UNIPOL™ Polypropylene Technology

Simple and ReliableBroadest Product Range

Low Investment CostLow Operating Cost

Easy To OperateOutstanding Profit Potential

Setting the standard for polypropylene process technologyBy any measure, including process design and operation, catalyst performance, products produced, economics, and value as well as technology advancement and licensee support, UNIPOL™ Polypropylene Technology is considered an industry leader worldwide. Here are the reasons why:

Simple, Reliable, Proven Technology – UNIPOL Polypropylene Technology is an all gas-phase technology that is stable and predictable, and designed to have fewer moving parts and less equipment than any competing technology. UNIPOL Polypropylene Technology is the least complex process of all polypropylene technologies. The simple process design leads to lower capital costs and lower operating costs, while maximizing reliability and lowering maintenance costs.

Although mechanically simple, the underlying technology enables the production of homo-polymers or random copolymers in a single reactor plant design regardless of capacity. The same plant can also produce impact copolymers with the addition of a second reactor of identical technology. This feature of UNIPOL Polypropylene Technology enables producers exceptional flexibility to easily change their product mix to meet market demands both now and as markets develop in the future.

The simple, reliable design of UNIPOL Polypropylene Technology, coupled with SHAC™ Catalyst Systems and CONSISTA™ Donor Technology from Dow, offers another significant economic benefit – the ability to operate the plant above nameplate capacity.

Plants utilizing UNIPOL Polypropylene Technology routinely run above nameplate capacity, delivering even higher return on the original investment. In fact, this technology delivers the highest on-stream time in the industry, with exceptional aim-grade per-formance to further enhance the capacity of UNIPOL Polypropylene Technology.

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UNIPOL™ Polypropylene Technology

If you are evaluating options for

large-scale polypropylene production,

you know there is more to consider

than just the unit operations of

the process technology itself.

Successful resin producers

understand the need for a process

that delivers a broad range of market-

leading products; low operating

costs to help ensure sustainable

profitability; ease of operation;

and continuous technology

advancements and support to

keep them competitive and market

leading year after year.

It is for those reasons, and

more, that leading resin producers

around the world have chosen

the UNIPOL™ Polypropylene

Technology, marketed and

supported worldwide by

The Dow Chemical Company.

A Smart Choice for Profitable Polypropylene Production

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Broadest Product Range – UNIPOL™ Polypropylene Technology can make the broadest range of polypropylene products available. From commodity raffia grades, to market leading BOPP (biaxially oriented polypropylene) grades for today’s high-speed lines, to unrivalled random copolymers, to high-performance impact grades for automo-tive and aerospace applications, UNIPOL Polypropylene Technology offers both market-leading and competitive products that are proven performers.

Utilizing CONSISTA™ D7000 Donor, resin producers can now make high melt flow impact copolymer polypropylene resins for automotive interior and food contact appli-cations without post-reaction cracking.

And of equal importance is the fact that every licensee has access to the full complement of improved products as they are developed. As a producer, you have the ability to tailor your product selection to meet the demands of your custom-ers in your markets, helping to maximize your return on investment in UNIPOL Polypropylene Technology.

Catalyst Portfolio – Experienced polypro-pylene producers recognize the importance of the catalyst system in the operation of the process. For polypropylene producers, SHAC™ Catalyst Systems are the best catalyst systems to deliver market-leading products, world-class operability, and com-petitive conversion cost. The portfolio of SHAC Catalyst Systems includes a range of custom-engineered, integrated catalyst and Advanced Donor Technology (ADT) – the Dow external donor systems that enable efficient, economical production of our broad product line.

The CONSISTA Donor Technology is specifi-cally designed for high melt flow applications and is compatible with the existing portfolio of SHAC Catalyst Systems.

SHAC Catalyst Systems, ADT, and CONSISTA Donor Technology, while designed for use in the UNIPOL Polypropylene Process, are also suitable for all other gas phase polypropylene technologies.

Consistent catalyst performance that trans-lates to product consistency, our unique morphology-controlled catalysts that deliver high productivity with excellent operating reliability, and the Dow commitment to advancing the science of catalysis are addi-tional benefits that come with a UNIPOL Polypropylene Technology license.

