UNIPOL Polypropylene Technology

Simple and Reliable Broadest Product Range Low Investment Cost Low Operating Cost Easy To Operate Outstanding Profit Potential

UNIPOL Polypropylene Technology

A Smart Choice for Profitable Polypropylene Production

If you are evaluating options for large-scale polypropylene production, you know there is more to consider than just the unit operations of the process technology itself. Successful resin producers understand the need for a process that delivers a broad range of marketleading products; low operating costs to help ensure sustainable profitability; ease of operation; and continuous technology advancements and support to keep them competitive and market leading year after year. It is for those reasons, and more, that leading resin producers around the world have chosen the UNIPOL Polypropylene Technology, marketed and supported worldwide by The Dow Chemical Company.

Setting the standard for polypropylene process technology

By any measure, including process design and operation, catalyst performance, products produced, economics, and value as well as technology advancement and licensee support, UNIPOL Polypropylene Technology is considered an industry leader worldwide. Here are the reasons why: Simple, Reliable, Proven Technology UNIPOL Polypropylene Technology is an all gas-phase technology that is stable and predictable, and designed to have fewer moving parts and less equipment than any competing technology. UNIPOL Polypropylene Technology is the least complex process of all polypropylene technologies. The simple process design leads to lower capital costs and lower operating costs, while maximizing reliability and lowering maintenance costs.

Although mechanically simple, the underlying technology enables the production of homopolymers or random copolymers in a single reactor plant design regardless of capacity. The same plant can also produce impact copolymers with the addition of a second reactor of identical technology. This feature of UNIPOL Polypropylene Technology enables producers exceptional flexibility to easily change their product mix to meet market demands both now and as markets develop in the future. The simple, reliable design of UNIPOL Polypropylene Technology, coupled with SHAC Catalyst Systems and CONSISTA Donor Technology from Dow, offers another significant economic benefit the ability to operate the plant above nameplate capacity. Plants utilizing UNIPOL Polypropylene Technology routinely run above nameplate capacity, delivering even higher return on the original investment. In fact, this technology delivers the highest on-stream time in the industry, with exceptional aim-grade performance to further enhance the capacity of UNIPOL Polypropylene Technology.

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Broadest Product Range UNIPOL Polypropylene Technology can make the broadest range of polypropylene products available. From commodity raffia grades, to market leading BOPP (biaxially oriented polypropylene) grades for todays high-speed lines, to unrivalled random copolymers, to high-performance impact grades for automotive and aerospace applications, UNIPOL Polypropylene Technology offers both marketleading and competitive products that are proven performers. Utilizing CONSISTA D7000 Donor, resin producers can now make high melt flow impact copolymer polypropylene resins for automotive interior and food contact applications without post-reaction cracking. And of equal importance is the fact that every licensee has access to the full complement of improved products as they are developed. As a producer, you have the ability to tailor your product selection to meet the demands of your customers in your markets, helping to maximize your return on investment in UNIPOL Polypropylene Technology. Catalyst Portfolio Experienced polypropylene producers recognize the importance of the catalyst system in the operation of the process. For polypropylene producers, SHAC Catalyst Systems are the best catalyst systems to deliver market-leading products, world-class operability, and competitive conversion cost. The portfolio of SHAC Catalyst Systems includes a range of custom-engineered, integrated catalyst and Advanced Donor Technology (ADT) the Dow external donor systems that enable efficient, economical production of our broad product line. The CONSISTA Donor Technology is specifically designed for high melt flow applications and is compatible with the existing portfolio of SHAC Catalyst Systems.

