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TRANSCRIPT
Polyolefin innovations & new catalyst systems
Thorsten Merz - Business Team Manager, Catalyst Sales Middle East & Africa
12th Saudi-Japan Symposium15 & 16 December 2002
The Research Institute Dhahran, Saudi Arabia
Slide 1
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
�State-of-the-art: why change ?
� Basell and Avant catalysts
� Phthalate catalysts - evolution
� Diether/Succinates catalysts - revolution
� Catalyst selection
� PE 100 pipe grades
Topics
� Conclusions
Slide 2
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
� Operational problems
� Time / resources needed for trials
� Dispose of non-standard products
� Customer re-qualifications
� Loss of existing business
Why change catalysts?
Risks Rewards� Expand product capability
� Expand capacity
� Generate new business
� Better plant operability
� Improve economics
Slide 3
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
�State-of-the-art: why change ?
� Basell and Avant catalysts
� Phthalate catalysts - evolution
� Diether/Succinates catalysts - revolution
� Catalyst selection
� PE 100 pipe grades
Topics
� Conclusions
Slide 4
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Our key strength is process and catalyst integration
Slurry
Bulk Gas
SpheripolLIPP
Lupotech GSpherilene
Hostalen
ZieglerChrom
e
Ziegler Chrome
Zieg
ler-
Nat
ta
Metallocene
� Avant ZN Ziegler Natta PP
� Avant Z Ziegler PE
� Avant C Chromium PE
� Avant M Metallocene PP
Slide 5
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
MgCl2
1. Base Support
2. Titanation
3. Avant ZN Catalyst
internal donor
Catalyst manufacture
Basic principles of Avant ZN catalysts
alcohol
TiCl4
Slide 6
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Basic principles of Avant ZN catalysts - role of internal donor
With the internal donor,it is possible to modulate:
• Catalyst Activity• Stereocontrol• Hydrogen Response
• Polymer MW & MWD• Microtacticity• Oligomers Content
improvement of thepolymerisation process
improvement/tailoring ofpolymer mechanical andrheological properties
Slide 7
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
PP manufacture
Basic principles of Avant ZN catalysts - usage
external donoraluminum alkyl
1. Avant ZN Catalyst
2. Activation
3. Polymerizationpropylene
4. PP products
Slide 8
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN Range - 35 Catalysts to choose from!
Spheripol Slurry LIPPBulk
Bulk +Gas Phase
Gas Phase
Avant ZN (4th Generation: Phthalate)Homopolymer � � � � �
Random copolymer � � � � �
Heterophasic copolymer � � * � �
Avant ZN (5th Generation: Diether)Homopolymer � � � � �
Random copolymer � � � � �
Heterophasic copolymer � ‡ * � �
Avant ZN (5th Generation: Succinate)Homopolymer � ‡ � ‡ ‡Random copolymer ‡ ‡ ‡ ‡ ‡Heterophasic copolymer � ‡ * ‡ ‡
‡ - Under development / * - Not applicable for this technology
Slide 9
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Catalyst requirements for different process technologies
� Activity profiles
� Morphology
� Porosity
1st considerations 2nd considerations� Yield (mileage)
� Stereo-regularity
� Hydrogen response
� Bulk density
� External donor
Slide 10
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
�State-of-the-art: why change?
� Basell and Avant catalysts
� Phthalate catalysts - evolution
� Diether/Succinates catalysts - revolution
� Catalyst selection
� PE 100 pipe grades
Topics
� Conclusions
Slide 11
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
O O
O
OR
R
What is a phthalate catalyst?
� 4th generation
� uses phthalates as internal donor
� good morphological control
� multi-purpose catalyst
� general applications
Slide 12
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN Series Catalysts - drop-in product capability
ZN111 Catalyst vs Traditional CatalystH2 Response
1
10
100
100 1000 10000
H2 concentration (ppm)
MFR
(g/1
0 m
in)
ZN111 Catalyst Traditional 4th Gen. Catalyst
Slide 13
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN Series - superior polymerisation activity
ZN111 Catalyst vs. Traditional 4th Generation CatalystYield - MFR Response
30
40
50
60
70
0.1 1 10 100 1000
MFR (g/10 min)
Cata
lyst
Yie
ld (k
g/g)
ZN111 Catalyst Traditional 4th Gen. Catalyst
Slide 14
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
�State-of-the-art: why change?
� Basell and Avant catalysts
� Phthalate catalysts - evolution
� Diether/Succinates catalysts - revolution
� Catalyst selection
� PE 100 pipe grades
Topics
� Conclusions
Slide 15
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
What is a diether catalyst?
� 5th generation
� uses diethers as internal donor
� benzene free
� high mileage
� H2 control
� narrow MWD
� SB & MB fibres, TWIM, highstiffness IM
Slide 16
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Diether Catalysts - even higher polymerisation activity
Diether Catalyst vs Traditional CatalystsYield/Melt Flow Response
30
40
50
60
70
80
90
100
110
0.1 1 10 100 1000
MFR (g/10 min)
Yiel
d (k
g/g)
Diether Diether + D-Donor ZN111 Traditional 4th Gen. Catalysts
Slide 17
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Diether Catalysts - reaching ever higher isotacticity levels
Diether Catalyst vs. Traditional CatalystMFR vs. Xylene Insolubles
96
96.5
97
97.5
98
98.5
99
99.5
0.1 1 10 100 1000
MFR (g/10 min)
Xyle
ne In
solu
bles
(wt %
)
Diether Diether + D-donor Traditional 4th Gen. Catalyst
Slide 18
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN diether catalysts - high MFR from the reactor high MFR from the reactor
Avant ZN diether vs Traditional 4th Generation catalystH2 Response
1
10
100
1000
1000 10000
H2 concentration (ppm)
MFR
(g/1
0 m
in)
Diether Catalyst Traditional 4th Gen. Catalyst
Slide 19
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN diether catalysts - non woven applications
Slide 20
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN diether catalysts - Melt Blown Fibres
Conventional catalyst Diether catalyst
Uniform fibre thickness distribution
Slide 21
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN diether catalysts - TWIM applications
� High flow
� Faster molding &lower thicknessimprovingproductivity and cost
� Superior impact-stiffness balance
Slide 22
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
� State-of-the-art: why change?
