Production of PPHomopolymer, random copolymer, heterophasic impact copolymer

English

Technology

Spheripol Processand Services

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3

1. An Introduction to Basell

A True PolyolefinPerspective

Basell is the world’s largest

producer of polypropylene and

advanced polyolefins products, a

leading supplier of polyethylene

and catalysts, and a global leader

in the development and licensing

of polypropylene and polyethylene

processes.

Basell, together with its joint ventures,

has manufacturing facilities around

the world and sells products in

more than 120 countries. With

research and development activities

in Europe, North America and

the Asia-Pacific region, Basell is

continuing a technological heritage

that dates back to the beginning of

the polyolefins industry. Basell is

committed to innovation both through

improvements of its processes

and a continuous extension of the

properties of its polyolefins portfolio.

The company is organised in three

businesses:

• Technology Business, which

includes licensing, catalysts

development and sales, R&D

and new projects;

• Advanced Polyolefins Business,

which consists of polypropylene

compounds and other specialty

products, and

• Polyolefins Business, which

comprises polypropylene and

polyethylene.

Basell has its corporate centre in The

Netherlands and has regional offices

in Belgium, Germany, the United

States, Brazil and Hong Kong, as well

as sales offices in the major markets

around the globe.

For further information on Basell,

please see separate leaflets in the

pocket-page in the back of this

brochure or visit the company’s

web site: www.basell.com.

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The history of Basell and its prede-

cessors is one of continuing achieve-

ments and breakthroughs in cata-

lysts, process and product develop-

ments in the field of polyolefins.

It began with the discoveries in poly-

olefins technology and catalysts by

Karl Ziegler and Giulio Natta, reward-

ed with the Nobel Prize in 1963, and

has continued through five revolu-

tionary generations of Ziegler-Natta

catalysts to the development of a

new metallocene-based polypropy-

lene catalyst family and products.

From the first industrial polypropy-

lene and polyethylene processes to

our latest multi-zone circulating re-

actor developments, Basell and its

predecessors have delivered state-

of-the-art polyolefin catalysts, tech-

nologies, and products to customers

world-wide.

For us, creating innovative poly-

olefin products is a way of life, deliv-

ering both superior performances

2 Your Partner in the World of Polyolefins Technology

2.1 Leading the Technology Race

and cost-effective solutions that

meet the changing requirements of

our customers.

Thanks to the close integration be-

tween our marketing, R&D and man-

ufacturing, new developments of cat-

alysts, processes and products are al-

ways focused on meeting market de-

mands and commercialised quickly

in a responsible manner.

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2.2 A Licensing Portfolio for Any Producer’s Needs

Basell is the only licensor offering

process technologies for production

of all PP and PE product families. Our

technologies are some of the most

reliable, efficient and cost-effective in

the world, and can meet both the di-

verse needs of performance plastics

manufacturers and those of com-

modity-oriented polyolefin produc-

ers.

Basell’s licensing portfolio of process-

es and services includes the following

technologies:

❏ Spheripol, the world’s leading tech-

nology for the production of

polypropylene homopolymer plus

random and heterophasic copoly-

mers

❏ Spherizone, this new manufactur-

ing platform with a multi-zone cir-

culating reactor system that cre-

ates polypropylene and novel,

propylene-based polyolefinic ma-

terials with outstanding quality

❏ Hostalen, the leading low-pressure

slurry process technology for the

production of bimodal HDPE

❏ Spherilene, the dual reactors swing

gasphase process technology for

the production of LLDPE and HDPE

❏ Lupotech G, the fluidised bed gas-

phase technology for the produc-

tion of chromium type HDPE and

MDPE or ZN based HDPE / LLDPE

❏ Lupotech T, the high pressure tubu-

lar reactor process technology for

the production of LDPE homopoly-

mers and EVA-copolymers

Some of the processes can be easily

upgraded in capacity and capability

to produce more sophisticated prod-

ucts, if required.

Basell’s Avant catalyst range covers

titanium, chromium and zirconium-

based polymerisation and is the opti-

mal solution for the process tech-

nologies we offer. Avant catalysts

can also be used in most other types

of polyethylene and polypropylene

process technologies.

PP consumption trend 1975 - 2005

Source: TECNON, Basell19

75

45,0

40,0

35,0

30,0

25,0

20,0

15,0

10,0

5,0

0,0

kt/

a

19

77

19

79

19

81

19

83

19

85

19

87

19

89

19

91

19

93

19

95

19

97

19

99

20

01

20

02

20

05

6

3 Technology

3.1 Introduction to Spheripol Technology

Global demand for polypropylene

(PP) has grown quickly over many

decades. There are three major rea-

sons for this:

❏ As a well-established plastic resin

with a broad application range, PP

usage has grown in line with the

overall economy.

