basell pp

English

Technology

Spheripol  Process and Services Production of PP Homopolymer, random copolymer, heterophasic impact copolymer

2

3

A True Polyolefin Perspective

1. An Introduction to Basell Basell is the world’s largest

• Advanced Polyolefins Business,

producer of polypropylene and

which consists of polypropylene

advanced polyolefins products, a

compounds and other specialty

leading supplier of polyethylene

products, and

and catalysts, and a global leader in the development and licensing

• Polyolefins Business, which

of polypropylene and polyethylene

comprises polypropylene and

processes.

polyethylene.

Basell, together with its joint ventures,

Basell has its corporate centre in The

has manufacturing facilities around

Netherlands and has regional offices

the world and sells products in

in Belgium, Germany, the United

more than than 120 countries. With

States, Brazil and Hong Kong, as well

research and development activities

as sales offices in the major markets

in Europe, North America and

around the globe.

the Asia-Pacific region, Basell is continuing a technological heritage

For further information on Basell,

that dates back to the beginning of 

please see separate leaflets in the

the polyolefins industry. Basell is

pocket-page in the back of this

committed to innovation both through

brochure or visit the company’s

improvements of its processes

web site: www.basell.com.

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;

4

2

Your Partner in the World of Polyolefins Technology

2.1 Leading the Technology Race The history of Basell and its prede-

and cost-effective solutions that

cessors is one of continuing achieve-

meet the changing requirements of 

ments and breakthroughs in cata-

our customers.

lysts, process and product developments in the field of polyolefins.

Thanks to the close integration between our marketing, R&D and man-

It began with the discoveries in poly-

ufacturing, new developments of cat-

olefins technology and catalysts by

alysts, processes and products are al-

Karl Ziegler and Giulio Natta, reward-

ways focused on meeting market de-

ed with the Nobel Prize in 1963, and

mands and commercialised quickly

has continued through five revolu-

in a responsible manner.

tionary generations of Ziegler Ziegler-Natta -Natta catalysts to the development of a new metallocene-based polypropylene catalyst family and products. From the first industrial polypropylene and polyethylene processes to our latest multi-zone circulating reactor developments, Basell and its predecessors have delivered stateof-the-art polyolefin catalysts, technologies, and products to customers world-wide. For us, creating innovative polyolefin products is a way of life, delivering both superior performances

5

2.2 A Licensing Portfolio for Any Producer’s Needs Basell is the only licensor offering

❏

Spherilene, the dual reactors swing

process technologies for production

gasphase process technology for

of all PP and PE product families. Our

the production of LLDPE and HDPE

technologies are some of the most

❏

Lupotech G, the fluidised bed gas-

reliable, efficient and cost-effective in

phase technology for the produc-

the world, and can meet both the di-

tion of chromium type HDPE and

verse needs of performance plastics

MDPE or ZN based HDPE / LLDPE

manufacturers manufactur ers and those of com-

❏

Lupotech T, the high pressure tubu-

modity-oriented polyolefin produc-

lar reactor process technology for

ers.

the production of LDPE homopoly-

Basell’s licensing portfolio of process-

mers and EV EVA-copolymers A-copolymers

es and services includes the following technologies:

Some of the processes can be easily upgraded in capacity and capability

❏

Spheripol , the world’s leading tech-

to produce more sophisticated prod-

nology for the production of 

ucts, if required.

polypropylene homopolymer plus

❏

❏

random and heterophasic copoly-

Basell’s Avant  catalyst range covers

mers

titanium, chromium and zirconium-

Spherizone, this new manufactur-

based polymerisation and is the opti-

ing platform with a multi-zone cir-

mal solution for the process tech-

culating reactor system that cre-

nologies we offer. Avant  catalysts

ates polypropylene and novel,

can also be used in most other types

propylene-based polyolefinic ma-

of polyethylene and polypropylene

terials with outstanding quality

process technologies.

Hostalen, the leading low-pressure

slurry process technology for the production of bimodal HDPE

6

PP consumption trend 1975 - 2005 45,0 40,0 35,0 30,0      a        /       t        k

25,0 20,0 15,0 10,0 5,0 0,0         5         7         9         1

        7         7         9         1

        9         7         9         1

        1         8         9         1

        3         8         9         1

        5         8         9         1

        7         8         9         1

        9         8         9         1

        1         9         9         1

        3         9         9         1

        5         9         9         1

        7         9         9         1

        9         9         9         1

        1         0         0         2

3 Technology 3.1 Introduction to Spheripol  Technology Global demand for polypropylene

This includes Exxon, Dow, Borealis,

(PP) has grown quickly over many

Showa Denko, Hyundai and Sinopec,

decades. There are three major rea-

to name but a few. Today, products

sons for this:

from the Spheripol  process are routinely sold in over 100 countries, and

❏

As a well-established plastic resin

future licensees will certainly benefit

with a broad application range, PP

from this wide acceptance and prod-

usage has grown in line with the

uct standardisation standardisation..

overall economy. ❏

During their transition phase, developing countries experience rapid growth in their per capita PP consumption.

