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www.albemarle.com KFUPM Catalyst Symposium Dr Jiang Bian Global Business Development Manager – PO Catalysts Albemarle’s Role in Polyolefin Catalyst Albemarle’s Role in Polyolefin Catalyst

Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Page 1: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

www.albemarle.com

KFUPM Catalyst SymposiumDr Jiang Bian

Global Business Development Manager – PO Catalysts

Albemarle’s Role in Polyolefin CatalystAlbemarle’s Role in Polyolefin Catalyst

Page 2: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Presentation OverviewPresentation Overview

• Albemarle overview

• Albemarle's Role in PO catalysts– Case study

• ActivCatTM – Transformational Activator Technology

• Latest Development & Conclusions

Page 3: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Albemarle Corporation…who we are

Polymer Additives39%

Catalysts38%

Fine Chemicals23%

2007 Net Sales - $2.33 billion

• Provider of unique technical solutions• Supports three business segments with strong, balanced product

portfolios• Leading positions in key markets with strong growth fundamentals• Proprietary technology and service-driven business model• Fundamentally strong margin and cash flow businesses

Page 4: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Global Presence

Research & Development• Baton Rouge, La.• Dayton, Ohio• Tyrone, Penn.• Pasadena, Texas• Santa Cruz, Brazil• Amsterdam, Netherlands• Louvain-La-Neuve, Belgium• Bergheim, Germany• Nanjing, China• Niihama, Japan

Sales/Tech Service• Baton Rouge• Houston• Amersfoort, Netherlands• Bergheim• Dubai, UAE• Louvain-La-Neuve• Tokyo• Beijing• Guangzhou, China• Nanjing• Shanghai, China• Seoul, Korea• Singapore

Manufacturing• 21 Manufacturing Sites

• 3,700 associates• Sales in more than 100 countries• 2007 Net Sales: 44% Americas, 38% EU-ME-A, 18% Asia Pacific

Page 5: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Albemarle Catalyst OverviewLeveraging Expertise Across All Catalyst DisciplinesAlbemarle Catalyst OverviewLeveraging Expertise Across All Catalyst Disciplines

• $1 billion in total catalyst revenue

• 250 employees in R&D

• Dedicated resources for polyolefin catalyst

• Manufacturing and R&D at same location

• A Global Leader in – Activator production and technology development– Metallocenes and single site catalysts– Organometallics for ZN catalysts

Our expertise makes us the preferred catalyst Our expertise makes us the preferred catalyst manufacturing partnermanufacturing partner

Page 6: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Market Dynamics Demand InnovationChallenges for Catalyst Suppliers and Resin ProducersMarket Dynamics Demand InnovationChallenges for Catalyst Suppliers and Resin Producers

• Market recession weakens demand for PO resins

• Excess global capacity of PE and PP with new ME plants

• Need for Western producers to differentiate product line

• Need for global catalyst production expansion– Launched 2008 expansion and planned expansion in 2010

• Increased demand for development and scale-up

• New catalyst systems in commercialization stages

Resin producers need a reliable, valueResin producers need a reliable, value--added catalyst strategy for added catalyst strategy for growing specialty Zieglergrowing specialty Ziegler--Natta and metallocene catalyst systemsNatta and metallocene catalyst systems

Page 7: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Albemarle Corporation – PO CatalystsOur Value Offering to the Polyolefin IndustryAlbemarle Corporation – PO CatalystsOur Value Offering to the Polyolefin Industry

• Commercial Supply– Catalyst and component manufacturing– Back integrated in aluminoxane and organoboron activators– Total supply management

Procurement, production, hopper maintenance, testing, and shipping– Asset management (working capital and capacity management)– Safety and Product Stewardship

• Product Development – Speed to market– World class facilities

• Technology Innovation– Process Development– Activation Technology

Albemarle can make your life easierAlbemarle can make your life easierAlbemarle can make your company more moneyAlbemarle can make your company more money

Page 8: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Finished Catalyst Capability – PE/PPAlbemarle’s Expanding Role in Finished Catalyst SupplyFinished Catalyst Capability – PE/PPAlbemarle’s Expanding Role in Finished Catalyst Supply

MetalloceneCatalysts

Res

inPe

rfor

man

ce

Catalyst Cost-in-use

Zielger-Natta

Catalyst Systems

MetalloceneSSC

Ziegler-Natta

Improve value to customer without compromise to Improve value to customer without compromise to resin performance / propertiesresin performance / properties

AlbemarleStrategy

Page 9: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Albemarle’s Role in Catalyst DevelopmentCommercialization of Customer Catalysts is our SpecialtyAlbemarle’s Role in Catalyst DevelopmentCommercialization of Customer Catalysts is our Specialty

