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Coimbatore November 20-21 , 2009

Metal Replacement

Opportunities with LFTPP

T.C.N Sairam, Sr. Manager – Polymers

Reliance Industries Limited

SIEMA - CII

National Conference on Pumps

“ Energy Efficiency in Pumping Systems”

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• Overview of Reliance

• Polymers , Types & PP Characteristics

• LFTPP Solutions for Metal Replacement in Pump

• Conclusion

Index

4From India’s no.1 company to one of the world’s leading energy giants

An Overview of Reliance

• India’s largest private sector enterprise

with strong financials:

• Revenue ~ US$ 30 billion

• Exports ~ US$ 19 billion

• EBITDA ~ US$ 5 billion

• Global player in Refining and Petchem -

contribute 97% to revenues

• Recent capex > $ 15 billion completed

• Production commenced from KG D6

• World-class refinery commissioned

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RIL features in Forbes Global list of the world’s 400 best big companies

Ranks amongst the ‘World’s 25 Most Innovative Companies’

Global Recognition

Amongst the 30 fastest climbers ranked by Fortune

Rank

Net Prof it 103

Assets 273Revenues 206

2008

Leading Global Capacities

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4

1

5

Polyester( Fibre & Yarn)

PP

Ref ining *

LAB

7PTA

Amongst top 10 global players in all its core businesses

6 MEG

* Jamnagar-( at a single location)

**

** as per list compiled by the US financial publication-BusinessWeek in collaboration with the Boston Consulting Group

4 PX

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Plastics( PE, PP, PVC, PET)

Petrochemicals( LAB, EO, ACN, Cyclohexane)

Oil and GasExploration

PetroleumRetailing

Oil and GasProduction

Polyester( Fiber, Filament)

FiberIntermediates

( PX, PTA & MEG)

Olef ins and Aromatics

PetroleumRef ining

Polyolef in Pipes

Elastomers( Butadiene, PBR)

Textiles

The integration strategy has been at the core of our evolution & growth

Oil to Textiles: Value from Integration

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Jamnagar - The new refining capital with 1.24 MBPSD

New Township

Control Room

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• Wide range of products with large capacities

Polymers (PP,PE, PVC) , Polyester, Polyester Intermediates

Cracker Products (Ethylene, Propylene, Butadiene)

Chemicals (Benzene, LAB, Xylene)

• World’s largest polyester producer with capacity of 2.03 MTPA.

• Top 5 producer of PP in the world - capacity of 2.7 MTPA

• Over 50% share in domestic polymer and polyester markets

• Concerted effort to develop new applications & market through various

customer centric initiatives

• Focus on product differentiation, competitive pricing & operating strategy

India’s Leading Petrochemical Player

Leadership through global scale, competitiveness and specialty products

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Vadodara Gandhar

Hazira

Jamnagar

• Ahmedabad

Mumbai

Patalganga Nagothane

• Allahbad• Barabanki

• Hoshiarpur

• Pune

• Den Kanal

• Bhopal

• Silvassa

• Polyester sites

Petrochemical sites

Refining & Petrochemical sites

Overseas :

Polyester Manufacturing Site:

• Trevira (Germany, Denmark, Belgium)

• Recron Malaysia

Manufacturing Sites

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Polymers , Types & PP Characteristics

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Chemical compounds formed when many small chemical

units (monomers) combine to form large molecules

with a regular repeating structure.

MonomerPolymer

What is Polymer ?

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Thermosets

Thermoplastics

Polymer

Plastics

Rubber

Fibers

Adhesives

Surface Coating

Inks

Paints

Types of Polymer

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Plastics

Thermosetting Thermoplastic

Commodity Engineering Specialty

Semi-Crystalline Amorphous

CLASSIFICATION OF PLASTICS

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Why Plastics?• Lightest among other materials• Design Friendly• Low processing cost• Optimum Performance• Corrosion Resistance• Chemical Resistance • Excellent Aesthetics• High Productivity

Why Polymer in metal replacement ?

Plastics saves fuel, saves environment !

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Role of Composite Plastics

Excellent Rigidity

Toughness

Composite Thermoplastics -

Superior combination of mechanical, thermal, electrical and other properties offer better product possibilities in engineering applications compared to conventional materials.

Thermal Resistance

Dimensional Stability Long Life

Engg Plastics Offer

–Design flexibility –Eliminates number of primary and secondary operations over metal and wood –Total System Cost Reduction–Unmatched strength to weight ratio.–Cost effective only when engineers & designers "think"

Source : www.fibre2fashion.com16

Role of Plastics

Protection

Safety

Economy

Units

Presentation

Information

Standardization

Storability

Convenience

EnvironmentalCompatibility

Preservation

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Polymers - PP

18Designed for diverse applications….