❏ During their transition phase, de-

veloping countries experience

rapid growth in their per capita PP

consumption.

❏ There is huge untapped technical

potential in PP resins, which con-

tinues to extend their usage into

market segments of traditional ma-

terials like glass, wood, paper,

metal, etc., other plastics and, in

some cases, even engineering

plastics.

Basell's Spheripol process is the most

widely licensed technology ever de-

veloped for the production of

polypropylene. Since 1982, proof of

its enduring worldwide success is

the number of leading polypropylene

producers choosing this technology.

This includes Exxon, Dow, Borealis,

Showa Denko, Hyundai and Sinopec,

to name but a few. Today, products

from the Spheripol process are rou-

tinely sold in over 100 countries, and

future licensees will certainly benefit

from this wide acceptance and prod-

uct standardisation.

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3.1.1 An overview of Spheripol Technology development

Today’s Spheripol process is the re-

sult of forty years of continual im-

provement. However, to truly appre-

ciate the unique capabilities of this

technology, it is helpful to under-

stand the evolution of the polypropy-

lene industry and the breakthroughs

that led to the discovery of the

Spheripol process.

In the 1960s, polypropylene processes

employed first generation low yield

catalysts (<1,000 kg PP/kg catalyst) in

mechanically stirred reactors filled with

an inert hydrocarbon diluent. Polymer

produced with these catalysts had un-

acceptably high residual metals, and

contained 10 % atactic polypropylene,

which required separation. Removal of

catalyst residues and atactic PP in-

volved treatment of the polymer with

alcohol, multiple organic and/or water

washings, multistage drying and elabo-

rate solvent, amorphous and catalyst

separation systems. These processes

were costly and difficult to operate,

and also required extensive water

treatment facilities, and catalyst residue

disposal systems.

In the 1970s, the discovery of se-

cond-generation high yield catalysts

(6,000 kg PP/kg catalyst) eliminated

the need for catalyst residue re-

moval, but atactic was still unaccept-

ably high. This simplified the wash-

ing but did not eliminate the atactic

recovery steps.

In the 1980s, third generation high

yield, high selectivity (HY/HS) cata-

lysts (30,000 kg PP/kg catalyst) elim-

inated the need for catalyst and atac-

tic removal. This further simplified

the process and improved product

quality. Other breakthroughs oc-

curred in the process design,

through the refinement of gas-phase

and bulk polymerisation reactors

that led to the development of

Spheripol technology in 1982.

Today, the capabilities of the

Spheripol process are further en-

hanced by the current catalyst gene-

ration, which has the ability to pro-

duce new families of reactor-based

products with improved properties.

They offer even greater control over

morphology, isotacticity and molecu-

lar weight, and continually challeng-

ing new frontiers in the development

of propylene polymers.

Due to its low density, good physical

properties and easy processability,

polypropylene is the world’s fastest

growing thermoplastic.

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3.2 Spheripol Key Characteristics

The Spheripol process offers li-

censees a simple and economical

method of producing a wide range of

PP products of the highest quality.

Today, more companies are using the

Spheripol process than the technolo-

gies of the three closest competitors

combined.

The unmatched success of Spheripol

technology is a result of our focus on

polyolefins and a commitment to

continuous improvement.

Safety & Loss prevention

Basell has a safety record among the

best in the industry. To date, Basell

technologies have achieved nearly 7

million operating hours without any

major incident.

Reducing Resource Intensity

Spheripol technology includes fea-

tures that reduce both resource con-

sumption and emissions from the

process. These include use of high

yield, highly stereospecific catalysts,

the absence of solvents in the

process to suspend the polymer (the

suspension agent is the monomer it-

self), recovery and recycling of unre-

acted monomers, and the absence of

undesired by-products from the reac-

tion.

Reliability

At the end of 2002, a year-on-year

analysis of operating records from

over 80 Spheripol process plants

worldwide, showed the average

overall operability rate is about 98 %.

Of an average 2 % downtime, less

than 1 % is due to process features.

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Versatility

In comparison with any gas-phase

technology, a Spheripol process

plant offers on a single polymeriza-

tion line the widest range of ho-

mopolymers, random copolymers

and terpolymers, as well as het-

erophasic impact and specialty im-

pact copolymers covering all PP ap-

plication fields. Intense efforts in

product application development

for all the major market areas in the

world, ensures Basell's PP products

keep a leading position in most

profitable market segments, with

excellent results in PP specialties

and "high quality" demanding appli-

cations development.

Quality

Spheripol technology delivers un-

matched quality with minimum

property variation due to excellent

process stability and the consisten-

cy of Basell's catalysts performance.

Design flexibility

A range of single line capacities

from 40 – 450 kt/a are available for

homopolymer, random copolymer

or heterophasic impact copolymer,

either using polymer or chemical

grade monomer.