Industry-leading Economics – A simple, reliable design coupled with efficient, consistent catalyst systems result in both low investment costs and low operating and maintenance costs for UNIPOL Polypropylene Technology. Used together, custom-designed catalyst systems and ADT enable customers to lower their raw material costs because of higher activity and lower use of peroxide. The number of catalysts producers have to carry in inventory is greatly reduced, as is the producer’s required working capital. A small plant footprint, low number of moving parts, and a streamlined process help keep land costs as well as equipment fabrication and installation costs lower than competing processes.

UNIPOL Polypropylene Technology, combined with the comprehensive Dow technology transfer services and support, result in swift and efficient project execution, putting licensees in the marketplace quickly.

The mechanical simplicity of the process, coupled with exceptional process stability and catalyst consistency, and further enhanced by UNIPOL™ UNIPPAC™ Advanced Process Control technology helps keep operating costs among the lowest in the industry.

New process, product, and catalyst developments are designed to drop into existing units to give licensees the ability to move with the market of the future while minimizing capital costs.

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Unmatched Licensee Support – Comprehensive, ongoing licensee support is a vital part of the Dow commitment to helping you succeed. Backed by more than 25 years of operating history and more than 400 reactor years of experience, the support you receive from Dow is among the most thorough in the industry. Your support starts with expert advice and counsel from Dow process experts during the evaluation stage and continues during design, construction, startup, and beyond.

Dow is committed to advancing UNIPOL Polypropylene Technology in every way we can, from a continuous investment in R&D and innovation, to new products and catalysts, to ongoing operator training and process improvements. We share our advancements regularly with licensees through our Global Technology Exchange Meetings, frequent contact with our licensees, as well as customized technical service and training sessions.

UNIPOL Polypropylene Technology – your best choiceThe information on the pages that follow detail many of the important features and benefits that make UNIPOL Polypropylene Technology your best choice for polypro-pylene production. Please contact your Dow representative or the sales office nearest you for additional help, or visit www.dow.com/unipol.

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Products

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Licensees of UNIPOL™ Polypropylene Technology know from their experience that they can produce the broadest range of products with the greatest flexibility and compete in any global market with market-leading products.

The industry’s most complete product capabilityIt isn’t just how many types of products can be produced using UNIPOL Polypropylene Technology. Equally important is the depth in each product family that enables our licensees to produce market-leading products and compete in all major market applica-tions. Licensees of UNIPOL Polypropylene Technology have access to more classes of products, and grades within those classes, than is available from any other commer-cial technology.

The ability to produce a wide range of poly-propylene resins must be a key consideration as you evaluate the process technology you will choose. Experienced resin producers have identified four important product-related questions to ask when comparing the various technologies:

•What is the breadth and depth of the product offerings?

•Does the technology allow the production of market-leading products?

•Does the process offer flexibility to allow easy and economical changes in the product mix being produced?

•Does the process have favorable economics across the entire product range?

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Figure 1: Product Line Markets Served

Product Family

End Use Applications

Film TextilesDurable & Industrial Products

Rigid Packaging

BO

PP

Cast

TWQ

Mon

ofila

men

t &

Rafi

a

Stap

le

CF &

BCF

Spun

Bon

d

Mel

t Blo

wn

Inje

ctio

n

Mol

ding

Extr

usio

n

TWM

Ther

mof

orm

ing

&

Blo

w M

oldi

ng

Homopolymers • • • • • • • • • • •Random Copolymers • • • • • • • •Impact Copolymers • • • • •

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Meet market demands through production flexibilityProducers who can’t easily and economically vary their product mix are at a disadvantage in meeting customer demands in fast-changing markets. UNIPOL™ Polypropylene Technology enables exceptional flexibility by allowing all products to be created in just two reactors (versus 3-4 reactors in other competitive processes). Homopolymer and random copolymer products can be made in the same reactor, while impact copolymers can be made with an additional identical shaped reactor.

UNIPOL™ UNIPPAC™ Advanced Process Control software automatically controls grade changes, optimizing on-stream time and minimizing the production of transi-tion material.