❏

There is huge untapped technical potential in PP resins, which continues to extend their usage into market segments of traditional materials 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 developed for the production of  polypropylene. Since 1982, proof of  its enduring worldwide success is the number of leading polypropylene producers choosing this technology.

        2         0         0         2

        5         0         0         2

Source: TECNON, Basell

7

3.1.1 3.1 .1 An ove overvi rview ew of Spheripol  Technology development

Today’s Spheripol  process is the re-

In the 1970s, the discovery of se-

morphology, isotacticity and molecu-

sult of forty years of continual im-

cond-generation high yield catalysts

lar weight, and continually challeng-

provement. However, to truly appre-

(6,000 kg PP/kg catalyst) eliminated

ing new frontiers in the development

ciate the unique capabilities of this

the need for catalyst residue re-

of propylene polymers.

technology, it is helpful to under-

moval, but atactic was still unaccept-

stand the evolution of the polypropy-

ably high. This simplified the wash-

Due to its low density, good physical

lene industry and the breakthroughs

ing but did not eliminate the atactic

properties and easy processability,

that led to the discovery of the

recovery steps.

polypropylene is the world’s fastest

Spheripol  process.

growing thermoplastic. In the 1980s, third generation high

In the 1960s, polypropylene processes

yield, high selectivity (HY/HS) cata-

employed first generation low yield

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

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

inated the need for catalyst and atac-

mechanically stirred reactors filled with

tic removal. This further simplified

an inert hydrocarbon diluent. Polymer

the process and improved product

produced with these catalysts had un-

quality. Other breakthroughs oc-

acceptably high residual metals, and

curred in the process design,

contained 10 % atactic polypropylene,

through the refinement of gas-phase

which required separation. Removal of 

and bulk polymerisation reactors

catalyst residues and atactic PP in-

that led to the development of 

volved treatment of the polymer with

Spheripol  technology in 1982.

alcohol, multiple organic and/or water washings, multistage drying and elabo-

Today, the capabilities of the

rate solvent, amorphous and catalyst

Spheripol  process are further en-

separation systems. These processes

hanced by the current catalyst gene-

were costly and difficult to operate,

ration, which has the ability to pro-

and also required extensive water

duce new families of reactor reactor-based -based

treatment facilities, and catalyst residue

products with improved properties.

disposal systems.

They offer even greater control over

8

3.2 Spheripol  Key Characteristics

The Spheripol  process offers li-

self), recovery and recycling of unre-

censees a simple and economical

acted monomers, and the absence of 

method of producing a wide range of 

undesired by-products from the reac-

PP products of the highest quality.

tion.

Today, more companies are using the Spheripol  process than the technolo-

Reliability

gies of the three closest competitors

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

combined.

analysis of operating records from

The unmatched success of  Spheripol 

over 80 Spheripol  process plants

technology is a result of our focus on

worldwide, showed the average

polyolefins and a commitment to

overall operability rate is about 98 %.

continuous improvement.

Of an average 2 % downtime, less than 1 % is due to process features.

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 consumption 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-

9

Versatility

Design flexibility

Dedicated support

In comparison with any gas-phase

A range of single line capacities

The experience of Basell's dedica-

technology, a Spheripol  process

from 40 – 450 kt/a are available f or

ted technology team is made avail-

plant offers on a single polymeriza-

homopolymer,, random copolymer homopolymer

able to Spheripol  process licensees

tion line the widest range of ho-

or heterophasic impact copolymer copolymer,,

to ensure the highest degree of suc-

mopolymers, random copolymers

either using polymer or chemical

cess during project implementation

and terpolymers, as well as het-

grade monomer.

and plant operation.

erophasic impact and specialty impact copolymers covering all PP ap-

Modular installation

plication fields. Intense efforts in

By a modular installation, Spheripol 

product application development

process technology is easily adapt-

for all the major market areas in the

ed to meet changing market re-

world, ensures Basell's PP products

quirements when new business op-

keep a leading position in most

portunities arise for licensees. This

profitable market segments, with

flexible modular design has virtual-

excellent results in PP specialties

ly no impact on initial investment

and "high quality" demanding appli-

costs. On existing plants, expan-

cations development.

sions of up to 30 - 4 0 % of the initial capacity have been achieved

Quality

through minor adjustments.