Modular installation

By a modular installation, Spheripol

process technology is easily adapt-

ed to meet changing market re-

quirements when new business op-

portunities arise for licensees. This

flexible modular design has virtual-

ly no impact on initial investment

costs. On existing plants, expan-

sions of up to 30 - 40 % of the ini-

tial capacity have been achieved

through minor adjustments.

Low capital and operating costs

Capital costs for the Spheripol

process are competitive with cur-

rently available PP processes. The

technology also offers the lowest

operating costs and excellent plant

reliability and transition efficiency.

Dedicated support

The experience of Basell's dedica-

ted technology team is made avail-

able to Spheripol process licensees

to ensure the highest degree of suc-

cess during project implementation

and plant operation.

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3.3 Process Description

The Spheripol process, using high

yield/high selectivity (HY/HS) catalysts

supplied by Basell, has the unique abil-

ity to produce polymer spheres direct-

ly in the reactor. Spherical polypropy-

lene differs considerably from the

small, irregularly shaped, granular par-

ticles produced with some other tech-

nologies and provides significant ad-

vantages in terms of process reliability.

The Spheripol process is a modular

technology. In its most widely adopted

configuration the polymerisation sec-

tion involves the following main units:

❏ Catalyst feeding

❏ Polymerisation

- Bulk polymerisation (homopoly-

mer/random copolymer and ter-

polymer)

- Gas-phase polymerisation (het-

erophasic impact and speciality

copolymer) - option (gas-phase

copolymer unit can be added at a

later stage without affecting initial

plant configuration or involving

significant implementation costs)

❏ Finishing

Bulk polymerisation employs tubular

loop reactors filled with liquid propy-

lene to produce homopolymer and

random copolymer or terpolymer.

The catalyst, liquid propylene and

hydrogen for molecular weight con-

trol are continuously fed into the

loop reactor. Residence time in the

reactor is lower than other technolo-

gies because of the high monomer

density and increased catalyst activi-

ty. The loop reactor is used because

it offers low cost, high heat transfer

and maintains uniform temperature,

pressure and catalyst distribution.

The low residence time also results

in short transitions during grade

changes, while the complete filling of

the reactors eliminates any risk of

contamination between different

grades due to the presence of an in-

terface between the actual reaction

volume and disengagement.

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Propylene + Hydrogen

Propylene + Hydrogen

Catalyst

Ethylene

Ethylene

Steam

Nitrogen

To polymer handlingand extrusion

Spheripol process

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A homogeneous mixture of poly-

propylene spheres is circulated in-

side the reactor loop. If the produc-

tion of random copolymer or terpoly-

mer is desired, ethylene and/or

butene-1 are introduced in small

quantities into the loop reactor. This

process achieves very high solid con-

centration (>50% by weight), excellent

heat removal (by water circulation in

the reactor jacket) and temperature

control (no hot spots). The resulting

polymer is continuously discharged

from the reactor through a flash

heater into a first-stage de-gassing

cyclone. Unreacted propylene from

the cyclone is recovered, condensed

and pumped back into the loop reac-

tor.

For the production of impact and

specialty impact copolymers, poly-

mer from the first reactor is fed to a

gas-phase fluidised bed reactor that

operates in series with the loop reac-

tor (this gas-phase reactor is by-

passed when homopolymer or ran-

dom copolymer is produced). In this

reactor, an elastomer

(ethylene/propylene rubber) formed

by the introduction of ethylene is al-

lowed to polymerise within the ho-

mopolymer matrix that resulted from

the first reaction stage. The carefully

developed pores inside the polymer

particle allow the rubber phase to de-

velop without the sticky nature of

the rubber to disrupt the operation

by forming agglomerates.

Fluidisation is maintained by ade-

quate recirculation of reacting gas:

reaction heat is removed from the re-

cycled gas by a cooler, before the

cooled gas is recycled back to the

bottom of the gas-phase reactor for

fluidisation. This type of gas-phase

reactor is efficient because it main-

tains a high degree of turbulence in

order to enhance monomer diffusion

and reaction rates, and offers an effi-

cient heat removal system.

Some speciality products, incorpora-

ting two different ethylene content

copolymers, require a second gas-

phase reactor in series.

In impact copolymer production, at

least 60% of the final product is pro-

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duced in the first-stage loop reactor.

In addition, since ethylene is more re-

active than propylene, the gas-phase

reactors are smaller than would be re-

quired if this design were to be used

for homopolymer production. Spheri-

cal morphology ensures high reliabili-

ty and elimination of fouling phenom-

ena, which frequently disrupt other

gas-phase systems.

Polymer discharged from the reactors

flows to a low-pressure separator and

subsequently to a steam treatment

vessel where catalyst residues are

neutralised and the dissolved

monomer is removed, recovered and

recycled back to the reactor system.