Keep margins highUNIPOL Polypropylene Technology sets the standard for low investment cost and low operating cost across all product types. UNIPOL Polypropylene Technology will help make you competitive in your most important markets.

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

SHAC™ Catalyst Systems and Donor Technologies

SHAC™ Catalyst Systems, ADT Donors, and CONSISTA™ Donor Technology are comple-mentary components designed specifically for the UNIPOL™ Polypropylene Technology. They are also suitable for all other gas phase polypropylene technologies. SHAC Catalyst Systems are easy to use, consistent, and contribute to the low operating cost of the process. The entire family of SHAC Catalyst Systems and Donor Systems are regularly updated, and licensees and other gas phase polypropylene resin producers can benefit from the Dow commitment to advancing the science of catalysis.

A versatile catalyst familyA range of SHAC Catalyst Systems enables the polypropylene producer to choose the best catalyst and donor combination to meet specific requirements, as shown in Figure 2.

Figure 2: Versatility of SHAC™ Catalyst Systems

Product Family Catalyst System

Homopolymers SHAC 201 Catalyst or SHAC 320 Catalyst + ADT Donor

Random Copolymers SHAC 205 Catalyst + ADT Donor

Impact Copolymers SHAC 320 Catalyst + ADT Donor

High Melt Flow Impact Copolymers SHAC 320 Catalyst + CONSISTA D7000 Donor

Simple to useAn important advantage of SHAC Catalyst Systems is ease of use. Unlike some compet-itive technologies, SHAC Catalyst Systems can be fed directly as shipped into a reactor employing UNIPOL Polypropylene Technology as well as other gas phase systems, which helps to keep operating costs low.

•No pretreatment required

•No activation required

•No pre-polymerization required

SHAC Catalyst Systems are suitable for all other gas phase polypropylene technologies.

Morphology-controlled catalysts offer advantagesCatalyst particle size and shape directly translate to polymer particle size and shape. The portfolio of SHAC Catalyst Systems includes controlled morphology catalysts with spherical particles that are consistent in size.

Compared to traditional catalysts, these high-performance systems produce powder-stage resins that are more uniform in shape. The result is higher powder flow rates and higher powder settled bulk density that enables plants to achieve the highest pro-duction rates.

5 ™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Figure 3: Controlled Morphology SHAC Catalyst and Effect on Polymer Particle

Catalyst productivity equals economyExcellent uniformity and high catalyst productivity help lower catalyst cost per unit of resin produced.

Focusing on catalyst developmentCatalysis is a core science for Dow across a wide range of chemical and polymer fields. Applying world class Dow skills and facilities, development programs for SHAC™ Catalyst Systems bring benefits to licensees of UNIPOL™ Polypropylene Technology and other gas phase polypropylene producers, as new products and technology platforms are developed. Examples include:

•Catalysts for high crystallinity homopoly-mers and blends.

•Advanced Donor Technology (ADT) to maximize reactor operating time through superior reliability, while producing advantaged polymer products.

CONSISTA™ Donor Technology is a result of the Dow R&D commitment to catalysisThe first product in the CONSISTA Donor portfolio of advanced catalyst systems is CONSISTA™ D7000 Donor. It is designed for applications that require a combination of high stiffness and high melt flow and adds to an already broad catalyst system offering that includes SHAC Catalysts and ADT Donors.

From automotive interior applications to food contact applications, CONSISTA D7000 Donor was developed to optimize the processing of high-melt impact copolymer polypropylene resins, with no capital invest-ment required, and to deliver exceptional end-product advantages.

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Controlled Morphology Catalyst

Process Benefits

•Enables a reduction in resin manufactur-ing costs through reduced peroxide usage

•Maintains the excellent operability you have come to expect from Dow catalyst and donor systems

•Compatible with the existing Dow family of SHAC Catalysts and Donor Systems

•Suitable for all other gas phase polypro-pylene technologies

Product Benefits

•Extends the in-reactor melt flow capabil-ity for impact copolymers

•Achieves high impact/stiffness balance

• Improves the polymer taste/odor profile in food contact applications due to reduc-tion or elimination of peroxide residuals

• Increases acceptability in automo-tive interior markets due to reduced C-emission levels

•Enables entry into premium markets and applications that benefit from per-formance differentiation

Polymer

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

UNIPOL™ Polypropylene Technology – Simple to Build, Operate, and Maintain

The core facility for UNIPOL™ Polypropylene Technology requires a small footprint of 60 meters by 65 meters or a total of 3,900 square meters. This includes the purification, reaction, purging, vent recovery, additive addition, and pelleting operations.