ConceptCatalyst and

Resin Development

Albemarle Arena

Need Concept Prototype Test Commercial

Bench Kilo Lab Pilot Plant Scale-up Commercial

Technology Transfer

Catalyst Development

Process Development

ConceptReview

MarketNeed

FeasibilityStudy

PreliminaryDesign of Catalyst

FinalDesign /

Plant modifications

PrototypePO

ProductionField Test

ProductionScale-up

MarketingReview

ProductLaunch

Resin Production

Catalyst SalesIterative Process

Page 10: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Case Study One: SSC for slurry process

• Objective–Good morphology: right PSD, no fine particles–Higher productivity: lower cost in use–No reactor fouling

• Experimental program–Silica selection–Silica calcination T–MAO loading–Metallocene/MAO ratio–Impregnation conditions:

T, T profile, time, concentration–Bench polymerization testing

Page 11: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Case Study Two: Ziegler-Natta Catalyst

• Objective– Good morphology: right PSD– Lower manufacturing cost

Shorter cycle timeHigher slurry concentration

• Experimental program– Process conditions optimization

T, T profile, time, concentration– Filtration vs decantation– Bench polymerization and polymer characterizations

Page 12: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Recent Catalyst System ImprovementsSuccessful Collaboration with AlbemarleRecent Catalyst System ImprovementsSuccessful Collaboration with Albemarle

• Catalyst Reactor Fouling

• Productivity Improvement

• Catalyst Flowability

• Catalyst Agglomeration

• Resin Particle Size / Resin Flowability

• Halide-Free Activation

• Catalyst Sensitivity to Poisoning

Solutions through Albemarle innovation and Solutions through Albemarle innovation and process developmentprocess development

Page 13: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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I N T R O D U C I N GI N T R O D U C I N G

Customer Supported Catalysts Employing our

Next Generation Family of Activators

Customer Supported Catalysts Employing our

Next Generation Family of Activators

TMTMActivCatActivCat

Page 14: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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The Value of Our Activation TechnologyThe Value of Our Activation Technology

• Extended I-P for your custom catalyst systems– Protect current market channels through I-P barriers

• Improved value for commercial catalyst systems

• Optimized cost-in-use and increased market penetration rate of newly commercialized catalyst systems

• Dedicated R&D for new activators

Customer value gained through lower costCustomer value gained through lower cost--inin--use and defended use and defended market position through intellectual property protectionmarket position through intellectual property protection

Page 15: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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ActivCat – What is it?Lowering Cost-in-Use and Eliminating Perceived Cost IssuesActivCat – What is it?Lowering Cost-in-Use and Eliminating Perceived Cost Issues

TMTM

• Based on aluminoxane co-catalyst

• Typical productivity at 200% of conventional MAO/silica type catalysts with metallocenes

• PE and PP resin production

• Resin properties equivalent to standard MAO/silica catalysts

• Tested with different types of metallocenes– About one dozen to date

• Albemarle I-P and available to our customers

• Working with our customers to commercialize finished catalysts

Customize Customize YOURYOUR catalyst systems with catalyst systems with ActivCatActivCat TMTM

Page 16: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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ActivCat Productivity ImprovementsAlbemarle Activation InnovationActivCat Productivity ImprovementsAlbemarle Activation Innovation

TMTM

0

5,000

10,000

15,000

20,000

25,000

30,000

1 2

ActivCat

ActivCat

PE PP

Prod

uctiv

ityg/

g/h

Transformational Productivity ImprovementTransformational Productivity Improvement

Metallocene System

Page 17: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Latest development

Capacity and Capability ExpansionManaging our Customer Growth Demands

• China Aluminium Alkyls distribution site established in 2006, to serve the Chinese market

• Developing a strategy to address growth in the Middle East region

• Approved the new Catalyst Manufacturing Unit at the Process Development Center in the USA (under construction)

Market growth demands met through Albemarle expansion

Market growth demands met through Albemarle expansion

Page 18: Albemarle’s Role in Polyolefin Catalyst - KFUPM Symppsium Papers/18 Albem… · Albemarle Catalyst Overview Leveraging Expertise Across All Catalyst Disciplines • $1 billion in

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Conclusions

• Albemarle adds value and reliability– Fully integrated catalyst supplier– Effective supply chain management– Capital expansions– Product and safety stewardship– Process development and innovation

• Albemarle is the leader in activation technology– Extends customer intellectual property – While driving improvements in catalyst cost-in-use

•Contact us to find out…… What two can do!