From the steamer, polymer is dis-

charged into a small fluidised-bed

dryer with a hot nitrogen closed loop

system to remove the moisture.

The final product is conveyed to an

extrusion unit, where it is mixed with

additives and extruded to pellets.

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3.4 Safety and Environment

Basell has a safety record among the

best in the industry. To date, Basell

technologies have achieved nearly 7

million operating hours without any

major incident.

Spheripol process plants are built ac-

cording to the Basell Safety Design

Criteria and must undergo Safety Au-

dits prior to commissioning and

start-up.

All licensed sites receive visits from a

team of specialists experienced in di-

verse fields, including:

❏ Safety and Loss Prevention

❏ Health & Environmental

❏ Process Operations

❏ Instrument/Electrical/Mechanical

design

This team verifies and ensures that

the plant is built according to the

Basell Safety Design Criteria, and as-

sists the licensee with any safety,

health or environmental concerns re-

garding the process and related faci-

lities.

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3.4.1 Intrinsic safety of the process

3.4.2 Spheripol: Technology designed to lower environmental impacts

The design of each Spheripol process

plant includes a number of safety

features, such as:

❏ Proprietary Catalyst Deactivation

System, which immediately stops

all reaction

❏ Computer controlled emergency

shutdown systems

❏ Uninterruptible Power Supply (UPS)

for computer control and critical

instrumentation control

❏ Instrument air emergency buffer

❏ Emergency Blowdown System to

empty the plant quickly, in the

event of an emergency

❏ Gas detectors which instantly de-

termine and highlight (on a graph-

ic easy-to-read board) the source

of any hydrocarbons in the event

of leakage into the atmosphere

❏ Automatic fire protection systems

Depending upon the severity of the

situation, the plant can be shut down

manually in a step-by-step, con-

trolled fashion, more rapidly by both

manual and computer control, or by

instant automatic shutdown.

Spheripol process units are config-

ured so that unreacted monomers

are recovered and recycled. If neces-

sary, other discontinuous hydrocar-

bon purges can be sent to "off-gas

recovery” for use as a fuel supply or

to a flare system.

The Spheripol process does not use

hydrocarbon diluents nor contami-

nant chemicals and the only waste-

water is released from the steam-

ing/drying section of the plant which

contains steam condensate and a

small amount of inert polymer fines,

which are recovered by a separator.

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3.5 Process Capability

Spheripol process plants are de-

signed to meet the particular require-

ments of individual licensees, yet

they are flexible enough to be easily

expanded to meet future needs as

the business develops. Two critical

design elements that are easily ex-

panded include capacity and product

range.

Spheripol process facilities have been

designed with capacities ranging

from 40 - 450 kt/a. This wide capaci-

ty range and the modular installation

approach allows, within limits, easy

debottlenecking. This minimises ini-

tial capital costs and allows new ca-

pacity to be added later when re-

quired.

The product range can also be easily

expanded. Often new entrants to the

polypropylene business will build a

plant to produce only homopolymer

and random copolymer products as

these are the least expensive, are

easy to operate and their products

account for 75% of all polypropylene

sold in the world. A basic homopoly-

mer plant can be easily expanded at

a later date to produce heterophasic

impact and speciality impact copoly-

mers. Impact copolymers are more

specialised products, which require

additional capital investment and

technical support.

The simple design of a Spheripol

process plant does not require

mandatory equipment or instru-

ment/electrical vendor lists. There is

also a list of suitable suppliers and

designs for critical equipment, en-

abling purchasers to benefit from the

most economic pricing available.

3.5.1 Design Flexibility

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Spheripol technology's versatility is

demonstrated by its easy process op-

eration and ability to deliver a pro-

duct range that includes all standard

polypropylene grades, and many

unique, special products.

Key to this versatility is the applica-

tion of Basell's high yield / high se-

lectivity Avant catalysts:

❏ High polymerisation activity

(mileage over 40,000 kg PP/kg cat-

alyst), resulting in extremely high

polymer purity

❏ Stereospecificity control of poly-

mer

❏ Morphology control of particle

size, shape and distribution

❏ Molecular weight distribution con-

trol

❏ Use of polymer or chemical grade

monomer

❏ Homopolymer, random copolymers

and terpolymers, heterophasic im-

pact and speciality impact copoly-

mer production

3.5.2 Versatility

Although the standard control sys-

tems are highly capable of control-

ling the process reliably and effi-

ciently, Advanced Process Control

software can be made available to

Spheripol licensees in order to fur-

ther benefit from the process capa-

bilities.

3.5.3 Advanced Process Control

A special developed simulation pro-

gram is used for training and deve-

lopment purposes, and can be made

available to Spheripol licensees. The

program allows training for start-up,

steady state, grade-change and shut-

down operations, and can assist in

optimising your Spheripol plant.

