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Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor...

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© INEOS Technologies Polyolefins Technology for the New Millennium Global Plastics Summit 2015 Randall Wu, PhD Vice President, M&S October 29, 2015 Chicago, IL
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Page 1: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Polyolefins Technology for the New Millennium

Global Plastics Summit 2015

Randall Wu, PhDVice President, M&S

October 29, 2015Chicago, IL

Page 2: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

a 3 Act play

a new beginning

Innovene™ G, S, PP

2

Page 3: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Act I

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Page 4: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

growth in the new Millenium

320 470

45005400 5800

7400

9800

35500

43600

47400

28900

36200

43000 43000

47000

-

5,000

10,000

15,000

20,000

25,000

30,000

35,000

40,000

45,000

50,000

1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013

Turn

over

-U

SD M

illio

ns

Act II4

Page 5: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

a 21st century company- Act III

Entrepreneurial & InnovativeStrategic partnerships, M&A’s and growth

JV with PetroChina forrefining and trading

Former JV with BASF nowwholly owned for Styrenic & PS

JV with Solvay for the chlorine/PVC chain (to be fully owned by INEOS in 3 years)

JV with Sasol in the US for a new 470 kta HDPE unit (start up 2017)

5

Page 6: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

A new millenium company6

Page 7: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

TechnologyHeritage

Licensees in 56 countries

384 licenses granted

Cracker

Chlor-Alkali

EDC/VCM

PE

AN

PP

MAN

EPS

PVC

Brine

Electricity

Chlorine

Innovene™ GInnovene™ S

Innovene™ PP

C2

C3

C4

C6

A new millenium company

7

Page 8: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Our polyolefins technologiesInnovene™ G

Advanced gas phaseSwing LLDPE/HDPE

Innovene™ SBimodal slurry loopsHDPE/Bimodal HDPE

Innovene™ PPPlug flow gas phasePP (homo, RCP, ICP)

• Superior mLL and HAO LL products

• Unique C4-C6-C8 comonomer versatility

• Clean Loop Process• High reliability / Low

Maintenance• Low Capex & Opex

• Superior bimodal HDPE products

• Routine Ziegler/Cr & mono-/bimodal swing Quick transitions

• No wax generation• Low Capex & Opex

• Superior ICP’s• Highest product

consistency• Unique plug flow

process• Quick transitions• Low Capex & Opex

8

Page 9: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

millions tonnes

Our polyolefins licensing successes

9

INEOS is a leading licensor of PE & PP technology50 % of our sales are based on multi-platforms

projects

Page 10: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Innovene™ G

Application TypeFilm LL C4

LL C6 or C8

mLL C6 or C8

mVLDPE

HDPE Cr

Blow Molding Medium Mw Cr

High Mw Cr

Injection Molding LLDPE

HDPE

Pipe & Conduits Non pressure

PE80

Textile Monofilament

Tape

Rotomolding MDPE C4 and C6

mMDPE

Others W&C

Geomembrane

Extrusion coating

Commercial

Metallocene VLDPE, LLDPE & MDPESuperior processability, optical & ESCR properties

Ziegler LLDPE, MDPE & HDPEVast product & application coverage with C4-C6-C8

comonomers

Chromium HDPEVast product & application coverage

10

Page 11: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Innovene™ G

INEOS Innovene™ GInnovene™ G builtInnovene™ G in design

Built : 5,400 ktpa with 39 G LinesProject : 4,720 ktpa with 13 G Lines

11

Page 12: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

An advanced gas phase

......

............

Gas & Polymer @ T (poly)

Clean loop technology with cyclones

Benefits : no circulating fines, no cleaning shutdown requirement Unique on-stream time capability

High Performance Condensation for Injecting condensation liquid into the reactor

Benefits : Effective liquid vapourisation directly into the reactor. No fluidisation issues, no liquid

pooling

......

......

......

Exchanger

Compressor

Gas & Condensate @ T (cold)

Clean Gas @ T (poly)

Liquid @ T (cold)

Clean Gas @ T (cold)