Spheripol  technology delivers un-

matched quality with minimum

Low capital and operating costs

property variation due to excellent

Capital costs for the Spheripol 

process stability and the consisten-

process are competitive with cur-

cy of Basell's catalysts performance.

rently available PP processes. The technology also offers the lowest operating costs and excellent plant reliability and transition efficiency. efficiency.

10

3.3 Process Description

The Spheripol  process, using high

Bulk polymerisation employs tubular

yield/high selectivity (HY/HS) catalysts

loop reactors filled with liquid propy-

supplied by Basell, has the unique abil-

lene to produce homopolymer and

ity to produce polymer spheres direct-

random copolymer or terpolymer. terpolymer.

ly in the reactor. Spherical polypropy-

The catalyst, liquid propylene and

lene differs considerably from the

hydrogen for molecular weight con-

small, irregularly shaped, granular par-

trol are continuously fed into the

ticles produced with some other tech-

loop reactor. Residence time in the

nologies and provides significant ad-

reactor is lower than other technolo-

vantages in terms of process reliability.

gies because of the high monomer

The Spheripol  process is a modular

density and increased catalyst activi-

technology. In its most widely adopted

ty. The loop reactor is used because

configuration the polymerisation sec-

it offers low cost, high heat transfer

tion involves the following main units:

and maintains uniform temperature, pressure and catalyst distribution.

❏

Catalyst feeding

The low residence time also results

❏

Polymerisation

in short transitions during grade

- Bulk polymerisation (homopoly-

changes, while the complete filling of 

mer/random copolymer and ter-

the reactors eliminates any risk of 

polymer)

contamination between different

- Gas-phase polymerisation (heterophasic impact and speciality

terface between the actual reaction

copolymer) - option (gas-phase

volume and disengagement.

copolymer unit can be added at a later stage without affecting initial plant configuration or involving significant implementation costs) ❏

grades due to the presence of an in-

Finishing

11

Spheripol  process

Propylene + Hydrogen Steam Catalyst

Ethylene Nitrogen

Propylene + Hydrogen Ethylene

To polymer handling and extrusion

12

A homogeneous mixture of poly-

(ethylene/propylene rubber) formed

propylene spheres is circulated in-

by the introduction of ethylene is al-

side the reactor loop. If the produc-

lowed to polymerise within the ho-

tion of random copolymer or terpoly-

mopolymer matrix that resulted from

mer is desired, ethylene and/or

the first reaction stage. The carefully

butene-1 are introduced in small

developed pores inside the polymer

quantities into the loop reactor. This

particle allow the rubber phase to de-

process achieves very high solid con-

velop without the sticky nature of 

centration (>50% by weight), excellent

the rubber to disrupt the operation

heat removal (by water circulation in

by forming agglomerates.

the reactor jacket) and temperature control (no hot spots). The resulting

Fluidisation is maintained by ade-

polymer is continuously discharged discharged

quate recirculation of reacting gas:

from the reactor through a flash

reaction heat is removed from the re-

heater into a first-stage de-gassing

cycled gas by a cooler, before the

cyclone. Unreacted propylene from

cooled gas is recycled back to the

the cyclone is recovered, condensed

bottom of the gas-phase reactor for

and pumped back into the loop reac-

fluidisation. This type of gas-phase

tor.

reactor is efficient because it maintains a high degree of turbulence in

For the production of impact and

order to enhance monomer diffusion

specialty impact copolymers, poly-

and reaction rates, and offers an effi-

mer from the first reactor is fed to a

cient heat removal system.

gas-phase fluidised bed reactor that

Some speciality products, incorpora-

operates in series with the loop reac-

ting two different ethylene content

tor (this gas-phase reactor is by-

copolymers, require a second gas-

passed when homopolymer or ran-

phase reactor in series.

dom copolymer is produced). In this

In impact copolymer production, at

reactor, an elastomer

least 60% of the final product is pro-

13

duced in the first-stage loop reactor. reactor. In addition, since ethylene is more reactive than propylene, the gas-phase reactors are smaller than would be required if this design were to be used for homopolymer production. Spherical morphology ensures high reliability and elimination of fouling phenomena, 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 discharged 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.

14

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 Audits prior to commissioning and start-up. All licensed sites receive visits from a team of specialists experienced in diverse 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 assists the licensee with any safety, health or environmental concerns regarding the process and related facilities.