3.5.4 Simulation / Operator Training program

Spheripol Process Capability

MFR (g/10’) 0.3 to > 1600

Xylene Insolubles (%) 90 to 99 %

Particle size (mm) 0.3 to 5.0

Melting point (°C) 130 to 165

Flexural Modulus (MPa) 600 to > 2400

IZOD impact at 23°C (J/m) 30 to 1000

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3.5.5 Technology Summary

The Spheripol process is the most cost effective technology for whole PP family production

Other Processes Spheripol Process

Conventional gas-phase design suffers from equip-

ment size scale up problems and constraints in

plant operation economics due to monomer losses

and mechanical weakness.

Spheripol process operation is not affected by the

presence of critical machines. Complete monomers

recovery is possible even in case of chemical grade

monomer use. Catalyst yield is higher.

Gas-phase operating window is limited in terms

of hydrogen response and heat removal.

Plant configuration is modular in order to optimise

investment costs to product slate requirements, loop

reactors design allows for better scale up efficiency

(single line over 400 kt/a does not imply any critical-

ity in equipment sizing or reactors configuration)

Hydrogen response is higher. Loop reactors design

and liquid monomer operation grants extremely effi-

cient heat removal and temperature control.

Spheripol technology ensures better product quality and reproducibility

Other Processes Spheripol Process

Polymer morphology may affect process reliability

and represent a constraint to finishing efficiency

and complete monomer recovery.

Controlled morphology of the polymerising particle

(independently from average particle size) improves

finishing efficiency and eliminates risk of fouling

when producing impact copolymers even at high

ethylene content.

Hydrogen response is limited and reactors cascade

operating mode (bimodal operation) is not available.

Polymerisation conditions are completely homoge-

neous and can be reproduced exactly any time by

simple parameter selection.

Catalyst system distribution and process parame-

ters control is more critical.

Hydrogen response is very high, catalyst system ca-

pabilities and bimodal operation mode allows for ac-

curate control of product quality in a wide range of

properties.

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Spheripol technology provides the easiest and cheapest grade change

Other Processes Spheripol Process

Cumbersome product transition from grade to

grade, especially when switching to or from copo-

lymers. Presence of an interface between polymer

bed and disengagement section increases risk of

product contamination.

The switch from one grade to another is particularly

easy, quick, and low cost because hydrogen composi-

tion can be adjusted immediately without reducing ca-

pacity and impact copolymer production can be star-

ted by just feeding homopolymer to copolymer reac-

tor.

Off-grade material associated with each cam-

paign takes up a recognisable portion of the pro-

duction.

Very low residence time, allowed by extremely high

reactivity conditions, minimise transition material.

Full reactors avoid product contamination .

Spheripol technology has reduced environmental impact to negligible levels

Other Processes Spheripol Process

Conventional approach. Extremely high attention to environmental and safety

considerations due to the "liquid phase hydrocarbons

culture".

Lower efficiency associated with hydrocarbons

polluted nitrogen stream recovery and polymer

residual volatiles.

All monomer residues are recovered to the polymeri-

sation thanks to the unique "live steam” stripping

which ensures a complete polymer "finishing”.

20

The Spheripol process has proven to

be extremely reliable. In use since

1982, it has been continuously re-

fined and optimised. Yearly world-

wide surveys of operating Spheripol

process lines reveal an average on-

stream operability of around 98%.

Key contributors to this remarkably

high operability include:

❏ A simple, straightforward process

design with simple and reliable

equipment

❏ Easy on-line product change

❏ Rapid restart after shutdown

❏ No scheduled maintenance down-

time for cleaning or inspection

purposes

3.6 Process Economics

3.6.1 Reliability and operability

In addition to high operating rates,

products produced with the

Spheripol process maintain consis-

tently high quality from one run to

the next. Products are identical from

different plants, wherever located.

3.6.2 Quality

Products from the Spheripol process

are superior in quality. The Spheripol

process was designed around the

catalyst to minimise property varia-

tions and to ensure consistent results

with regard to:

❏ Particle size and shape

❏ Crystallinity and stiffness

❏ Melt flow

❏ Molecular weight distribution

❏ Comonomer distribution

❏ Physical and optical property per-

formance

High catalyst mileage results in ex-

tremely low residual metal content.

