New developments in Polypropylene grades

1. New developments in Polypropylene grades Polypropylen Innovativ 05.-06.05.04 Würzburg Ben Raven SABIC EuroPetrochemicals Technical Marketing PP Moulding & Extrusion

2. Contents • Basic facts SABIC • Developments in polypropylene grades • Evolution of MFR • Application of nucleators • Multi-functional PP grades • Conclusions

3. Intermediates Polymers Fertilizers Metals Basic Chemicals SABIC: Saudi Arabian Basic Industries Corporation • Started from scratch in 1976, produced first tons in 1983 • World wide 16.000 employees in 22 countries • Turn-over of € 11,4 bln in 2002 • Is 70% owned by Saudi government and 30% by private sector • 100% owner of SABIC EuroPetrochemicals

4. SABIC EuroPetrochemicals Gelsenkirchen site Geleen site SABIC’s first major acquisition outside Saudi Arabia

5. West-Europe PP/PE Supply 2003

6. Developments in polypropylene grades • Increasing MFR • shorter cycle times • thinner wall thicknesses • Nucleation • Multi functional PP grades

7. Increasing MFR - evolution of grade portfolio block-copolymers 100 1980 Notched Izod impact (kJ/m²) 10 1 0,1 1 10 100 Melt flow rate (g/10 min)

8. Increasing MFR - evolution of grade portfolio block-copolymers 100 1980 1990 Notched Izod impact (kJ/m²) 10 1 0,1 1 10 100 Melt flow rate (g/10 min)

9. Increasing MFR - evolution of grade portfolio block-copolymers 100 1980 1990 2000 Notched Izod impact (kJ/m²) 10 1 0,1 1 10 100 Melt flow rate (g/10 min)

10. SABIC® PP Increasing MFR - evolution of grade portfolio block-copolymers 100 2010 ? 1980 1990 2000 Notched Izod impact (kJ/m²) 10 1 0,1 1 10 100 Melt flow rate (g/10 min)

11. Increasing MFR - processing advantages (example MFI 15 vs. MFI 35 grade) 140 120 100 80 Traditional grade Index figure High MFR grade 60 40 20 0 Flow Mould Cycle time Output pressure rate

12. Increasing MFR – reduced wall thicknesses (example MFI 15 vs. MFI 35 grade) 800 700 600 500 Traditional grade 400 Flow length (mm) High MFR grade 300 200 100 0 0,5 1,0 1,5 2,0 Wall thickness (mm)

13. Improved pail grade:SABIC PP 612MK10 New Grade Old Grade 100 Notched izod impact (KJ/m²) 10 SABIC® PP 612MK10 MFR 15 MFR 35 1 0,1 1 10 100 Melt flow rate (g/10 min)

14. Improved high MFR multipurpose grade:SABIC PP 513MNK40 New Grade Old Grade 100 SABIC® PP 513MNK40 Notched izod impact (KJ/m²) 10 MFR 70 MFR 40 1 0,1 1 10 100 Melt flow rate (g/10 min)

15. Improved beaker grade:SABIC PP 313MNK40 New Grade Old Grade 100 Notched izod impact (KJ/m²) 10 SABIC® PP 313MNK40 MFI 90 grade 1 0,1 1 10 100 Melt flow rate (g/10 min)

16. Improved high impact grade: SABIC PP PHC26 100 SABIC® PP PHC26 75MR10 New Grade Old Grades 10 Notched Izod impact (kJ/m²) 66MNK10 Suitcases Crates & Boxes 1 0,1 1 10 100 Melt flow rate (g/10 min)

17. Developments in polypropylene grades • Increasing MFR • Nucleation • increased stiffness • better transparency • higher crystallisation temperatures • Multi functional PP grades

18. The influence of nucleation non-nucleated nucleated

19. Nucleation- increased stiffness Non-nucleated Nucleated 2000 Flexural modulus [MPa] 1500 1000 PP copolymer PP homopolymer

20. Nucleation- increased transparency

21. Nucleation- increased transparency Cross-section

22. Spherulitic growth in praxis In-line thermoforming Sheet thickness = 2 mm PP grade non-nucleated

23. New SABIC® PP grade for thermoforming PS Clarity clarified nucleated PP Stiffness possibility of down gauging

24. New SABIC® PP grade for thermoforming Clarity clarified SABIC® PP 523K nucleated PP Stiffness possibility of down gauging

25. Nucleation- higher crystallisation temperatures (Tc) Tc Addition of nucleating agent

26. Nucleation- influence nucleation agent (DSC test) Tc

27. Nucleation- higher crystallisation temperatures; faster cycle times Required cooling time T crystallisation

28. Mold plates Indentation point Indentation pin Hydraulic cylinder Runner (5 mm) Cavity Injection point Pressurizedoil Ejection pins Injection sprue Nucleation- influence Tc on cooling time; indentation test

29. Indentation test Non nucleated PP Nucleated PP

30. Developments in polypropylene grades • Increasing MFR • Nucleation • Multi functional PP grades • reduction in number of PP grades • broader application range

31. SABIC EPC Comp 1 Comp 2 Comp 3 Decreasing number of W.European COPOL PP grades 200 nr of COPOL PP grades 0 1997 1999 2001 2003

32. SABIC EPC Comp 1 Comp 2 Comp 3 Decreasing number of W.European HOPOL PP grades 300 nr of HOPOL PP grades 0 1997 1999 2001 2003

33. Reduction in number of PP grades • SABIC EuroPetrochemical’s answer: Multi-functional PP grades Broad application area Ultimate product consistency

34. The multi-functional block copolymer grades for injection moulding offer: • Shot to shot consistency • Short cycle times • Acceptable stiffness / impact balance • Dimensional stability • Good surface appearance • Low blushing performance • Good organoleptics

35. Multi-functional block copolymers (1) Cycle time SABIC® PP 412MN40 DimensionalStability Organoleptic Tamper evidence Impact/stiffnessBalance Surface Appearance

36. Multi-functional block copolymers (2) SABIC® PP PHC31 Surface Appearance Impact Impact/stiffnessBalance Dimensional stability Cycle time

37. Conclusions • Increasing MFR • shorter cycle times • reduced wall thicknesses • Nucleation • increased stiffness • better transparency • higher crystallisation temperatures • Multi functional PP grades • reduction in number of PP grades • broader application range