Polypropylene

• Lightest Commodity Plastics – Density of 0.90

• High strength to weight ratio

• Excellent chemical and fungal resistance

• Easily molded / extruded in any fiber / filament form

• Low cost

• Easy Availability

• Easily recyclable

Polypropylene : Designer’s choice

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PP - A versatile polymer…with the widest performance envelope

Optimum impact-stiffness balance

400

600Izod impact at RT, J/m2

Flexural modulus, MPa

0 1000 2000

200

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Polymers: Presence across Sectors

Focused on core sectors of the economy

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Metal Replacement Opportunities with LFTPP

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Thermoplastics types - overview

AMORPHOUS SEMICRYSTALLINE

COMMODITIES

ENGINEERING PLASTICS

HIGH PERFORMANCE PLASTICS

PVCPS

HIPSPolyethylene

PolypropyleneABSPC

PMMA POM

PET

PEI

PSU

LCPPPS

PC blends

PPE / PSblends PBT

PBT blends

PAPA

blends

PEEK

Tg, Heat Stabi l i ty,

Processing temperature and Cost

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ATC’s - Advanced Thermoplastic Composi tes

Chopped Fibres

GMT

LFTGlass mat Thermoplastics

Long Fibre Thermoplastics

ATC’s

Special ty pol ymers reinforced wi th Carbon,

Aramid fibres and/or Sandwiched wi th cores

4 mm

8 mm

Continuous

Fibre Length Process

I njection Mouldin

g

Compression, Pul trusion, Autoclave

Vf

(%)

Modulus (GPa)

6

16

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206

70 %

50 %

30 %

1 5 %

Thermoplastic Composites

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The long and the short of LFT

Typical Short Fiber pellets

• Random fibers

• <3 mm fiber length

• Fiber length after Injection molding - 0.4

mm

Typical Long Fiber pellets

• Aligned fibers

• 11-12 mm fiber length

• Fiber Length after injection

molding – 4-6 mm

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The Long Fiber Advantage

Structural Metals

TS Composites

SFRT LFTPP

Price

Perf

orm

ance

Advanced CompositesGMT

• Greater Design Freedom• Potential for Parts

Consolidation• Weight Reduction• Extreme Toughness

& Durability• Dimensional Stability• Corrosion and Chemical

Resistance• Elimination of Secondary

Operations(painting, welding, etc.)

• Lower Total System Cost

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Long Glass vs Short Glass Functional Advantage

• Surface finish using long fiber thermoplastic is much better due to

aligned fibers and lower fiber ends

• Much lower warpage and shrinkage (0.1-0.3%) compared to short glass

compounds with the same resin & glass content

• Better flow properties due to aligned fibers and hence lower injection

pressures

• It is possible to design parts with much lower thickness using LFT

which results in lower overall weight & cost

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LFT special molding requirements

For optimum properties the following is

recommended

• General purpose screw with an L/D ratio of 18:1 to 20:1

• Compression ratio of 2:1 to 2.5:1

• General purpose nozzle with a minimum orifice diameter

of 5.5mm

• Screw speed between 20 and 50 rpm

• Back pressure less than 3.75 kg/cm2

Need of Low Compression Screw

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10

2220

13.3

32

12.2114

26.7

0

5

10

15

20

25

30

35

Impa

ct S

tren

gth

KJ/

m2

PPLG 40

PPSG 40

Nylon6 LG 40

PET SG 40

PBT SG 40

Nylon6 SG 40

Nylon66 LG 40

Nylon66 SG 40

PPS SG 40

Impact Strength - LFT vs SFT

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Long Glass vs Short Glass – Mechanical Properties Summary

Test Method Unit PP HP PPSFT

30%PPLFT

30% PA-6 PA-6SFT 30%

PA-6LFT 30%

Density ISO-1183 gm/cm3 0.9 1.12 1.12 1.13 1.37 1.37

Tensile Strength ISO 527 Mpa 40 80 103 79 165 170

Tensile Elongation ISO 527 % 2 3 2.3 3 3 2.2

Flexural Strength ISO 178 Mpa 48 105 146 103 230 245

Flexural Modulus ISO 178 Mpa 1600 5700 5950 2826 6200 8200

Notched Izod Impact ISO 180 KJ/

M2 3 12.5 19 7 13 28

HDT @ 1.820 MPa load ISO 75 0C 140 145 159 190 210 210

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Metal versus LFT Property Summary

0 0.5 1 1.5 2

Property Unit Aluminum Steel Nylon-6 LG40

PP LG40

Tensile Strength Mpa 255 640 200 115

Specific Tensile Strength

Mpa cc/gm

94 82 138 95

Tensile Modulus Mpa 68,948 201,000 12,500 9,555

Tensile Elongation % 10 21 2 1.95

Flexural Modulus Mpa 26,518 - 11,500 8,450

Coefficient of Thermal Expansion

in/inF * 10E-5

1.3 0.75 - 1.17

Density gm / cc 2.7 7.85 1.45 1.21

Specific tensile strength of LFT is higher than steel and aluminum leading to parts with much lower weight

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INTERIOR EXTERIOR SEMI-STUCTURAL