21

Spheripol process plant capital and

operating costs are among the low-

est in the industry as a result of:

❏ Smaller reactor volumes

❏ Minimum transition time

❏ Lowest monomer consumption

❏ Utilisation of low cost chemical

grade or polymer grade monomer

❏ Low steam and electric power con-

sumption

Typical specific consumption (per

1000 kg of PP produced)

3.6.3 Consumptions

Homopolymer Impact Copolymer

Monomers (kg) (1) 1002 1002

Hydrogen (Nm3) (2) 0.01-0.5 0.01-0.5

Catalysts & Chemicals ($) (3) 22-25 23-26

Electric power (kWh) (4) 250-270 280-300

Steam (kg) (5) 280 280

Cooling water (m3) (6) 110 120

Nitrogen (Nm3) 15 15

(1) Net consumption of 100% monomers / co-monomers included(2) Depending of reactor gas composition, according to polymer MFR(3) Typical General Purpose stabilisation(4) Extrusion included, consumption depending on product MFR(5) Low pressure steam, high pressure steam consumption for extruder die plate or barrels heating is excluded(6) At �T = 10°C

22

Isotactic polypropylene is well suited

for a variety of end uses, ranging

from flexible and rigid packaging to

fibres and large moulded parts for

automotive and consumer products.

Polypropylene is recyclable, an im-

portant consideration in many pack-

aging and automotive applications,

and it can be incinerated without

toxic emissions. It can be processed

using most methods including extru-

sion, extrusion coating, blow mould-

ing and stretch blow moulding, injec-

tion moulding, and thermoforming.

Its physical properties can be easily

enhanced through the addition of

fillers such as calcium carbonate or

talc. Polypropylene has excellent

chemical resistance and electrical in-

sulating properties.

Typical applications for polypropy-

lene products produced in the

Spheripol process include fibres and

filaments, oriented and cast film, in-

jection-moulding items, blow-mould-

ed bottles and parts, and thermo-

formed containers.

Random copolymers can be pro-

duced with excellent optical proper-

3.7 Products and Applications

ties and sealing initiation tempera-

tures in compliance with the U.S.

Food and Drug Administration (FDA)

regulations for food contact.

Heterophasic copolymers with out-

standing low-temperature behaviour,

high-impact strength and enhanced

stiffness can be obtained in the

widest range of melt viscosities.

As a global average, homopolymer

accounts for 65-70 % of all

polypropylene, random copolymer

and terpolymer for 10-15 % and het-

erophasic copolymer for 15-20 %.

Film and fibre are the two largest

segments in the global PP market,

but injection/blow moulding and ex-

trusion account for significant quan-

tities. Typical polypropylene fabrica-

tion processes and end uses include

the following major fields:

23

Fabrication Process Markets/End Uses

Film Extrusion BOPP film / WQB film / cast film/ (flexible packaging for tex-tiles, confectionery, bakery and cigarette wrap)

Multifilaments woven sacs (raffia)/fibrillated tape for carpet backing, geotex-tiles, rope and twine, upholstery and cigarette tow

Nonwovens geotextiles, medical application(meltblown and spunbonded)

Injection moulding automotive, appliances, houseware,furniture, consumer products, packaging (crates, cases, caps and closures, thin walled and transparent containers)

Blow moulding packaging

Profiles extrusion pipes, conduits, corrugated sheet, wire and cable extrusion coating, lamination.

Basell Avant catalysts are capable of

manufacturing products with virtually

unlimited combinations of physical

properties to meet the increasing de-

mands of customers in new and more

challenging applications.

In comparison with any competitor

gas-phase technology, a Spheripol

process plant is making available on a

single polymerization line the widest

range of PP products, including ho-

mopolymers, random copolymers and

terpolymers, as well as heterophasic

impact and specialty impact copoly-

mers covering all PP application fields.

Extensive product application develop-

ment has enabled products from the

Spheripol technology to keep a leading

position in most market segments

worldwide, and particularly in PP spe-

cialties and applications demanding

high quality levels, where excellent re-

sults have been achieved.

For better evaluation of the capabili-

ties of the Spheripol process, and to

demonstrate its superiority to any

competing technology, listed overleaf

are some of the Spheripol process

products which ensure Basell's leading

position in specialties and high perfor-

mance PP market segments:

By courtesy of SIMONA

24

Homopolymers

❏ Very high processability BOPP, for

application on very fast tenter ma-

chines (over 300 m/min).

❏ Single and multi-layer cast film

produced on high-speed lines

using new grades particularly suit-

able for thin gauges.

❏ Fine denier continuous filament

and non-woven fabrics products

for disposable clothing, lining,

medical hygienic, feminine care,

diapers, crop protection in agricul-

ture.

❏ High clarity gamma ray resistant

for syringes injection grade.

In addition, a number of new com-

mercial grades have been successful-

ly introduced to the market for very

high stiffness homopolymers (Flexur-

al Modulus higher than 2300 MPa)

for injection and thermoforming.

