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© 2018 W. R. Grace & Co.1
Talent | Technology | Trust™
Product Innovation through Catalyst Solution to Polyolefin Producers
Mohd Rohizat Aziz TsRegional Technical Manager-A/P
Innovative
Performance Driven
Focused
© 2018 W. R. Grace & Co.2
Talent | Technology | Trust™
• Introduction of Grace Business
• Grace’s Catalyst Solution
• Product Innovation to Polyolefin Producers
• Summary
Agenda
© 2018 W. R. Grace & Co.3
Talent | Technology | Trust™
The Leader in Polyolefin Catalysts and More
1 Sales based on FY2016; Catalysts Technologies includes unconsolidated ART joint venture. FCC = Fluid Catalytic Cracking, SC = Specialty Catalysts, ART = Advanced Refining Technologies®
FCC and ART together are referred to as Refining Technologies
Organic Chemicals
MgCl2Silica
AluminaAlumina Raney
Metal
MATERIALS
Intermediatesand Excipients
CATALYSTS
Chemical
MATERIALS
Additives & Processing
Polyolefin Catalysts CATALYSTS
Refining(FCC and HPC)
CATALYSTS
Polyolefin
Silica
$~$2B in 2017 Sales
Refining Technologies Specialty Catalysts Materials Technologies
Over $1B in Strategic Acquisitions to Strengthen Polyolefin Catalyst Portfolio
2010 –Synthetech for Single-Site Catalysts 2013 –UNIPOL® PP Licensing and Catalysts Business2016 –BASF / LYNX® Polyolefin Catalysts Business 2018 –Albemarle Polyolefin Catalysts Business
#1� FCC Catalysts� Hydroprocessing� Hydrocracking� Polyolefin catalysts� Independent polypropylene process
technology licensing� Specialty silica gel
Strong Market Positions and Financial Performance
© 2018 W. R. Grace & Co.4
Talent | Technology | Trust™
Meeting
refiners’
needs and
ensuring
success
FCCCatalysts
ARTHydroprocessing
Catalysts
FCCAdditives
� Customer-focused, solutions-oriented approach
� Broad, highly-differentiated portfolio of products
� Industry-leading technical service
� Flexible manufacturing system
� Research leadership and innovation centered on customers’ current and future needs
Key Customers
Competitive Advantages
� Global public oil companies
� National (state-owned) oil companies
� Regional independent refining companies
• Fixed and ebulating bed resid
• Hydrocracking
• Distillates
• Improving specific yields
• Enhancing product quality
• Reducing emissions
• Achieving maximum yields of most valuable refining products
• Providing optimal catalyst selection for refinery crude slates
Catalysts / Refining Technologies
© 2018 W. R. Grace & Co.5
Talent | Technology | Trust™
POLYOLEFINCatalysts
PROCESS
LICENSINGCHEMICAL
Catalysts
� Customer-focused, solutions-oriented approach
� Broad, highly-differentiated portfolio of products
� Ability to develop and optimize catalyst properties to specific applications
� Flexible assets for the scale-up and production of commercial catalysts
� Wide range of analytical tools and testing for product and process improvements
Key Customers
Delivering Value
� Global petrochemical companies
� National (state-owned) petrochemical companies
� Plastic resin producers
• UNIPOL® PP Proprietary Gas Phase Polypropylene Process Technology
• Simple to build, operate, and maintain
• Catalysts and supports
• Hydrogenation catalysts
• Technologies for alternative andtraditional feedstock
• Polyethylene (PE) catalysts
• Polypropylene (PP) catalysts
• Catalyst supports
• Components
Catalyst
performance
is a combination
of design,
characterization,
and manufacturing
Catalysts Technologies | Specialty Catalysts
© 2018 W. R. Grace & Co.6
Talent | Technology | Trust™
Grace Specialty Catalysts Solution
© 2018 W. R. Grace & Co.7
Talent | Technology | Trust™
Bulk/Gas
Grace Integrated Polyolefin Catalyst Portfolio
The only fully integrated supplier of polyolefin catalyst solutions across all processes and catalyst technologies
Gas PhaseGas Phase Loop CSTR/SolutionCSTR
Polyethylene Polypropylene
Chromium CatalystsZiegler Natta Catalysts
Single Site CatalystsSupports and Components
SYLOPOL®MAGNAPORE®
ActivCat®
POLYTRAK®SHAC®, CONSISTA®
LYNX® LYNX®
Catalyst Polymer
Lab Scale Bench scale reactors
Mini-plant (1-3 kg) PP Pilot plant
Pilot plant (20-100 kg) Polymer characterization lab
Commercial scale (200+ kg)
POLYTRAK®, HYAMPP®, SHAC®, CONSISTA®
Custom SSC Solutions•Specialized Supports•SSC Components