15

3.4.1 Intrinsic safety of the process

3.4.2 Spheripol : Technology designed to lower environmental impacts

The design of each Spheripol  process

Spheripol  process units are config-

plant includes a number of safety

ured so that unreacted monomers

features, such as:

are recovered and recycled. If necessary, other discontinuous hydrocar-

❏

❏

Proprietary Catalyst Deactivation

bon purges can be sent to "off-gas

System, which immediately stops

recovery” for use as a fuel supply or

all reaction

to a flare system.

Computer controlled emergency shutdown systems

The Spheripol  process does not use

Uninterruptible Uninterruptibl e Power Supply (UPS)

hydrocarbon diluents nor contami-

for computer control and critical

nant chemicals and the only waste-

instrumentation control

water is released from the steam-

❏

Instrument air emergency buffer

ing/drying section of the plant which

❏

Emergency Blowdown System to

contains steam condensate and a

empty the plant quickly, in the

small amount of inert polymer fines,

event of an emergency

which are recovered by a separator.

❏

❏

Gas detectors which instantly determine and highlight (on a graphic 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, controlled fashion, more rapidly by both manual and computer control, or by instant automatic shutdown.

16

3.5 Process Capability 3.5.1 Design Flexibility Spheripol  process plants are de-

a later date to produce heterophasic

signed to meet the particular require-

impact and speciality impact copoly-

ments of individual licensees, yet

mers. Impact copolymers are more

they are flexible enough to be easily

specialised products, which require

expanded to meet future needs as

additional capital investment and

the business develops. Two critical

technical support.

design elements that are easily ex-

The simple design of a Spheripol 

panded include capacity and product

process plant does not require

range.

mandatory equipment or instrument/electrical vendor lists. There is

Spheripol  process facilities have been

also a list of suitable suppliers and

designed with capacities ranging

designs for critical equipment, en-

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

abling purchasers to benefit from the

ty range and the modular installation

most economic pricing available.

approach allows, within limits, easy debottlenecking. This minimises initial capital costs and allows new capacity to be added later when required. 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 homopolymer plant can be easily expanded at

17

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

3.5.2 Versatility

3.5.3 Advanced Process Control

Spheripol  technology's versatility is

Although the standard control sys-

demonstrated by its easy process op-

tems are highly capable of control-

eration and ability to deliver a pro-

ling the process reliably and effi-

duct range that includes all standard

ciently, Advanced Process Control

polypropylene grades, and many

software can be made available to

unique, special products.

Spheripol  licensees in order to fur-

ther benefit from the process capaKey to this versatility is the applica-

bilities.

tion of Basell's high yield / high selectivity Avant  catalysts: ❏

High polymerisation activity (mileage over 40,000 kg PP/kg cat-

3.5.4 Simulation / Operator Training program

alyst), resulting in extremely high ❏

❏

❏

❏

polymer purity

A special developed simulation pro-

Stereospecificity Stereospecificit y control of poly-

gram is used for training and deve-

mer

lopment purposes, and can be made

Morphology control of particle

available to Spheripol  licensees. The

size, shape and distribution

program allows training for start-up,

Molecular weight distribution con-

steady state, grade-change and shut-

trol

down operations, and can assist in

Use of polymer or chemical grade

optimising your Spheripol  plant.

monomer ❏

Homopolymer, random copolymers and terpolymers, heterophasic impact and speciality impact copolymer production

18

3.5.5 Technol echnology ogy Summar Summary y

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-

Spheripol  process operation is not affected by the

ment size scale up problems and constraints in

presence of critical machines. Complete monomers

plant operation economics due to monomer losses

recovery is possible even in case of chemical grade

and mechanical weakness.

monomer use. Catalyst yield is higher higher..

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 criticality in equipment sizing or reactors configuration) configuration)

Gas-phase operating window is limited in terms

Hydrogen response is higher. Loop reactors design

of hydrogen response and heat removal.

and liquid monomer operation grants extremely efficient heat removal and temperature control.

Spheripol  technology ensures better product quality and reproducibility

Other Processes

Spheripol  Process

Polymer morphology may affect process reliability

Controlled morphology of the polymerising particle

and represent a constraint to finishing efficiency

(independently from average particle size) improves

and complete monomer recovery. recovery.

finishing efficiency and eliminates risk of fouling when producing impact copolymers even at high ethylene content.

Catalyst system distribution and process parame-

Polymerisation conditions are completely homoge-

ters control is more critical.

neous and can be reproduced exactly any time by simple parameter selection.

Hydrogen response is limited and reactors cascade

Hydrogen response is very high, catalyst system ca-

operating mode (bimodal operation) is not available.

pabilities and bimodal operation mode allows for accurate control of product quality in a wide range of  properties.