Random copolymers and

terpolymers

A new family of very high clarity ran-

dom copolymers of propylene and

butene-1 with less hexane extracta-

bles (very important for food con-

tact) is under commercial develop-

ment. Uses will include high perfor-

mance cast film application with dif-

ferent stabilization package as well

as for extrusion applications, such as

thermoforming, blow molding, sheet

extrusion and blown film.

Copyright Citroen Communications..

25

Heterophasic impact copolymers

❏ Improved impact/stiffness balance

copolymers for corrugated pipe,

injection and thin wall injection-

moulding applications. These

grades have been recently intro-

duced on a commercial scale and

made available to the Spheripol

process licensees.

❏ Very high MFR impact copolymers

for thin wall injection (MFR 70 and

100 g/10' pelletised commercial

grades are regularly produced in

Basell's Spheripol process plants).

❏ Specialty impact heterophasic

copolymers for bumpers present-

ing extremely high impact resis-

tance even at very low tempera-

tures. These reactor grades were

developed in the Spheripol

process to the requirements of all

major car manufacturers in Eu-

rope.

❏ High impact for special applica-

tions such as a low MFR grade free

of fish eyes for film and tape or

extrusion and blow moulding.

In addition, heterophasic copolymers

with very high creep resistance are

now available for pipe applications.

There are also a whole family of high

rigidity "ultra" grades for fast injec-

tion applications, and high clarity im-

pact grades for cosmetic packaging

and houseware.

26

During the development of a project

and throughout the operation of the

plant, experts from the Licensing De-

partment and the Technology Trans-

fer Centre will be dedicated to the li-

censee’s needs in the following areas

of activity:

Licensing process

Prior to the granting of a license,

Basell will actively participate in the

definition of the project, based on

the product and marketing expecta-

tions from the customer. This stage

defines the optimal technology and

particular design features - such as

capacity, reactor configuration, cata-

lyst system, etc. - under a confiden-

tiality agreement.

Once the scope of the plant has been

jointly identified, a draft License

Agreement will be prepared and ne-

gotiated; the agreement will contain

articles that define the type and ca-

pacity of the plant, the product grade

slate, etc. The supply of the Process

Design Package, the extent of the

granting of the license, the license

fee and the payment conditions are

4 Licensing Customer Services

also described. Payment conditions

vary from lump sums to running roy-

alties, or an appropriate combination

of both these elements.

Further sections of the License

Agreement stipulate the project as-

sistance, particularly during commis-

sioning and start-up of the plant and

the performance testruns, by Basell

experts in process design, polymeri-

sation, extrusion and quality control.

Other more formal chapters cover se-

crecy, liability, patent issues, force

majeure, applicable law, etc.

Business start-up support

27

Basell is open to discuss possible sup-

ply of resins from Basell production for

pre-marketing of resins by the li-

censee, and use the Basell marketing

and sales organisations to support the

licensee in the development of the

polyolefins business, by agreement on

defined off-take volumes of resins

until the licensee can market the entire

production volume itself.

Process Design Services -

Engineering

The Process Design Package (PDP)

provided by Basell Process Design

contains a comprehensive technical

description of the entire process, and

is adequate to allow for the prepara-

tion of the engineering of the plant,

application to authorities for environ-

mental licenses, and the preparation

of the operating manual. Typical PDP

content is:

❏ Process description

❏ Process flow diagram (PFD) with

heat and material balances

❏ Piping and instrument diagrams

(PIDs)

❏ Equipment list + data sheets

❏ Instrument list + data sheets

❏ Safety valve list + data sheets

❏ Plot plans

❏ Safety design criteria

❏ Emergency flaring load

❏ Fluid list and piping classes

❏ Environmental information

❏ Guidelines for the operating manu-

al

❏ Etc.

Ideally the Basic Engineering may be

provided by a contractor with a

proven record of the Basell technolo-

gy. Alternatively this can be done by

another contractor on the basis of

the PDP.

The Detailed Engineering – at least in

part - is typically done by a local en-

gineering company in the region of

the license plant.

Experts from Basell Process Design

can assist the engineering activities.

28

Technology Transfer:

Besides some initial support during

the licensing process, the main ser-

vices provided to the Licensees by

Technology Transfer are in agree-

ment with the Licensing Agreement,

and consist of the following:

Training

Prior to the start-up, highly experi-

enced trainers at Basell’s training

centres (Ferrara, Italy / Bayport,

Texas, USA / Aubette, France) will

train licensees’ experts on Opera-

tions, Quality Control, Maintenance,

Applications and Safety. Comput-

erised dynamic process simulators

are available to enable licensees’ per-

sonnel to train for start-up, steady

state, grade-change and shutdown

operations.

Courses are tailored to fit the specific

needs of the customer, not only with

regard to content, but also accom-

modation, interpretation, transporta-

tion, visas, etc.

Start-up support and guarantee

testruns

A start-up team, consisting of Basell

expert operators, will provide assis-

tance during pre-commissioning and

commissioning of the plant.