SYSTEMS E&E/COMPONENTS

Instrument panels

Sun roofs Front end carriers Inlet manifolds Pulley covers Spare Wheel trays

Door handles Splash shields Fan shrouds Engine covers Spare wheel covers

Bumper beams

Radiator Fans Rocker valve coversSeat shells

Door modules Pedal systems

Rear seat backs

Hatchback structures

Rear shelves

Headliners

Load floors

Typical LFTPP Applications in Auto

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LGFPP FOR FLUID ENGINEERING APPLICATIONS

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PUMPS

•Property Benefits with LFT versus Metal

• Excellent Impact Strength

• Excellent Corrosion Resistance compared to metals

• Good Surface Finish due to lower molding defects

• Lower Warpage and Good Dimensional Stability

• Lower Cost per Volume

• Greater Design Freedom

• Option of Precolored material as per requirements

LFTPP is clearly the future for the pump industry

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IMPELLER

Monoblock pump parts that can be replaced with LFT

GUIDE VANE

BLOW FAN PUMP BODY END SHIELD

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MonoBlock Pump parts identified for replacement with LFTPP

Part Name Existing

Material Of Construction

Suggested material

Est. Wt. Saving in LFTPP(%)

Est. cost saving in

LFTPP (%)Important Criteria

Delivery Casing

Cast Iron LFTPP 60 to 75 30 to 40 1.Dimensinal Stability

2.Good HygroscopicProperties

3.High Impact Strength

4.Corrosion Resistance

5.Good Wt/Performance ratio

6.Good Weatherability

7.Chemical Resistance

Mounting Casing Cast Iron

LFTPP60 to 75 30 to 40 Same

End Cap Cast IronLFTPP

60 to 75 30 to 40 Same

Motor Housing Al /Cast Iron

LFTPP40 to 75 30 to 40 Good Wear Resistance

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Case studies

Critical parameters• The Part should have high Impact Strength

• It should be Anti Corrosive

• It should be able to withstand load and damp

conditions

• It should have excellent electrical insulation

properties

• It should have good hydrolitic stability

• It should have good wear resistance

RESULT - all these issues are met and even improved upon by RePlet, a next generation compound for the pump industry

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UPPER HOUSING

Submersible pump parts that can be replaced with LFTPP

LOWER HOUSING

MOTOR BASE

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Parts that are under development for replaced with LFTPP

NON RETURN VALVE

SUCTION

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Cost Benefit of using RePlet in Submersible Pump parts

Part Name

Previous LFT-Material CostCost

Saving(%)Material Wt. (gm) Material Wt. (gm) Prev RePlet

Upper Housing Cast Iron 2090 LFT PP 300 141 54 60

Lower Housing Cast Iron 1610 LFT PP 230 112 44 60

Motor Base Cast Iron 2530 LFT PP 360 168 65 60

Suction Cast Iron 2510 LFT PP 360 166 65 60

NRV Cast Iron 1850 LFT PP 260 127 50 60

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10

2220

13.3

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12.2114

26.7

0

5

10

15

20

25

30

35

Impa

ct S

tren

gth

KJ/

m2

PPLG 40

PPSG 40

Nylon6 LG 40

PET SG 40

PBT SG 40

Nylon6 SG 40

Nylon66 LG 40

Nylon66 SG 40

PPS SG 40

Impact Strength - LFT vs SFT

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Revolutionizing New Application thru Composites

• Avg. mid-sized car in US contains $2219 of Chemistry (Including both Chemical Products & Processing)

• Total amount of Chemistry in Automobiles US$ 31.5 bln

• Chemical products make up ~ US$ 800 of the total value of the car

• On an avg. contains 150 kg of Plastics (8% of total wt)

• Enhancing Efficiency (West Europe Case)

• Each 4.5 kg of plastics substituted improves fuel efficiency by 0.11 to 0.14%

• Annual fuel savings of over 2.3m t – equivalent to 9.2 m t CO2 emissions

Polyolefins Composites – offering hygienic, environmentally safe products in Various sector and can be repeated in Pump Industry

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Conclusion - LGFPP

• LGFPP Can be used to replace Metal / High Cost Engg Plastics & Thermosets

• LGFPP improves temperature resistance

• Improved Impact / Energy Absorbtion

• Part Consolidation & Weight Savings

• Lower Weight can Improve pump performance and efficiency

• Sound damping Characteristics & Very Low Warpage

• Easy handling and transportations & Ease of assembly

• Pump Industry to Engineer expectations based on product characteristics

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Acknowledgments• M/s Indore Composites for their valuable inputs

• Any queries / technical details can be addressed to

Sh T.C.N SAIRAM

M/s Reliance Industries Ltd

Cont : 9940102676

E mail : n.sairam@ril.com

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“Knowing is not enough

We must apply. Willing is

not enough ;We must do”

- Goethe

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For most people the horizon is as far as they can see for some it represents the threshold to an unseen world of

New OpportunitiesCourtesy: Swiss Re

Think Out of the Box

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Thank You