SYLOPOL® MAGNAPORE®
Development Capabilities
© 2018 W. R. Grace & Co.8
Talent | Technology | Trust™Better Resin Performance by Design
COMONOMER
RESINARCHITECTURE
Homopolymer
Copolymers type
SCB/LCB
Terpolymers/Diene
Gas PhaseBulk
SlurrySolution
Hybrid Process
Broad Multi site: Cr
Multi Site: Ziegler Natta
Single site: Metallocene
• The possible combinations provide the basis for dif ferentiation in our industry
• Controlling the inputs defines the resin architectu re output
• Catalyst is ultimately the key for unlocking a plant’s resin design capabi lities
© 2018 W. R. Grace & Co.9
Talent | Technology | Trust™Enhance Polymer Resin designing with Catalyst Platform
���� Homogeneous Active Center
���� Homogeneous Polymer
Properties
Narrow MwD & CCD Broad MwD & CCD
* CCD
� Chemical
Composition
Distribution
mPO Z/N and Cr -PO
���� Various Active Center
���� Various Polymer Properties
© 2018 W. R. Grace & Co.10
Talent | Technology | Trust™
What exactly is this revolution?� With single site catalysts it is possible to “design” the architecture of the polymer
by modifying the structure of the metallocene.• Control of comonomer incorporation across the range of MWD
• Control of MWD
• Control of branching
� Exponential growth in variations of highly complex molecules*
*Metallocene structures from: Aitola, E. “Tailoring polyolefin properties by metallocene catalysts”. Ph.D. Thesis U of Helsinki. Nov 30, 2006
© 2018 W. R. Grace & Co.11
Talent | Technology | Trust™
2000s1990s
Polyolefin Catalyst Trends
� Early generation catalyst innovations and incremental process developments
� Focus on catalysts coupled to process technologies to differentiate
1980s
� Focus on higher throughput and high operating rates of plants
� Less focus on new process technologies
� Metallocene beachhead begins
� Wave of PO expansions based on advantaged feedstock costs
� Large new plants with smaller product wheels to maximize utilization
� Strong driver for differentiation via new catalyst technologies
50
100
150
200
250
2000 2005 2010 2015 2020
Avg
. P
O P
lan
t
Ca
pa
cit
y, k
ta
PolyethylenePolypropylene
1990 1995 2000 2005 20100%
15%
10%
5%
25%
20%
Process and Catalyst Patents
% of Total Polyolefins
Source: IHS Markit 2017Source: Cap Gemini, EspaceNet, EBB analysis
Max unit size has increased by 67% for PP and 44% for PE since 2000
UNIPOL® PP plants can be >650 kton as a single train
Grace has invested to support our customers through out these changes
© 2018 W. R. Grace & Co.12
Talent | Technology | Trust™Polyolefins Developments
Dual Reactor, Multi-Stage
• Early developments with smaller range of resin options
• Resin improved through catalyst development and process improvements
• Enhanced resins with dual catalysts but difficult to mix types and harder to control
Single Reactor
• Enabled value added solutions• Bimodal PE resins• High rubber ICP / PP resins• Catalyst developments and process control critical to success• Kinetics, comonomer incorporation• Broader reactivity range catalysts
Degree of Difficulty to Operate
Time
MetalloceneZNCr
An
nu
al
Se
gm
en
t G
row
th R
ate
PE and PP catalyst developments aligned with increa sing resin design control needs
CONSISTA® HYAMMP®
1st 2nd
3rd
4th
5th
6th
LYNX® SHAC®
Resin Control
Pro
duct
and
P
erfo
rman
ce B
read
th
Broad O
perating Window
Non-phthalate
Narrow
Operating W
indow
Non-phthalate
PP
© 2018 W. R. Grace & Co.13
Talent | Technology | Trust™
Z/N
Grace® Catalyst Building Blocks for the Future
Specialization through Product Performance
Key takeaways:
� It is critical to carefully match catalyst to process to optimize product performance
� Catalyst innovations by Grace will continue to drive product and performance enhancements across all process platforms
Re
sin
Arc
hit
ec
ture
UNIPOL® PP ICPSpherizone®
Borstar®
ADL
INNOVENE ® SUNIPOL® PEUNIPOL® PPCSTR
Single LoopDual CSTR
Me
tallo
ce
ne
Cr
Terpolymers
Copolymers
Homopolymer(HD)
POLYTRAK®
LYNX® PP
CONSISTA®
SHAC®
HYAMPP®
ADT Donors
MAGNAPORE®
LYNX® PE
SYLOPOL® 9800
SYLOPOL® 5800
SYLOPOL® 7510
Custom Metallocenes –ActivCat®
Spheripol®
PEPP
Borstar®
INNOVENE® G
SYLOPOL® 53THC
SolutionNovolen®
INNOVENE® PPBulk
Continued Innovation to meet technology and market needs