� Basell and Avant catalysts
� Phthalate PP catalysts - evolution
� Diether/Succinate PP catalysts - revolution
� PP catalyst selection
� Avant Z 501 catalyst for PE 100 pipe grades
Topics
� Conclusions
Slide 23
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
What is a succinate catalyst?
O
OR
RO
O
RR
RR
� 5th generation
� uses succinates as internal donor
� benzene free
� broad MWD
� BOPP, pipes, injection molding
Slide 24
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN succinate catalysts - general characteristics
Homopolymers
� High isotacticity with broad MWD
� High stiffness injection molding grades
� Pipes with improved processability & physical properties
� BOPP improved cost / performance
Copolymers
� High stiffness / impact injection molding applications
Slide 25
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Succinate Catalysts - superior HeCo balance
Succinate Catalyst vs. Traditional CatalystsUn-nucleated HeCo Impact/Stiffness Balance
1100
1200
1300
1400
1500
1600
1700
1800
0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0
Izod + 23C (kJ/m2)
Flex
ura
l Mod
ulu
s (m
Pa)
Succinate/D (monomodal)Phthalate/D (monomodal)
Slide 26
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
� State-of-the-art: why change?
� Basell and Avant catalysts
� Phthalate PP catalysts - evolution
� Diether/Succinate PP catalysts - revolution
� PP catalyst selection
� Avant Z 501 catalyst for PE 100 pipe grades
Topics
� Conclusions
Slide 27
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
TWIM - inc. stiffness
Pipes,Extrusion
General IM
BOPP,Cast Film
Polydispersity Index
3.0 5.0 8.0
Isot
actic
ity (
XI)
96 %
97 %
98 %
99 %
Avant ZN catalyst selection - homopolymers
Succinate
4.0 6.0 7.0
Phthalate
Multi-modal
ProcessCapability
Multi-modal
ProcessCapability
Diether
BCF,MB
Fibre
Slide 28
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Sealing,Cast Film
High impactapplications
Pipes, Extrusion
TWIM - inc. stiffness
GeneralIM
Polydispersity Index
3.0 5.0 8.0
Ethy
lene
Con
tent
0 %
10 %
20 %
30 %
Avant ZN catalyst selection - copolymers
Succinate
4.0 6.0 7.0
Multi-modal
ProcessCapability
PhthalateDiether
Multi-modal
ProcessCapability
Slide 29
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant ZN catalysts - summary
� If new catalysts are to be successful, it is essential to have athorough understanding of the process and the products, as well asthe catalyst.
� There are risks in changing catalysts, but there may also be rewards.
� The evolution of existing phthalate catalysts is still ongoing, and willcontinue to play an important role in the future.
� The use of new revolutionary internal donors, such as diethers andsuccinates, enhance the capabilities of the catalysts.
� Basell has multiple Avant ZN PP catalysts suitable for bulk, slurry andgas phase processes.
� Basell is uniquely positioned as the leading catalyst supplier, processlicensor and PP manufacturer to generate and successfullycommercialise new innovations.
Slide 30
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
� State-of-the-art : why change ?
� Basell and Avant catalysts
� Phthalate PP catalysts - evolution
� Diether/Succinate PP catalysts - revolution
� PP catalyst selection
� Avant Z 501 catalyst for PE 100 pipe grades
Topics
� Conclusions
Slide 31
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant Z 501 - Bimodal structure property relationship
Tailoring of product propertiesbytailoring of molecular mass distribution and comonomer distribution
log M
m(log M) SCB
• very low molecular mass• homopolymer• high crystallinity� processability� stiffness
• very high molecular mass• copolymer• low crystallinity� impact strength� stress crack resistance
• broad molecular mass distribution• inverse comonomer distribution� melt flowability� long time hydrostatic strength (pipe)� strain hardening (film)
Slide 32
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Avant Z 501 - PE 100 HDPE pipe application
ADVANTAGES:
�higher stiffness (high modulus)
�higher toughness
�higher stress crack resistance(long life time under stress)
�higher resistance to rapidcrack propagation
�better processability
�Hostalen CRP 100 is listed inthe PE 100+ Association
Slide 33
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
� State-of-the-art: why change?
� Basell and Avant catalysts
� Phthalate PP catalysts - evolution
� Diether/Succinate PP catalysts - revolution
� PP catalyst selection
� Conclusions
Topics
� Avant Z 501 catalyst for PE 100 pipe grades
Slide 34
Polyolefin innovations & new catalyst systems
12th Saudi-Japan Symposium - Dhahran, Saudi Arabia15 & 16 December 2002
Conclusions
Basell predecessor companies have played animportant role in the evolution of the polyolefins
industry through new catalyst and process developments.
We expect our new revolutionary systemswill continue to shape the future of this industry.
Avant, Spheripol, Spherilene, Hostalen, Lupotech T, Lupotech G are trademarks owned orused by Basell.Spherilene, Hostalen and Lupotech are registered in the U.S. Patent and Trademark Office.