SHAC Catalyst Systems, ADT, and CONSISTA Donor Technology, while designed for use in the UNIPOL Polypropylene Process, are also suitable for all other gas phase polypropylene technologies. Consistent catalyst performance that translates to product consistency, our unique morphology-controlled catalysts that deliver high productivity with excellent operating reliability, and the Dow commitment to advancing the science of catalysis are additional benefits that come with a UNIPOL Polypropylene Technology license. Industry-leading Economics A simple, reliable design coupled with efficient, consistent catalyst systems result in both low investment costs and low operating and maintenance costs for UNIPOL Polypropylene Technology. Used together, custom-designed catalyst systems and ADT enable customers to lower their raw material costs because of higher activity and lower use of peroxide. The number of catalysts producers have to carry in inventory is greatly reduced, as is the producers required working capital. A small plant footprint, low number of moving parts, and a streamlined process help keep land costs as well as equipment fabrication and installation costs lower than competing processes. UNIPOL Polypropylene Technology, combined with the comprehensive Dow technology transfer services and support, result in swift and efficient project execution, putting licensees in the marketplace quickly. The mechanical simplicity of the process, coupled with exceptional process stability and catalyst consistency, and further enhanced by UNIPOL UNIPPAC Advanced Process Control technology helps keep operating costs among the lowest in the industry. New process, product, and catalyst developments are designed to drop into existing units to give licensees the ability to move with the market of the future while minimizing capital costs.

Unmatched Licensee Support Comprehensive, ongoing licensee support is a vital part of the Dow commitment to helping you succeed. Backed by more than 25 years of operating history and more than 400 reactor years of experience, the support you receive from Dow is among the most thorough in the industry. Your support starts with expert advice and counsel from Dow process experts during the evaluation stage and continues during design, construction, startup, and beyond. Dow is committed to advancing UNIPOL Polypropylene Technology in every way we can, from a continuous investment in R&D and innovation, to new products and catalysts, to ongoing operator training and process improvements. We share our advancements regularly with licensees through our Global Technology Exchange Meetings, frequent contact with our licensees, as well as customized technical service and training sessions.

UNIPOL Polypropylene Technology your best choice

The information on the pages that follow detail many of the important features and benefits that make UNIPOL Polypropylene Technology your best choice for polypropylene production. Please contact your Dow representative or the sales office nearest you for additional help, or visit www.dow.com/unipol.

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Products
The ability to produce a wide range of polypropylene resins must be a key consideration as you evaluate the process technology you will choose. Experienced resin producers have identified four important productrelated questions to ask when comparing the various technologies: What is the breadth and depth of the product offerings? Does the technology allow the production of market-leading products? Does the process offer flexibility to allow easy and economical changes in the product mix being produced? Does the process have favorable economics across the entire product range? Licensees of UNIPOL Polypropylene Technology know from their experience that they can produce the broadest range of products with the greatest flexibility and compete in any global market with marketleading products.

The industrys most complete product capability

It isnt just how many types of products can be produced using UNIPOL Polypropylene Technology. Equally important is the depth in each product family that enables our licensees to produce market-leading products and compete in all major market applications. Licensees of UNIPOL Polypropylene Technology have access to more classes of products, and grades within those classes, than is available from any other commercial technology.

Figure 1: Product Line Markets Served

End Use Applications
Film Textiles Durable & Industrial Products Melt Blown Rigid Packaging Thermoforming & Blow Molding

Product Family
Monofilament & Rafia Spun Bond Extrusion Staple CF & BCF Injection Molding

BOPP

Homopolymers Random Copolymers Impact Copolymers

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TWM

TWQ

Cast

Meet market demands through production flexibility

Producers who cant easily and economically vary their product mix are at a disadvantage in meeting customer demands in fastchanging markets. UNIPOL Polypropylene Technology enables exceptional flexibility by allowing all products to be created in just two reactors (versus 3-4 reactors in other competitive processes). Homopolymer and random copolymer products can be made in the same reactor, while impact copolymers can be made with an additional identical shaped reactor.

UNIPOL UNIPPAC Advanced Process Control software automatically controls grade changes, optimizing on-stream time and minimizing the production of transition material.

Keep margins high

UNIPOL Polypropylene Technology sets the standard for low investment cost and low operating cost across all product types. UNIPOL Polypropylene Technology will help make you competitive in your most important markets.

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SHAC Catalyst Systems and Donor Technologies

SHAC Catalyst Systems, ADT Donors, and CONSISTA Donor Technology are complementary components designed specifically for the UNIPOL Polypropylene Technology. They are also suitable for all other gas phase polypropylene technologies. SHAC Catalyst Systems are easy to use, consistent, and contribute to the low operating cost of the process. The entire family of SHAC Catalyst Systems and Donor Systems are regularly updated, and licensees and other gas phase polypropylene resin producers can benefit from the Dow commitment to advancing the science of catalysis.