The total Inside Battery Limit (ISBL) occupies 14,000 square meters, measuring approxi-mately 115 meters by 120 meters. The ISBL area includes the core facility plus the alkyl supply, catalyst storage, laboratory, control room, and motor control center.

UNIPOL Polypropylene Technology is state-of-the-art technology, yet it is mechanically simple and easy to operate. A minimal amount of major equipment is required. There are only three to four pieces of major rotating equipment. A single reactor is used to produce homopolymers and random copolymers, plus one additional reactor in series to produce impact copolymers irre-spective of plant capacity.

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Figure 5: State-of-the-Art Process Technology with Mechanical Simplicity

Figure 4: Minimal Land Requirement

20 400

SCALE (METERS)

Simplicity

is a key characteristic of UNIPOL™

Polypropylene Technology:

• Fewer moving parts and less equipment overall compared to competing systems

• Smallest Inside Battery Limits (ISBL) footprint in the industry

• Easy access to key plant equip-ment for simplified maintenance

The result of our simple, common

sense design approach is that the

licensee will enjoy low capital

costs and the low operating costs

compared to competing systems.

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Figure 6: Simplicity of the Impact Reactor

Other benefits of UNIPOL™ Polypropylene Technology include:

•Up to 650 KTA single line capacity for full homopolymer, random, and impact grade product mix

•Uses readily available industry-standard equipment

•Least expensive standard materials of construction widely used due to non-corrosive process

•No mechanical agitation in the reactors

•Unique reaction kill system limits the rate of reaction gas venting during power outage

•Close-coupled pelleting, eliminating the need for intermediate resin storage

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The simplicity of UNIPOL Polypropylene Technology offers several additional benefits, because competitive technologies require additional processes and components. Other processes require some or all of these:

•Multiple processes to coordinate and control – as many as three in a series

•Multiple reactors needed for large capacities or advanced products – as many as five in a series

•Pre-polymerization and/or catalyst pretreatment

•Additional purification

•Stirrers or scrapers in the reactors

•Solid separation equipment

•Membrane separation unit for reactor vent gases

• Intermediate storage and conveying

The simplicity of the homopolymer/random copolymer system is mirrored in the impact copolymer stage, which operates with the same gas phase fluidized bed process in a slightly smaller reactor. For each reaction stage there are just three main pieces of equipment: the reactor, the cycle gas com-pressor, and the cycle gas cooler.

With active catalyst entering from the first stage, there is no need for additional cata-lyst feed to the impact reactor. The critical rubber component is polymerized directly in the growing polypropylene particles, achieving optimum rubber dispersion and morphology that results in the highest impact performance.

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

5 Plants in Construction/Start-up Phase46 Operational UNIPOLTM Polypropylene Technology Reactor Lines

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Pertamina 1

DatangGuangxiShunhuaFushunSichuanSinochem3

Basell 1

Ineos2

Sunoco 2

Conoco2

Dow Seadrift1

Pinnacle2FHR2

Propilco1TPI 3

PPM1

J.G. Summit1

JPC1

Hyosung1

L.G. Caltex1

Reliance8

PIC1

Ibn Zahr 3

Yansab1

Yanpet 1

OPC1

Slovnaft 1

Polychim 1

Ineos 1

Dow 1

SABIC Europe2

Stavrolen1

Figure 7: Serving Global Customers With Extensive Resources

Dow – A Strong Business ResourceFrom facilities and people in every

corner of the globe, to an R&D

budget approaching $1 billion,

Dow is focused on delivering

ongoing business success to its

licensing customers. Dow is a sci-

ence and technology leader that

supplies over 3,500 products

to customers in 175 countries.