19

Spheripol  technology provides the easiest and cheapest grade change

Other Processes

Spheripol  Process

Cumbersome product transition from grade to

The switch from one grade to another is particularly

grade, especially when switching to or from copo-

easy, quick, and low cost because hydrogen composi-

lymers. Presence of an interface between polymer

tion can be adjusted immediately without reducing ca-

bed and disengagement section increases risk of 

pacity and impact copolymer production can be star-

product contamination.

ted by just feeding homopolymer to copolymer reactor.

Off-grade material associated with each cam-

Very low residence time, allowed by extremely high

paign takes up a recognisable portion of the pro-

reactivity conditions, minimise transition material.

duction. Full reactors avoid product contamination .

Spheripol  technology has reduced environmental impact to negligible levels

Other Processes

Spheripol  Process

Conventional approach.

Extremely high attention to environment environmental al and safety considerations due to the "liquid phase hydrocarbons culture".

Lower efficiency associated with hydrocarbon hydrocarbons s

All monomer residues are recovered to the polymeri-

polluted nitrogen stream recovery and polymer

sation thanks to the unique "live steam” stripping

residual volatiles.

which ensures a complete polymer "finishing”.

20

3.6 Process Economics 3.6.1 Reliability and operability The Spheripol  process has proven to

Products from the Spheripol  process

be extremely reliable. In use since

are superior in quality. The Spheripol 

1982, it has been continuously re-

process was designed around the

fined and optimised. Yearly world-

catalyst to minimise property varia-

wide surveys of operating Spheripol 

tions and to ensure consistent results

process lines reveal an average on-

with regard to:

stream operability of around 98%. Key contributors to this remarkably

❏

Particle size and shape

high operability include:

❏

Crystallinity and stiffness

❏

Melt flow

A simple, straightforward process

❏

Molecular weight distribution

design with simple and reliable

❏

Comonomer distribution

equipment

❏

Physical and optical property per-

❏

❏

Easy on-line product change

❏

Rapid restart after shutdown

❏

No scheduled maintenance down-

High catalyst mileage results in ex-

time for cleaning or inspection

tremely low residual metal content.

purposes

3.6.2 Quality 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.

formance

21

3.6.3 Consumptions

Spheripol  process plant capital and

operating costs are among the lowest 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 consumption

Typical specific consumption (per 1000 kg of PP produced)

Monomers (kg)

(1)

3 (2)

Hydrogen (Nm )

Catalysts & Chemicals ($) Electric power (kWh) Steam (kg)

(5)

Cooling water (m3) 3

Nitrogen (Nm ) (1) (2) (3)) (3 (4) (5) (6)

(4)

(6)

(3)

Homopolymer

Impact Copolymer

1002

1002

0.01-0.5

0.01-0.5

22-25

23-26

250-270

280-300

280

280

110

120

15

15

Net consumption of 100% monomers / co-monomers included Depending of reactor gas composition, according to polymer MFR Typ ypic ica al Gen ene era rall Pur urp pos ose e st sta abil ilis isa ati tio on Extrusion included, consumption depending on product MFR Low pressure steam, high pressure steam consumption for extruder die plate or barrels heating is excluded At T = 10°C

22

3.7 Products and Applications

Isotactic polypropylene is well suited

ties and sealing initiation tempera-

for a variety of end uses, ranging

tures in compliance with the U.S.

from flexible and rigid packaging to

Food and Drug Administration (FDA)

fibres and large moulded parts for

regulations for food contact.

automotive and consumer products.

Heterophasic copolymers with out-

Polypropylene is recyclable, an im-

standing low-temperature behaviour,

portant consideration in many pack-

high-impact strength and enhanced

aging and automotive applications,

stiffness can be obtained in the

and it can be incinerated without

widest range of melt viscosities.

toxic emissions. It can be processed

As a global average, homopolymer

using most methods including extru-

accounts for 65-70 % of all

sion, extrusion coating, blow mould-

polypropylene, random copolymer

ing and stretch blow moulding, injec-

and terpolymer for 10-15 % and het-

tion moulding, and thermoforming.

erophasic copolymer for 15-20 %.