After completion of the commission-

ing, Basell HSE experts will partici-

pate in a Plant Safety Audit to verify

the adherence to the Safety Design

Criteria, with special attention to

health and environmental concerns.

The start-up team will assist during

the start-up, in order to obtain a safe

and reliable start-up, and normally

remain until the performance guaran-

tee testruns have been finalised.

29

Technical support after start-up

While the full commercial operation

of the plant will soon become a rou-

tine business of the licensee, devel-

opments in the world of polyolefins

will continue.

Safety information about Basell, its

joint ventures and/or licensees will

be directly shared unconditionally, in

order to continue to improve the

safety standard of our technologies.

In order to further benefit from

Basell’s technical knowledge and de-

velopments, licensees can enter into

a Technical Support Agreement (TSA)

with Basell, typically comprising the

following elements:

❏ Explanation and details of technical

improvements within the scope of

the original License Agreement

❏ Non-confidential information on

Basell’s R&D progress that goes be-

yond the current license

❏ Further training sessions

❏ Optimisation of plant efficiency:

trouble shooting / trial for new

products / new catalyst implemen-

tation, provided with technical assis-

tance at the customer’s site

❏ Advice on maintenance and quality

control procedures

❏ Marketing exchange

❏ New product development or adjust-

ments to local markets

❏ Periodical Technical Exchange

Meetings with focus on licensee’s

issues

❏ Periodical seminars / conferences

with focus on safety, best practice

and breakthrough in process and

catalysts

Engineering services

If market conditions change, and the

capacity of the plant needs to be in-

creased, or a variation in the product

grade slate needs to be made, Basell

can assist in the engineering activi-

ties needed to upgrade the plant ac-

cordingly.

30

Basell Technology Licensing –

Conclusion

Basell is unique in providing excel-

lent process technologies for all

polyolefin production for all fields of

product applications. This, together

with our drive for customer satisfac-

tion, continuing R&D developments,

and the support from the organisa-

tion of the world leader in poly-

olefins, will make Basell technology

the optimum choice for your poly-

olefin production, now and in the fu-

ture.

Source: Nasa

31

Befo

re u

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Bas

ell pro

duct

, cu

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use

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should

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they

can

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saf

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and le

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Corporate Centre

Basell B.V.Hoeksteen 662132 MS HoofddorpThe NetherlandsTel. +31 20 4468 644Fax +31 20 4468 649

Europe Regional Office

Basell Polyolefins Company B.V.B.A.Woluwe GardenWoluwedal 241932 Zaventem (Brussels)BelgiumTel. +32 2 715 80 00Fax +32 2 715 80 50

Main European Sales Offices*

Advanced Polyolefins

Basell Deutschland GmbHIndustriepark HoechstBuilding B 85265926 Frankfurt am MainGermanyTel. +49 69 305 85800Fax +49 69 305 85803

Polyolefins Europe

Basell Deutschland GmbHBruehler Strasse50389 WesselingGermanyTel. +49 2236 726000Fax +49 2236 726034

* For a complete list of Basell European sales offices, please visit www.basell.com

North America Regional Office

Basell North America Regional Office and Research & Development Centre912 Appleton RoadElkton, Maryland, USA 21921-3920 Tel. +1 410 996 1600Fax +1 410 996 1660

Basell North AmericanAdvanced Polyolefins Businessand Technical Centre2727 Alliance DriveLansing, Michigan, USA 48910Tel. +1 517 336 9600Fax +1 517 336 9611

South and Central America Regional Office

Basell Brasil Ltd. Estrada Samuel Aizemberg, 1707 Sao Bernardo do Campo 09851-550 Sao Paulo, Brazil Tel. + 55 11 4343 3461 Fax + 55 11 4343 3464

Asia-Pacific Regional Office

Basell Asia Pacific Ltd. 22/F Hennessy Centre 500 Hennessy Road Causeway Bay Hong Kong China Tel. + 852 2577 3855 Fax + 852 2895 0905

Australia Sales Office

Basell Australia Pty. Ltd.Level 2, 199 Toorak RoadSouth Yarra VIC 3141MelbourneAustraliaTel. + 61 3 9829 9455Fax + 61 3 9829 9431

For more information on Basell licensing services, Spheripol technology, or engineering, technical and marketing services, please contact: licensing@basell.com

You can find out more about Basell by visiting our website at: www.basell.com

Avant, Catalloy, Hostalen, Lupolen, Lupotech G, Lupotech T, Spherilene, Spheripol and Spherizone are trademarks owned or used by Basell. Hostalen, Lupolen and Spherilene are registered in the U.S. Patent and Trademark Office.

Copyright 2005 Basell Service Company BV. All rights reserved.

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