As a licensee of UNIPOL™

Polypropylene Technology you

can be assured that the strength

and skills of this market-leading

organization and its people are

behind you in every possible way.

Global Resources to Support You Wherever You Operate

The polypropylene industry is truly global, with resin producers and converters operat-ing in every major market around the world.

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As a global company, Dow has invested in resources to support its licensees no matter where they operate.

Our investments in strong local resources are helping licensees succeed.

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Technology Transfer, Training, and Ongoing Support to Help You Succeed

Best-in-class technology transfer helps ensure a smooth plant construction and start-up or retrofit. Our goal is to help each licensee become as successful as they can be. We focus our resources on your suc-cess – from the first meeting, through plant construction, to training, start-up and com-missioning, and long-term support – using experienced Dow personnel at every step.

Plant design and technology transferThe UNIPOL™ Polypropylene Technology is thoroughly documented in manuals that cover the underlying scientific knowledge, a comprehensive process design package containing the basic engineering informa-tion from which an engineering contractor can work, and a manual of typical plant operating procedures. An experienced multifunctional client team works closely with each licensee throughout the process of turning the basic technology into a new plant and maintains support through start-up and beyond.

TrainingLicensees are trained in all facets of the UNIPOL Polypropylene Technology – from process theory to practical experience.

Initial orientation courses, covering both process and product technology, are held for technical staff and the project team. Plant staff receives thorough operations training in advance of start-up. In this comprehen-sive program, licensee personnel from plant operations, maintenance, and laboratory groups attend the Dow university-like train-ing center in Houston, Texas, USA, joining a population of graduates that already num-bers over 1,500.

Coursework in the classroom is supple-mented by training using the UNIPOL™ UNIPPAC™ Virtual Plant Simulator, a com-puter-based plant simulator that reproduces the behavior and control room displays of an actual plant using UNIPOL Polypropylene Technology. Learning is greatly accelerated as the simulator models steady operation, grade changes, and even unexpected events like utility upsets in real-time or accelerated mode. Trainee responses can be replayed for study and correction if needed. Scale models are incorporated to teach plant layout and maintenance techniques, and trainees receive manuals to retain for con-tinuing reference.

Start-up assistanceAn experienced team of Dow people, including a chief commissioning engineer and several operating specialists, provide comprehensive, on-site support, assist-ing with the commissioning and start-up activity of each licensee’s new plant. The Dow team has demonstrated the fastest total project time from license signing to producing prime product. As testimony to the exceptional technology transfer and process simplicity, plants using UNIPOL Polypropylene Technology usually achieve nameplate rates and aim-grade production within hours of initial start-up.

Ongoing support through technology improvementsLicensees can participate in a technology exchange program after their plant begins operation and will receive process and product technology improvements. This program includes our highly regarded Global Technology Exchange Meeting, held annu-ally to encourage licensees to share best practices in a group setting. Licensees also have opportunities for one-on-one sessions with Dow experts.

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Putting It All Together

Every way you look at it, a license

for the UNIPOL™ Polypropylene

Technology is your best choice, bring-

ing you all the elements you need for

a successful polypropylene project:

• Streamlined and proven gas phase technology with low investment costs

• Excellent operating economics and reliability

• Widest product flexibility with market leading grades in key applications

• SHAC™ Catalyst Systems, ADT and CONSISTA™ Donor Technology optimized for gas phase process operation

• Superior technology transfer services and long-term support

• Continuing technology development backed by the commitment and resources of Dow

™ Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, the Customer is responsible for determining whether products and the information in this document are appropriate for the Customer’s use and for ensuring that the Customer’s workplace and disposal practices are in compliance with applicable laws and other gov ernmental enactments. Dow assumes no obligation or liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED.

Dow does not endorse or claim suitability of its products for specific medical applications. It is the responsibility of the medical device or pharmaceutical manufacturer to determine that the Dow product is safe, lawful, and technically suitable for the intended use. DOW MAKES NO WARRANTIES, EXPRESS OR IMPLIED, CONCERNING THE SUITABILITY OF ANY DOW PRODUCT FOR USE IN MEDICAL APPLICATIONS.

Published December 2010

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