Its physical properties can be easily enhanced through the addition of 

Film and fibre are the two largest

fillers such as calcium carbonate or

segments in the global PP market,

talc. Polypropylene has excellent

but injection/blow moulding and ex-

chemical resistance and electrical in-

trusion account for significant quan-

sulating properties.

tities. Typical polypropylene fabrica-

Typical applications for polypropy-

tion processes and end uses include

lene products produced in the

the following major fields:

Spheripol  process include fibres and

filaments, oriented and cast film, in jection-moulding items, blow-moulded bottles and parts, and thermoformed containers. Random copolymers can be produced with excellent optical proper-

23

By courtesy of SIMONA

Fabrication Process

Markets/End Uses

Film Extrusion

BOPP film / WQB film / cast film/ (flexible packaging for textiles, confectionery, bakery and cigarette wrap)

Multifilaments

woven sacs (raffia)/fibrillated tape for carpet backing, geotextiles, 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 

range of PP products, including ho-

high quality levels, where excellent re-

manufacturing products with virtually

mopolymers, random copolymers and

sults have been achieved.

unlimited combinations of physical

terpolymers, as well as heterophasic

properties to meet the increasing de-

impact and specialty impact copoly-

For better evaluation of the capabili-

mands of customers in new and more

mers covering all PP application fields.

ties of the Spheripol  process, and to

challenging applications.

Extensive product application develop-

demonstrate its superiority to any

ment has enabled products from the

competing technology, listed overleaf 

In comparison with any competitor

Spheripol  technology to keep a leading

are some of the Spheripol  process

gas-phase technology, a Spheripol 

position in most market segments

products which ensure Basell's leading

process plant is making available on a

worldwide, and particularly in PP spe-

position in specialties and high perfor-

single polymerization line the widest

cialties and applications demanding

mance PP market segments:

24

.. Copyright Citroen Communications

Homopolymers ❏

❏

❏

Very high processability BOPP, for

terpolymers

application on very fast tenter ma-

A new family of very high clarity ran-

chines (over 300 m/min).

dom copolymers of propylene and

Single and multi-layer cast film

butene-1 with less hexane extracta-

produced on high-speed lines

bles (very important for food con-

using new grades particularly suit-

tact) is under commercial develop-

able for thin gauges.

ment. Uses will include high perfor-

Fine denier continuous filament

mance cast film application with dif-

and non-woven fabrics products

ferent stabilization package as well

for disposable clothing, lining,

as for extrusion applications, such as

medical hygienic, feminine care,

thermoforming, blow molding, sheet

diapers, crop protection in agricul-

extrusion and blown film.

ture. ❏

Random copolymers and

High clarity gamma ray resistant for syringes injection grade.

In addition, a number of new commercial grades have been successfully introduced to the market for very high stiffness homopolymers (Flexural Modulus higher than 2300 MPa) for injection and thermoforming.

25

Heterophasic impact copolymers ❏

Improved impact/stiffness balance

with very high creep resistance are

copolymers for corrugated pipe,

now available for pipe applications.

injection and thin wall injection-

There are also a whole family of high

moulding applications. These

rigidity "ultra" grades for fast injec-

grades have been recently intro-

tion applications, and high clarity im-

duced on a commercial scale and

pact grades for cosmetic packaging

made available to the Spheripol 

and houseware.

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 presenting extremely high impact resistance even at very low temperatures. These reactor grades were developed in the Spheripol  process to the requirements of all major car manufacturers in Europe.

❏

In addition, heterophasic copolymers

High impact for special applications such as a low MFR grade free of fish eyes for film and tape or extrusion and blow moulding.

26

4 Licensing Customer Services

During the development of a project

also described. Payment conditions

and throughout the operation of the

vary from lump sums to running roy-

plant, experts from the Licensing De-

alties, or an appropriate combination

partment and the Technology Trans-

of both these elements.

fer Centre will be dedicated to the li-

Further sections of the License

censee’s needs in the following areas

Agreement stipulate the project as-

of activity:

sistance, particularly during commissioning and start-up of the plant and

Licensing process

the performance testruns, by Basell

Prior to the granting of a license,

experts in process design, polymeri-

Basell will actively participate in the

sation, extrusion and quality control.

definition of the project, based on

Other more formal chapters cover se-

the product and marketing expecta-

crecy, liability, patent issues, force

tions from the customer. This stage

majeure, applicable law, etc.

defines the optimal technology and particular design features - such as capacity, reactor configuration, catalyst system, etc. - under a confidentiality agreement. Once the scope of the plant has been  jointly identified, a draft License Agreement will be prepared and negotiated; the agreement will contain articles that define the type and capacity 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

Business start-up support

27

Basell is open to discuss possible sup-

❏

Equipment list + data sheets

ply of resins from Basell production for

❏

Instrument list + data sheets

pre-marketing of resins by the li-

❏

Safety valve list + data sheets

censee, and use the Basell marketing

❏

Plot plans

and sales organisations to support the

❏

Safety design criteria

licensee in the development of the

❏

Emergency flaring load

polyolefins business, by agreement on

❏

Fluid list and piping classes

defined off-take volumes of resins

❏

Environmental Environment al information

until the licensee can market the entire

❏

Guidelines for the operating manu-

production volume itself.

al ❏

Etc.

