Tubular LDPE has the EC future

Marcel NeilenSession + papernumber

Tubular LDPE has the EC future

Marcel NeilenJudith BoschSABIC Europe

Session: 3.1 Paper: 7651Shaping Success

1.3 Paper 7651 Marcel Neilen2

1. Introduction

2. CTR® Extrusion Coating project

• Target

• Approach

• Future

Content

1.3 Paper 7651 Marcel Neilen3

WE autoclave units

Total WE autoclave capacity ±2000 Kt

Higher end Lower end

EVA20%

EC30%

Other LDPE markets50%

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Market volume

Extrusion Coating WE 650 kt

Liquid packaging Photo Coating Rest Coating

3 companies: + 95%LDPE volume: 330 Kton

2 companies: + 95%LDPE volume: 50 Kton

3 companies: + 50%LDPE volume: 270 Kton

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Extrusion Coating process

Unwinder Corona Coating Station Coulisse

• Pilot Extrusion Coating Line PECL

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Key processing parameters for EC

Neck In• Contraction of the web

Web Stability• Variation in Neck-In

Draw Down• Maximum line speed

the film web can take without breaking

chill roll

film web

die

Extruder

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Tubular reactorCharacteristics:• Plug flow• Pressure ±2700 bar• Peak temperatures

±300oC

No Stirrer: • Laminar flow

behaviour

Initiators

Initiators

Initiators

Initiators

LDPE + ethylene

ethylene

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Autoclave reactorCharacteristics:• CSTR• Pressure ±1800 bar• Temperatures ±260oC

Mixing• Residence time

distribution• Broad MMD• Long chain branching

Initiators

LDPE + ethylene

ethylene

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MMD: Tubular vs. Autoclave LDPE

0,0

0,1

0,2

0,3

0,4

0,5

0,6

0,7

2,0 3,0 4,0 5,0 6,0 7,0 8,0

Log M

dW(M

) / d

(logM

)

Autoclave

Tubular

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Autoclave vs. Tubular LDPE

Current knowledge:

• Broad MMD and LCB is essential for NI and web stability

• Typical Autoclave grade behaviour; Low NI, stable film web

• Typical Tubular grade behaviour; Large NI, unstable film web

chill roll

film web

die

Extruder

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Current situation

Many autoclaves are:• Old• Cost inefficient• Limited in size

Significant investments in autoclaves required to complyto legislation

We expect that no new autoclave plants will be built in the future

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Alternative EC resins?At least 85 % of EC resin is autoclave LDPE

Excellent processability• Tension stiffening in web:

neck in + web stability

Easy processing (low motor load)• In extruder: shear thinning

No real alternative available!!vi

scos

ity

shear rate

LLDPE

HDPE

LDPE

visc

osity

shear rate

LLDPE

HDPE

LDPE

visc

osity

elongation rate

LDPE

HDPE

LLDPE

visc

osity

elongation rate

LDPE

HDPE

LLDPE

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1. Introduction

2. CTR® Extrusion Coating project

• Target

• Approach

• Future

Contents

1.3 Paper 7651 Marcel Neilen14

Target

SABIC dedicated EC player

Main driver project:• Long term security of supply

Requirements alternative EC resin:• Same quality incl. processability• No hard ware modifications at converters• No price increase

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Approach

AwarenessPositioningCalculations

etc

2001 20031 plant run

ModificationP/T

AlternativeChemistry

20042 plant runs

Combination

2005 April

1 plant run

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Approach

Q42005

Final Plant Run

Hardware modifications &

Market Introduction

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Expected advantages

• Tubular grades have the EC future, long term security of supply

• Applicable on any tubular reactor • Development partner in new EC tubular grades

• Product related:(e.g. Less machinery dependent; longer production runs; improved consistency end quality; more stable production; less complaint risk; lower energy costs)

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Expected advantages e.g.Stable productSmall MFR (melt flow rate) drop after processing

0

2

4

6

8

10

12

14

16

Resin Film at 300°C Film at 320°C

MFR

NC2792404AN001808AN001815AN00

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Expected advantages e.g.Higher line speeds possible at lower temperatures

0100200300400500600700800900

250 270 290 310

Temperature (deg.C)

DD

(m/m

in)

NC279

2404AN00

1808AN00

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Future

Real break through!!!

Original project completed successful

• Plant (trial runs/modification hard ware S17)• Marketing (customer + market approach)

Sharing our futures

Thank you