Introducing and Supporting Speciality Polymer [EVA] Applications GPCA PlastCon 7-9 April 2013 FINAL 8-4-13

Introducing and supporting speciality polymer [EVA] applications

Dr. Trevor J. Hutley

General Manager - Sipchem Technology

4th GPCA PlastCon - Dubai, UAE - Monday 8 April 2013

Sipchem4th GPCA PlastCon - Dubai, UAE - Monday 8 April 2013

• Sipchem EVA ethylene-vinyl acetate

• Sipchem PADC Product & Application Development Centre

• Product & Application Development

• Sipchem



• Sipchem

• Sipchem EVA

• Sipchem PADC



- 5 world-scale plants in Jubail, making 8 products

- producing 2.4 m tons of petrochemicals

~ 1000 employees

- a growing, private, Saudi petrochemical company

- 2011 revenue: $0.88 bn

methanol acetic acid acetic anhydride butanediol carbon monoxide maleic anhydride tetrahydrofuran vinyl acetate monomer VAM

Sipchem is

- market capitalisation: ~ $2 bn

- 5 plants under construction, 1 in the pipelineethyl / butyl acetate LDPE & EVA wire & cable compounds tools & dies EVA photovoltaic encapsulation film xxx polymer

- established in December 1999; IPO 2006start of operations 2004;

Turkey

Bahrain, Djibouti, Iran, Iraq, Israel, Jordan, Kuwait, Lebanon, Oman, Palestine, Qatar, Saudi Arabia, Syria, United Arab Emirates, Yemen; Algeria, Egypt, Libya, Morocco, Tunisia

15

MAP 1: COUNTRIES WHICH CONDUCTED SURVEYS IN 2000

Algeria

Morocco

Libya

Yemen

Egypt

UAESaudi Arabia

Kuwait

Djibouti

Sudan ***

Iraq Iran

Tunisia

Oman

Qatar

Jordan

Syria **

MICS 2 Data

Source: MICS 2 and DHS

No 2000 data

OPT *

Bahrain

Lebanon

** A separate survey has been conducted for the Palestinian population of Syria. See tables for details* For OPT, the data is presented separately for the Palestinian refugee camps. See tables for details

*** A separate survey has been conducted for Southern area of Sudan. See tables for details

DHS data MENA

Middle-East & North Africa

GCCGulf Cooperation Council

Bahrain, Kuwait, Oman, Qatar, Saudi Arabia, United Arab Emirates

Sipchem Jubail Industrial City

Sipchem HQAl-‐Khobar

100 km

2 kmSipchem PADCDhahran

Sipchem HQAl-‐Khobar

Sipchem Asset Por>olio:

Sipchemplants Jubail Industrial City

Sipchem PADC - Product & Application Development Centre

Dhahran Techno-Valley [DTV]

King Abdullah bin Abdulaziz Science Park [KASP]

King Fahd University of Petroleum & Minerals [KFUPM]

PADC conceptual design - acrylic model

PADCProduct &Application Development Centre

Business & Strategic Development

InstitutesKACSTHIPFUniversitiesKFUPMKAUST

Corporate Structure

SM

SipchemMarketing

Aectra

Singapore

International Methanol Company

International Diol

Company

International Acetyl

Company

International Vinyl Acetate

Company

International Gases

Company

1000k+ t 75k t 345k t 460k t 330k t

65 % 54 % 72 % 76 % 76 %

MeOH MAn BDO THF

CO AA AAn VAM EA W&C EVA

IPC

International PolymersCompany

75 %

200k t

IMC IDC IAC IVCIGC

Sipchem

SCC

Sipchem Chemical Company

100 %

100k t

25k t

50 %


• Sipchem

• Sipchem EVA

• Sipchem PADC




May 2009

Sipchem became the 9th licensee of the ExxonMobil high-pressure tubular technology for EVA and LDPE

A 200,000 ton plant is under construction........

start-up: 4Q13


LDPE

crystallinity

branching short-chain branching

long-chain branching

poly (ethylene)

densityρPEA 0.853

ρPEX 1.004

15- 25 short-chain branches per 1000 carbon atoms

ethylene


polymerdemand 2011 (000,000 tons)

LDPE 18.5

HDPE 34.7

LLDPE 22.9

UHMWPE 0.2

PP 52

EVA

ethylene - vinyl acetate copolymer

3.4

TOTAL 132

76.30

Global polyolefin demand:

EVA


• since PE is so successful, why do we need EVA ?