Process Design Services Engineering

Ideally the Basic Engineering may be

The Process Design Package (PDP)

provided by a contractor with a

provided by Basell Process Design

proven record of the Basell technolo-

contains a comprehensive technical

gy. Alternatively this can be done by

description of the entire process, and

another contractor on the basis of 

is adequate to allow for the prepara-

the PDP.

tion of the engineering of the plant,

The Detailed Engineering – at least in

application to authorities for environ-

part - is typically done by a local en-

mental licenses, and the preparation

gineering company in the region of 

of the operating manual. Typical PDP

the license plant.

content is:

Experts from Basell Process Design can assist the engineering activities.

❏

Process description

❏

Process flow diagram (PFD) with heat and material balances

❏

Piping and instrument diagrams (PIDs)

28

Technology Transfer:

Start-up support and guarantee

Besides some initial support during

testruns

the licensing process, the main ser-

A start-up team, consisting of Basell

vices provided to the Licensees by

expert operators, will provide assis-

Technology Transfer are in agree-

tance during pre-commissioning and

ment with the Licensing Agreement,

commissioning of the plant.

and consist of the following:

After completion of the commissioning, Basell HSE experts will partici-

Training

pate in a Plant Safety Audit to verify

Prior to the start-up, highly experi-

the adherence to the Safety Design

enced trainers at Basell’s training

Criteria, with special attention to

centres (Ferrara, Italy / Bayport,

health and environmental concerns.

Texas, USA / Aubette, France) will

The start-up team will assist during

train licensees’ experts on Opera-

the start-up, in order to obtain a safe

tions, Quality Control, Maintenance,

and reliable start-up, and normally

Applications and Safety. Comput-

remain until the performance guaran-

erised dynamic process simulators

tee testruns have been finalised.

are available to enable licensees’ personnel 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 accommodation, interpretation, transportation, visas, etc.

29

Technical support after start-up

❏

While the full commercial operation

Advice on maintenance and quality control procedures

of the plant will soon become a rou-

❏

Marketing exchange

tine business of the licensee, devel-

❏

New product development or adjust-

opments in the world of polyolefins will continue.

ments to local markets ❏

Safety information about Basell, its

Meetings with focus on licensee’s

 joint ventures and/or licensees will be directly shared unconditionally, in

Periodical Technical Exchange issues

❏

Periodical seminars / conferences

order to continue to improve the

with focus on safety, best practice

safety standard of our technologies.

and breakthrough in process and

In order to further benefit from

catalysts

Basell’s technical knowledge and developments, licensees can enter into

Engineering services

a Technical Support Agreement (TSA)

If market conditions change, and the

with Basell, typically comprising the

capacity of the plant needs to be in-

following elements:

creased, or a variation in the product grade slate needs to be made, Basell

❏

❏

Explanation and details of technical

can assist in the engineering activi-

improvements within the scope of 

ties needed to upgrade the plant ac-

the original License Agreement

cordingly.

Non-confidential information on Basell’s R&D progress that goes beyond the current license

❏

Further training sessions

❏

Optimisation of plant efficiency: trouble shooting / trial for new products / new catalyst implementation, provided with technical assistance at the customer’s site

30

Source: Nasa

Basell Technology Licensing – Conclusion

Basell is unique in providing excellent process technologies for all polyolefin production for all fields of  product applications. This, together with our drive for customer satisfaction, continuing R&D developments, and the support from the organisation of the world leader in polyolefins, will make Basell technology the optimum choice for your polyolefin production, now and in the future.