Separator

Pump

Provides outstanding operability and reliability

Cyclone

12

Page 13: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

HPLL™ High Performance Linear Low

Based on a proprietary Constrained Geometry metallocene Catalyst

Low High

Com

onom

er c

onte

ntLo

w

Hig

h

LCB Reverse ComonomerDistribution

13

Page 14: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

HPLL™ High Performance Linear Low

Based on a proprietary Constrained Geometry metallocene Catalyst

Low High

Com

onom

er c

onte

ntLo

w

Hig

h

LCB Reverse ComonomerDistribution

Extrudability

Bubble Stability

SealabilityOptics

Mechanicals

INEOS HPLL

Solution C8 Metallocene

Conventional Gas PhaseMetallocene

14

Page 15: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Innovene™ S Product CoverageApplication TypeFilm LL C4

mLL

HDPE Cr

Bimodal HDPE

Blow Molding Medium Mw Cr

High Mw Cr

Bimodal

Injection Molding Monomodal

Bimodal

Pipe & Conduits Non pressure

PE80

PE100+

PE100RC

SPC

Textile Monofilament

Tape

Bimodal

Others W&C

Geomembrane

Rotomolding

Metallocene HD

Commercial Development

Bimodal HDPESuperior ESCR/impact balance, access to leading products

like PE100RC

Chromium based HDPE & MDPEVast product & application coverage with popular grades

Ziegler based HDPE & LLDPEVast product & application coverage

Metallocene LLDPE & HDPEIn development (pilot scale)

15

Page 16: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Innovene™ S

INEOS Innovene™ S Innovene™ S builtInnovene™ S in design

Built : 2,090 ktpa with 13 S LinesProject : 7,100 ktpa with 18 S Lines

2 units Confidential

16

Page 17: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Etileno 21 the1st start up of the new wave

17

Coatzacoalcos, MexicoSeismic area

Green field projectLargest petchem investment in

30 years

Cracker & derivates750 kta HDPE

2 Innovene™ S trainsFull Ziegler/Cr product mix

State of the art process control and logistic

Signed: 2010 (Innovene™ S)Ground breaking: 2012EPC near completionStart up: Very Shortly

Page 18: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Streamlined process

Catalyst

Monomer

Hydrogen

Twin ReactorsIn Series

Bimodal Intermediate Treatment

Slurry Heater

High Pressure Separator

95% of hydrocarbon directly recycled

To extruder

Low Pressure Diluent

Recovery

FL

Nitrogen

18

Page 19: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

« Resistant to Crack PE100 designed for alternative installation

techniques »

PE100RC

PE100Requires sand bed

protection

Sand protection might representup to 50 % of the total cost !

PE100RCSandlessLaying

19

Page 20: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Innovene™ PP

Impact Copolymers Best in class stiffness / toughness performance balance

Random CopolymersSuperior clarity and optical properties

HomopolymersTailored to perform at most demanding applications,

e.g. BOPP film, fibers and injection molding

Commercial Development

Application Type

Injection Molding

Housewares

Crates & Pails

Rigid Packaging

TWIM

Caps & Closures

RTPO

Compounds

Fiber

Staple

Spunbond

Melt blown

FilmCast

BOPP

Extrusion

Sheet

Thermoforming

Non-pressure pipes

Pressure pipe

Blow molding

Foam

20

Page 21: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Innovene™ PP

INEOS Innovene™ PPInnovene™ PP builtInnovene™ PP in design

Built : 4,160 ktpa with 19 PP LinesProject : 7,350 ktpa with 20 PP Lines

Confidential

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Page 22: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

A plug flow process

First Reactor

Second Reactor

Catalyst

1. Catalyst is fed to the first reactor

2. Powder grows as polymer forms on catalyst particle

3. Plug flow of powder in reactor with gentle agitation

5. Powder transfer section keeps reactor compositions separate

4. Reactor offgas condensed and recycled – condensed monomer provides reactor cooling

6. Second reactor for impact copolymer

7. Powder goes to degasser for monomer removal and recycle

8. Powder is deactivated in purge column – purge column close coupled to finishing building for capex savings

9. Powder is melted with additives, extruded and pelletized

Simple and straight forward to operate22

Page 23: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Homogeneous ICP’s

Rubber segment through particle; (well-dispersed) “marbled”

Excellent ICP properties(Impact and Stiffness)

INNOVENE™ ICP

Rubber segment on surface;(not well-dispersed)Less ICP properties

(only Impact or Stiffness)

BACK-MIXED ICP

RubberPhase

10-20% less ethylene required23

Page 24: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Concluding remarksInnovene™ G

Advanced gas phaseSwing LLDPE/HDPE

Innovene™ SBimodal slurry loopsHDPE/Bimodal HDPE

Innovene™ PPPlug flow gas phasePP (homo, RCP, ICP)

24

3 premiere platformsWide market recognition

Access to specialties and advanced products

3 technologies, 1 single point of contact= Project & engineering synergies

Page 25: Polyolefins Technology for the New Millennium...A plug flow process First Reactor Second Reactor Catalyst 1. Catalyst is fed to the first reactor 2. Powder grows as polymer forms on

© INEOS Technologies

Solutions for the new millenium

© INEOS 2015 - Innovene™, INcat™, INcrease™, INpipe™, HPLL™ are trademarks of INEOS Technologies


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