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© 2018 W. R. Grace & Co. 1 Talent | Technology | TrustProduct Innovation through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager- A/P Innovative Performance Driven Focused

Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

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Page 1: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 2: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 2018 W. R. Grace & Co.2

Talent | Technology | Trust™

• Introduction of Grace Business

• Grace’s Catalyst Solution

• Product Innovation to Polyolefin Producers

• Summary

Agenda

Page 3: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 4: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 5: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 6: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 2018 W. R. Grace & Co.6

Talent | Technology | Trust™

Grace Specialty Catalysts Solution

Page 7: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 8: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 9: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 10: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 11: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 12: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 13: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 14: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 2018 W. R. Grace & Co.14

Talent | Technology | Trust™

Product Innovation with Catalyst Solution

Page 15: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 16: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 17: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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.

Page 18: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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!

Page 19: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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

Page 20: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 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.

Page 21: Product Innovation through Catalyst Solution to Polyolefin Producers · 2018-09-12 · through Catalyst Solution to Polyolefin Producers Mohd Rohizat Aziz Ts Regional Technical Manager-A/P

© 2018 W. R. Grace & Co.21

Talent | Technology | Trust™

THANK YOU

Questions?