- co-monomers modify the properties of LDPE

- polarity

- crystallinity

transparency

➔ elastomeric / tough

➔ adhesive

- VAM [vinyl acetate monomer] modifies the properties of LDPE

impactpuncture

heat-seal; compounding

flexibility

clarity

no polymer is perfect

% vinyl acetate monomer [VAM] in LDPE ➞

EVA VAE

poly (ethylene - co - vinyl acetate)

LDPE

0

PVA

100

emulsion polymerisation

high-pressure polymerisation

poly ethylene poly vinyl acetate


TECHNOLOGY MANUAL FOR IPC

EXXONMOBIL CHEMICAL EVA TECHNOLOGY 200 KTA TUBULAR REACTOR

ExxonMobil Proprietary-Confidential May not be Copied or Distributed without Authorization

© 2009 ExxonMobil Chemical Company

Section: Sub:

Page: Date: Rev.:

3 3.1 & 3.2 4 of 30 Dec. 2009 0

Figure 3.2.5

Polyethylene chain with Long Chain Branches

This chain transfer mechanism leading to long chain branching increases with rising reactor polymer concentration, with higher reactor temperatures, particularly above 200°C, and lower reactor pressures.

Long chain branching particularly influences the solution and melt rheological

properties of polymers.

3.2.1.2 Short Chain Branching

Short chain branches are made by a unimolecular, intramolecular process known as the Roedel Back Biting Mechanism. In this rearrangement, the growing end of a polymer chain can form a six-membered cyclic transition state thereby allowing the primary radical at the chain end to abstract a hydrogen atom from the carbon atom at position 5, as shown in fig. 3.2.4. This new secondary radical can propagate further resulting in a butyl side branch. In reality, several sequential back biting mechanisms can take place before propagation recommences thus producing a number of very specific short chain branches:

16-PR-00-TM-001 Rev 0 Page 99 of 438

LDPE manufacturing processEVA

ethylene

co-monomer VAM

initiator

chain-transfer agent

LDPEEVA

schematic process

Reactor

high-pressure (2000 - 3000 bar)free-radical initiated addition polymerisationchain


TECHNOLOGY MANUAL FOR IPC

EXXONMOBIL CHEMICAL EVA TECHNOLOGY 200 KTA TUBULAR REACTOR

ExxonMobil Proprietary-Confidential May not be Copied or Distributed without Authorization

© 2009 ExxonMobil Chemical Company

Section: Sub:

Page: Date: Rev.:

3 3.1 & 3.2 4 of 30 Dec. 2009 0

Figure 3.2.5

Polyethylene chain with Long Chain Branches

This chain transfer mechanism leading to long chain branching increases with rising reactor polymer concentration, with higher reactor temperatures, particularly above 200°C, and lower reactor pressures.

Long chain branching particularly influences the solution and melt rheological

properties of polymers.

3.2.1.2 Short Chain Branching

Short chain branches are made by a unimolecular, intramolecular process known as the Roedel Back Biting Mechanism. In this rearrangement, the growing end of a polymer chain can form a six-membered cyclic transition state thereby allowing the primary radical at the chain end to abstract a hydrogen atom from the carbon atom at position 5, as shown in fig. 3.2.4. This new secondary radical can propagate further resulting in a butyl side branch. In reality, several sequential back biting mechanisms can take place before propagation recommences thus producing a number of very specific short chain branches:

16-PR-00-TM-001 Rev 0 Page 99 of 438


autoclave tubular

1,670 m x 60mm

41% of installed capacity is

59% of installed capacity is


ethylene

very low >1 up to 7 Commodity films; bakery bags, ice bags, frozen food bags, overwrap and fresh produce wrap 499

low 7 up to17 Blow molding, foam applications, extrusion / lamination, injection molding, industrial stretch wrap and wire & cable 886

mid 17 up to 25Footwear, Extrusion coating, injection molding, lamination film,

coextruded films, heat seal layers, hot melt adhesives, agricultural films

1458

high 25 - 35 Carpet backing, hot melt adhesives, injection molding, wax blended coatings, extrusion, solar panels and photovoltaic cells

577

very high 36 - 45 Hot melt adhesives, coating, polymer modification, grafted polymers

577

The global demand mix in 2011 by EVA resin type:

Townsend Solutions3.4m tons

EVA type % vinyl acetate typical applications 2011 demand

(000 tons)

410 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

860

0.1

1

10

100

X Axis

Y A

xis

MFI melt flow index

% vinyl acetate monomerEVA products410 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40