Simple to use
An important advantage of SHAC Catalyst Systems is ease of use. Unlike some competitive technologies, SHAC Catalyst Systems can be fed directly as shipped into a reactor employing UNIPOL Polypropylene Technology as well as other gas phase systems, which helps to keep operating costs low. No pretreatment required No activation required No pre-polymerization required SHAC Catalyst Systems are suitable for all other gas phase polypropylene technologies.

A versatile catalyst family

A range of SHAC Catalyst Systems enables the polypropylene producer to choose the best catalyst and donor combination to meet specific requirements, as shown in Figure 2.

Morphology-controlled catalysts offer advantages

Catalyst particle size and shape directly translate to polymer particle size and shape. The portfolio of SHAC Catalyst Systems includes controlled morphology catalysts with spherical particles that are consistent in size. Compared to traditional catalysts, these high-performance systems produce powderstage resins that are more uniform in shape. The result is higher powder flow rates and higher powder settled bulk density that enables plants to achieve the highest production rates.

Figure 2: Versatility of SHAC Catalyst Systems

Product Family Homopolymers Random Copolymers Impact Copolymers High Melt Flow Impact Copolymers Catalyst System SHAC 201 Catalyst or SHAC 320 Catalyst + ADT Donor SHAC 205 Catalyst + ADT Donor SHAC 320 Catalyst + ADT Donor SHAC 320 Catalyst + CONSISTA D7000 Donor

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Catalyst productivity equals economy

Excellent uniformity and high catalyst productivity help lower catalyst cost per unit of resin produced.

Process Benefits Enables a reduction in resin manufacturing costs through reduced peroxide usage Maintains the excellent operability you have come to expect from Dow catalyst and donor systems Compatible with the existing Dow family of SHAC Catalysts and Donor Systems Suitable for all other gas phase polypropylene technologies Product Benefits Extends the in-reactor melt flow capability for impact copolymers Achieves high impact/stiffness balance Improves the polymer taste/odor profile in food contact applications due to reduction or elimination of peroxide residuals Increases acceptability in automotive interior markets due to reduced C-emission levels Enables entry into premium markets and applications that benefit from performance differentiation

Figure 3: Controlled Morphology SHAC Catalyst and Effect on Polymer Particle

Controlled Morphology Catalyst

Focusing on catalyst development

Catalysis is a core science for Dow across a wide range of chemical and polymer fields. Applying world class Dow skills and facilities, development programs for SHAC Catalyst Systems bring benefits to licensees of UNIPOL Polypropylene Technology and other gas phase polypropylene producers, as new products and technology platforms are developed. Examples include: Catalysts for high crystallinity homopolymers and blends. Advanced Donor Technology (ADT) to maximize reactor operating time through superior reliability, while producing advantaged polymer products.

Polymer

CONSISTA Donor Technology is a result of the Dow R&D commitment to catalysis

The first product in the CONSISTA Donor portfolio of advanced catalyst systems is CONSISTA D7000 Donor. It is designed for applications that require a combination of high stiffness and high melt flow and adds to an already broad catalyst system offering that includes SHAC Catalysts and ADT Donors. From automotive interior applications to food contact applications, CONSISTA D7000 Donor was developed to optimize the processing of high-melt impact copolymer polypropylene resins, with no capital investment required, and to deliver exceptional end-product advantages.

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UNIPOL Polypropylene Technology Simple to Build, Operate, and Maintain Simplicity

is a key characteristic of UNIPOL Polypropylene Technology: Fewer moving parts and less equipment overall compared to competing systems Smallest Inside Battery Limits (ISBL) footprint in the industry Easy access to key plant equipment for simplified maintenance The result of our simple, common sense design approach is that the licensee will enjoy low capital costs and the low operating costs compared to competing systems.
Figure 4: Minimal Land Requirement

The core facility for UNIPOL Polypropylene Technology requires a small footprint of 60 meters by 65 meters or a total of 3,900 square meters. This includes the purification, reaction, purging, vent recovery, additive addition, and pelleting operations. The total Inside Battery Limit (ISBL) occupies 14,000 square meters, measuring approximately 115 meters by 120 meters. The ISBL area includes the core facility plus the alkyl supply, catalyst storage, laboratory, control room, and motor control center. UNIPOL Polypropylene Technology is stateof-the-art technology, yet it is mechanically simple and easy to operate. A minimal amount of major equipment is required. There are only three to four pieces of major rotating equipment. A single reactor is used to produce homopolymers and random copolymers, plus one additional reactor in series to produce impact copolymers irrespective of plant capacity.