© 2018 W. R. Grace & Co.14
Talent | Technology | Trust™
Product Innovation with Catalyst Solution
© 2018 W. R. Grace & Co.15
Talent | Technology | Trust™Future Developments
• A focus on carbon efficiency will promote resin light weighting, supply efficiency and material substitution
• Recycling regulations will drive advancement in resins to meet more demanding application needs
• Growing middle class will drive plastics demand but with a focus on sustainability
• Responsible care on life cycle of resins being passed onto resin producers
• Shale Gas momentum and North America back in competitive mode, Anticipating erosion of margin for commodity PO resin
• New resin needs will be met through new catalyst developments and/or process developments with multi-catalyst inputs
• Advanced processes require advanced catalysts to meet increased requirements of operation
• Leverage catalyst capabilities to optimize resins for improved recyclability and sustainability
• Broad catalyst technology platform for polymer producers to maximize their asset and margin
Market Drivers Catalyst Opportunities
Grace has strategically invested and is positioned to enable resin producers to meet these market and catalyst n eeds
© 2018 W. R. Grace & Co.16
Talent | Technology | Trust™Grace Technology Enables Better Products by Design
Example 1: Catalyst Design
By designing a catalyst with superior Flexural
Modulus capability, tougher or stiffer products can be
produced in a given reactor
Customer ChallengeThe range of products a production plant can make i s a function of the catalyst
and the range of conditions under which it smoothly operates
Delivered Solution
• Leading UNIPOL ® PP process economics
• Phthalate free products
• 10% light weighting of finished articles
• Reduced energy & carbon usage
Example 2: Donor design
By designing PP donors with superior Hydrogen
response, higher melt flow products can be produced
in a given reactor
Delivered Solution
• Leading UNIPOL ® PP process economics
• Phthalate free products
• Minimize/eliminate peroxide usage
• Cleaner environmentally friendlier product
© 2018 W. R. Grace & Co.17
Talent | Technology | Trust™
Higher Activity = Lower Cost-in-Use
Catalyst Cost-in-Use
Resin
Perf
orm
ance
Ziegler Natta
Single Site
Single Site
17
Without Sacrificing Resin Properties
• Resin properties equivalent to standard MAO/silica catalysts
• Proven in a variety of process technologies
• Reduces the cost-in-use gap between conventional Z/N and metallocene catalyst.
© 2018 W. R. Grace & Co.18
Talent | Technology | Trust™
Value creation to Polyolefin Producers
Properties of LPG Cylinders
� Lightweight, up to 50% less then steel cylinders
� Composite cylinders are corrosion free
� More safety, burst pressure > 120 bar
� Easy to handle and stackable
� The valve is very well protected against impact
� It is easy to clean
� Typ IV cylinders are translucent
� The material is UV resistant to effects from sun,
rain, temperature variations and handling
� Less maintenance
� Flexible & attractive design
� Very good behavior in fire, no explosion!
© 2018 W. R. Grace & Co.19
Talent | Technology | Trust™
� Resin made with Grace Cr has been tested and passed the gas tank composite with our collaboration with Kautex, Germany.
LPG and CNG gas tank
Raw material HDPE
Liner Blow molding
Boss-PartHDPE / Steel / AL
WeldingBoss-Part and Liner
Resin / Glasfiber
Filament Winding
Cover HDPE
Cover Assembling
© 2018 W. R. Grace & Co.20
Talent | Technology | Trust™
Summary
� Grace is a fully integratedsupplier of polyolefin catalysts across all process and catalyst technologies.
� Wide and broad catalyst technology platform allow Polyolefin Producers to benefit the solution to face the dynamic and competitive business environment
� Grace focuses on high-performance products and services to enable our customers.
� Enable to maximize the product and asset.
� Grace has been continuously investing in capacity expansion, technology and quality improvement to better serve our customers.
Thank you for trusting us with your catalyst needs. Together, we look forward to increasing the value of your polyolefin business.
© 2018 W. R. Grace & Co.21
Talent | Technology | Trust™
THANK YOU
Questions?