycling
system
35
30
$ / t PE
23
22
25
17
•Standard Zeigler
catalyst
20
15
10
5
0
0
Competitor #1
Competitor #2
Competitor #3 Competitor #4
InnoveneS
•Competitive process
guarantees
Based on Nexant 2011 data
Innovene S: OPEX cost leader
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Innovene™S Product
3
Solutions
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Innovene™ S
HDPE Product Coverage
Application
Film
Blow Molding
Injection Molding
Pipe & Conduits
Textile
Others
Type
HDPE
Bimodal HDPE
Medium Mw Cr
High Mw Cr
Bimodal
Monomodal
Bimodal
Non pressure
PE80
PE100 bimodal
Monofilament
Tape
Bimodal
W&C
Geomembrane
Rotomolding
Innovene™ S
















A complete HDPE offer covering all applications
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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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
PEX
PE100
Only Bimodal grades comply with ISO PE100 requirements
SPC
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Innovene™ S
Bimodal Strength
• 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
Injection
moulding
Enhanced impact
and ESCR
Enhanced ESCR
Light weighting
Light weighting
Full Bimodal product Range with high Performance
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commercial services UK Limited , and the information and images it contains may not be altered or
amended, copied or used without the express permission of INEOS commercial services UK Limited .
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Conclusions 4
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Conclusions
• 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
Innovene™ S : THE leading industrial technology
for developing PE Bimodal markets worldwide
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commercial services UK Limited , and the information and images it contains may not be altered or
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Thank you !