Figure 5: State-of-the-Art Process Technology with Mechanical Simplicity

20 SCALE (METERS)

40

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Other benefits of UNIPOL Polypropylene Technology include: Up to 650 KTA single line capacity for full homopolymer, random, and impact grade product mix Uses readily available industry-standard equipment Least expensive standard materials of construction widely used due to non-corrosive process No mechanical agitation in the reactors Unique reaction kill system limits the rate of reaction gas venting during power outage Close-coupled pelleting, eliminating the need for intermediate resin storage

The simplicity of UNIPOL Polypropylene Technology offers several additional benefits, because competitive technologies require additional processes and components. Other processes require some or all of these: Multiple processes to coordinate and control as many as three in a series Multiple reactors needed for large capacities or advanced products as many as five in a series Pre-polymerization and/or catalyst pretreatment Additional purification Stirrers or scrapers in the reactors Solid separation equipment Membrane separation unit for reactor vent gases Intermediate storage and conveying

The simplicity of the homopolymer/random copolymer system is mirrored in the impact copolymer stage, which operates with the same gas phase fluidized bed process in a slightly smaller reactor. For each reaction stage there are just three main pieces of equipment: the reactor, the cycle gas compressor, and the cycle gas cooler. With active catalyst entering from the first stage, there is no need for additional catalyst feed to the impact reactor. The critical rubber component is polymerized directly in the growing polypropylene particles, achieving optimum rubber dispersion and morphology that results in the highest impact performance.

Figure 6: Simplicity of the Impact Reactor

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Global Resources to Support You Wherever You Operate

The polypropylene industry is truly global, with resin producers and converters operating in every major market around the world. As a global company, Dow has invested in resources to support its licensees no matter where they operate. Our investments in strong local resources are helping licensees succeed.

Figure 7: Serving Global Customers With Extensive Resources

Slovnaft 1 Polychim 1 Ineos 1 Sunoco 2

2 Pinnacle 2 Conoco 2 FHR 1 Dow Seadrift

1 Stavrolen 2 SABIC Europe 1 OPC 1 Yansab 1 PIC

Dow 1

Datang Guangxi Shunhua Fushun Sichuan Sinochem

3 4

1 L.G. Caltex 1 Hyosung 1 JPC 1 J.G. Summit

Dow A Strong Business Resource

From facilities and people in every corner of the globe, to an R&D budget approaching $1 billion, Dow is focused on delivering ongoing business success to its licensing customers. Dow is a science and technology leader that supplies over 3,500 products to customers in 175 countries. As a licensee of UNIPOL Polypropylene Technology you can be assured that the strength and skills of this market-leading organization and its people are behind you in every possible way.

2 Ineos

Yanpet 1 Ibn Zahr 3

8 Reliance

1 PPM

1 Propilco

TPI 3 Pertamina 1

Basell 1

46 Operational UNIPOLTM Polypropylene Technology Reactor Lines 5 Plants in Construction/Start-up Phase

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Technology Transfer, Training, and Ongoing Support to Help You Succeed

Best-in-class technology transfer helps ensure a smooth plant construction and start-up or retrofit. Our goal is to help each licensee become as successful as they can be. We focus our resources on your success from the first meeting, through plant construction, to training, start-up and commissioning, and long-term support using experienced Dow personnel at every step. Coursework in the classroom is supplemented by training using the UNIPOL UNIPPAC Virtual Plant Simulator, a computer-based plant simulator that reproduces the behavior and control room displays of an actual plant using UNIPOL Polypropylene Technology. Learning is greatly accelerated as the simulator models steady operation, grade changes, and even unexpected events like utility upsets in real-time or accelerated mode. Trainee responses can be replayed for study and correction if needed. Scale models are incorporated to teach plant layout and maintenance techniques, and trainees receive manuals to retain for continuing reference.