860

0.1

1

10

100

X Axis

Y A

xis

licen

se li

mit

Sipchem EVA MFI (2.16 kg / 190°C)

VAM %

LD 2023 2 0

EVA 2005 2 4.5

EVA 2009 2 9

EVA 3514 3.5 14.4

EVA 2018 2 18.2

EVA 3522 3.5 22

provisional Sipchem EVA grade range:


• Sipchem

• Sipchem EVA

• Sipchem PADC



R&D as % of GDP

Scie

ntis

ts &

Eng

inee

rs p

er m

illio

n pe

ople

1.00.5

Global R&D Funding ForecastBattelle Memorial Institute

0.50

1000

2000

3000

4000

5000

6000

7000

8000

Scie

ntist

s & E

ngin

eers

/Mill

ion

Peop

le

R&D as % GDP

1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5

AmericasAsiaEuropeOther

United States

Canada

Mexico

ArgentinaChina

IndiaMalaysiaIndonesia

Japan

Taiwan

Singapore

South KoreaNew

Zealand

Austrailia

Russia

Germany

Austria

Switzerland

Finland

Norway

Turkey

NetherlandsUK

BelgiumPortugal

Denmark

Poland

Romania

CzechRepublic

Ireland

Hungary

Greece

Italy

France

Sweden

Spain

Israel

SouthAfrica

SaudiArabia Brazil

R&D as % of GDP

Scie

ntis

ts &

Eng

inee

rs p

er m

illio

n pe

ople

2011

polymer processing is an integral part of the design of the PADC

Design Elements

Final Design

Sipchem PADC

Sipchem PADC

Final Design

NOV’09Dhahran TechnoValley

Progress of Construction

site of Sipchem PADC

142 m

177 m

94 m

MARCH 2010

Progress of Construction

11 May 2011PADC

19 May 2011PADC

27 September 2011

15 November 2011

March 2012

1 July 2012

TJH office

Laboratory for Visionary ArchitectureLAVAB A T T L E M c C A R T H Y

Consult ing Engineers and Landscape Architects

INTERIOR VIEW OFFICE

Product & Application Development Centre [ PADC ]

Draft



INTERIOR VIEW 2nd FLOOR


Draft



INTERIOR VIEW ENTRANCE


Draft

Sipchem PADCProduct & Application Development Centre

Overview

• 10 800 m2 of constructed area

• 3 floors + open basement + central atrium

• novel polymer façade

• state-of-the-art IT, instruments & equipment

• 7 expansion spaces

• 39 Laboratories

• 40+ offices

• design intent: collaboration, open, interaction, integration

• 8 facilities for Teaching

PADC Pathways 2013 - 2014

PADC is a mission-driven technical centre, focussed on delivering value to Sipchem

Establishing PADC

Product Development

Application Development

Engaging with and Developing the downstream [plastics processing] industry in the Kingdom

Customer Development [Technical Service]

Process Development

Training & Teaching

Research - creating the future through science, technology and creativity

Corporate & Strategic Development [includes Project Development]

Dev

elop

men

t


• Sipchem

• Sipchem EVA

• Sipchem PADC




Product & Application Development

• establishing the PADC

• building capability in polymer technology

• engaging with the industry


• adhesives, ink and paint [coatings]

• packaging films

• wire & cable

• footwear

• photo-voltaic encapsulation film

• films for agriculture & horticulture



Application Focus


• understanding LDPE and EVA

• structure / property relationships




% vinyl acetate monomer VAM ➞

EVA

poly (ethylene - co - vinyl acetate)

LDPE

0 100

high-pressure polymerisation

poly ethylene

28 86

Y = 47.683 - 1.034x R2 =0.9936%

cry

stal

linity

vinyl acetate (weight %)0 5 10 15 20 25 30 35 40 45

0

10

20

30

40

50

46.12

22 mole%

An algorithm for the accurate prediction of the detailed polymer architecture [2010]


• understanding LDPE and EVA

• structure / property relationships




• understanding market needs

• developing Products & Applications

• engaging with the industry

Engaging with & Developing the downstream [plastics processing] industry in the Kingdom

• understanding the local EVA demand

• identifying opportunities for collaboration

NAPCOputting science in to the application

di2discover

inventinnovate

Sipchem Technology one step ahead of the innovators

Documents

Introducing and Supporting Speciality Polymer [EVA] Applications GPCA PlastCon 7-9 April 2013 FINAL 8-4-13