31

   l     n     l   i   a  r   e   l   c  a  s  e   w  a   b   y    B   e  a    l    l    h  g   d  e    t   s   n  e    t   i   z  a   a   d   i   r   B    h   u  o   l    t   l    l    h   c   a   e   n   t   r   i   u   h   u  ,   a  s   s   d    t   n  e  n  n   e   i    l   a  e   y  v   o  p   b   s  m   e    l   a   i   d  o   r   e  n    d    l   o  n  n   g   i   u  s   i   o  s   s   d    h  e   g  n   s  r   p  n  a    i  ,   y  x   t   e  e   i   n    h  ,   r   i   o   y  w    T   n    i  .   t   n   n   e  a   i   p   s  r   t   o   u  r   p  s   a  e   ’    l    d  w  c    l   e   e    d  a  x   e  s   a   n  e   l   e   t   l   B    t   e   u  s   t   n   t   a    i    i    t   a  e   e  s   B  c    h   n    f    i    t   o  o  r   r   c   f   p   o   t   l   e    f   o  a  s   e  n   h    l   e  a    b  s   b   h   c   a  e   r    t   o  n  u    i   u   d  o  p   s   t   s   e  e   s  n   i    h    i    t   t   e   i    t   m    l   c    i   f    b   u   u   a  o    d  c    i   o   l   d   o   r   d  y  n   u   p  s   n   f    i   e   h  a  e   r    h    t   T  e  r  .   m  o    t   )   a   u   t   m  s  c    h    t   o  s  u   c  .   a   d   n   l   o   o   l   r    i   o  r    t   e   s   s  p   a  a   e  e   n   b   i    i  .   t   h   m   n   t   r   w  a   f   e  w  r   r   o    t   e  w  a   t    d   t   w  n   a   e    t   l   m   n   l   h   e   e  e  c    d  s   u   s  c   a   n  a  e   l    B   e   p    k   p   e   e  m  a  r    d  o   s   r   m    i   n    f    i   o   e   t   s   n   l   m    i    b   d   w   a  e  a   o   l    i   z   l   c   r   a   i   r   l    i   o   l   e  v   a   h  a    h    t    t   e   r   o   e  r   u   a   f    k  a  s   s   i   y   a   t   m  e  e   d   e   e  .    d   h  n   s    l   o  m   e  e   u   S  o  r   o  a   N   g   e  a    h   t   v  m   s  a  .   i    D  e  s   a   s   r   y  s   u   d    l   e   t   o   p   s   f   e   c   y   x  r   u  a  r   a   u  e   l   r   S  p   p   e   l   r   e    h    h   a  a   t   m    t   i    l  ,   e   o  r   x   e  u   c  g  e    d   t    i   n   n  a   t   r   i    t   r   a   M    i    (   a  r   o  ,   s  .   p   r   y    l   a  w  e   e   l   v    i   n   t    i   m  a  r    i   o   g   o  e   f   d  n    t   u   s   l   s  e   e  p   u   d  s  ,   c  n  e  r    l   n  g  ,   a   t   a   a    t    i    i   c   l   y   f   e   t   u  e  r   i   s   n    d   f   o   e   a  y  w  u   o   r   q   r   s   t   p   t   i   e  e    i   h  s    l   c   l    l   u   b   t   e   d   o  n   a   o   s    t   s   c   a  o  n  s  ,    B  r   a   l   e   l   p   h   a   a   l    i    l   c  n   g  e  r   U  c   n  s   e  .   e   p    i   a   e   s   B  m  e  s   u  e   f   y  r   o  o  o   e    f    h   r   t   y   l   o  e   t   p   l   e    f   e  s   n  m    b    B  u  a   r   e  a

Corporate Centre

North America Regional Office

Australia Sales Office

Basell B.V. Hoeksteen 66 2132 MS Hoofddorp The Netherlands Tel. +31 20 4468 644 Fax +31 20 4468 649

Basell North America Regional Office and Research & Development Centre 912 Appleton Road Elkton, Maryland, USA 21921-3920 Tel. +1 410 996 1600 Fax +1 410 996 1660

Basell Australia Pty. Ltd. Level 2, 199 Toorak Road South Yarra VIC 3141 Melbourne Australia Tel. + 61 3 9829 9455 Fax + 61 3 9829 9431

Europe Regional Office

Basell North American Advanced Polyolefins Business and Technical Centre 2727 Alliance Drive Lansing, Michigan, USA 48910 Tel. +1 517 336 9600 Fax +1 517 336 9611

For more information on Basell licensing services, Spheripol  technology, or engineering engineering,, technical and marketing services, please contact: [email protected]

Basell Polyolefins Company B.V.B.A. Woluwe Garden Woluwedal 24 1932 Zaventem (Brussels) Belgium Tel. +32 2 715 80 00 Fax +32 2 715 80 50

Main European Sales Offices* Advanced Polyolefins

Basell Deutschland GmbH Industriepark Hoechst Building B 852 65926 Frankfurt am Main Germany Tel. +49 69 305 85800 Fax +49 69 305 85803 Polyolefins Europe

Basell Deutschland GmbH Bruehler Strasse 50389 Wesseling Germany Tel. +49 2236 726000 Fax +49 2236 726034 * For a complete list of Basell European sales offices, please visit www.basell.com

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

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.

   5    0    /    6    0   e    C    L    5    4    0