Putting It All Together

Every way you look at it, a license for the UNIPOL Polypropylene Technology is your best choice, bringing you all the elements you need for a successful polypropylene project: Streamlined and proven gas phase technology with low investment costs Excellent operating economics and reliability Widest product flexibility with market leading grades in key applications SHAC Catalyst Systems, ADT and CONSISTA Donor Technology optimized for gas phase process operation Superior technology transfer services and long-term support Continuing technology development backed by the commitment and resources of Dow

Plant design and technology transfer

The UNIPOL Polypropylene Technology is thoroughly documented in manuals that cover the underlying scientific knowledge, a comprehensive process design package containing the basic engineering information from which an engineering contractor can work, and a manual of typical plant operating procedures. An experienced multifunctional client team works closely with each licensee throughout the process of turning the basic technology into a new plant and maintains support through startup and beyond.

Start-up assistance
An experienced team of Dow people, including a chief commissioning engineer and several operating specialists, provide comprehensive, on-site support, assisting with the commissioning and start-up activity of each licensees new plant. The Dow team has demonstrated the fastest total project time from license signing to producing prime product. As testimony to the exceptional technology transfer and process simplicity, plants using UNIPOL Polypropylene Technology usually achieve nameplate rates and aim-grade production within hours of initial start-up.

Training
Licensees are trained in all facets of the UNIPOL Polypropylene Technology from process theory to practical experience. Initial orientation courses, covering both process and product technology, are held for technical staff and the project team. Plant staff receives thorough operations training in advance of start-up. In this comprehensive program, licensee personnel from plant operations, maintenance, and laboratory groups attend the Dow university-like training center in Houston, Texas, USA, joining a population of graduates that already numbers over 1,500.

Ongoing support through technology improvements

Licensees can participate in a technology exchange program after their plant begins operation and will receive process and product technology improvements. This program includes our highly regarded Global Technology Exchange Meeting, held annually to encourage licensees to share best practices in a group setting. Licensees also have opportunities for one-on-one sessions with Dow experts.

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Contact us: US, Canada, Mexico The Dow Chemical Company Customer Information Group P.O. Box 1206 Midland, MI 48642-1206 Telephone: + 800 447 4369 Fax: +1 989 832 1465 Europe Dow Customer Information Group Prins Boudewijnlaan 41 B-2650 Edegem Belgium Telephone Europe toll free: +800 3 694 6367 Toll: +32 3 450 2240 Fax: +32 3 450 2815 Italy: 800 783 825 Moscow Office Dow Europe GmbH 17/23, Taganskaya Street 109147 Moscow Russia Telephone: +7 495 258 56 90 Fax: +7 495 258 56 92 India, Middle East, Africa Dow Export GmbH Level 22 Kendah House Sheikh Zayed Road Dubai United Arab Emirates Telephone: +971 4 332 8866 Fax: +971 4 332 8280 Asia Pacific Dow Chemical (China) Investment Co. Ltd. Room 1101, Tower W3, Oriental Plaza No. 1 East Chang An Avenue Dong Cheng District, Beijing 100738, China Telephone: +86 10 85279199 Fax: +86 10 85279299 Latin America Dow Brazil S.A. CIG Latin, 3C Floor Rua Alexandre Dumas, 1671 Chacara Santo Antonio 04717-903 Sao Paulo, Brazil Telephone: +55 11 5188 9000 Fax: +55 11 5188 9887

Visit our web site: www.dowunipol.com

NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use conditions and applicable laws may differ from one location to another and may change with time, the Customer is responsible for determining whether products and the information in this document are appropriate for the Customers use and for ensuring that the Customers workplace and disposal practices are in compliance with applicable laws and other gov ernmental enactments. Dow assumes no obligation or liability for the information in this document. NO WARRANTIES ARE GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE EXPRESSLY EXCLUDED. Dow does not endorse or claim suitability of its products for specific medical applications. It is the responsibility of the medical device or pharmaceutical manufacturer to determine that the Dow product is safe, lawful, and technically suitable for the intended use. DOW MAKES NO WARRANTIES, EXPRESS OR IMPLIED, CONCERNING THE SUITABILITY OF ANY DOW PRODUCT FOR USE IN MEDICAL APPLICATIONS. Published December 2010

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