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HIGH DENSITY LLDPE FOR INFRASTRUCTURE APPLICATIONS Dhananjay Sahoo
DGM- Tech IndianOil Corporation Limited
CONTENTS
1. PETCHEMICALS AND POLYMER - A GROWTH ENGINE
2. INFRASTRUCTURE – A NEW OPPORTUNITY
3. INDIANOIL PLANT AND TECHNOLOGY
4. VALUE ADDED HIGH PRODUCTIVITY AND HIGH STIFFNESS RESINS
5. OPPORTUNITY IN RETAIL PUMP STATIONS FOR FUEL TANKS
6. PRODUCT APPLICATION AND DEVELOPMENT CENTER
Natural Resources
• Crude Oil
• Gas
• Coal
Chemical Intermediates
• Naphtha
• Kerosene
• LPG
Basic Chemicals
• Olefins
• Propylene
• Ethylene
• Aromatics
• Benzene
• Toluene
• Xylene
Petrochemicals
• Polymers
• Polypropylene
• Polyethylene
• HDPE
• LLDPE
• PTA
• Glycols
• LAB
End Use Sectors
• Automotive
• Textiles
• Packaging
• Appliances
• Construction
• Healthcare
• FMCG
• Agriculture
• Infrastructure
Petrochemical Industry Value Chain
3
Global Polymer Market – 260 MMT
4
Global Polymer Market
Source: IHS
Net Import of Chemicals & Petrochemicals: Rs 80436 crore in 2015-16
World average
Per capita Polymer Consumption
Per capita Polymer Consumption shall reach world average of 32 by 2040 at CAGR of 5.6%. However current growth is 8%
Polyethylene
• Present Global demand is estimated at 92 MMT
• World capacities matching demand at the moment
• Global Polyethylene Market to grow at ~4.3% per annum from 2017 to 2021
• Growth in Last 5 years has been at ~3.6% per annum .
• Emerging economies are major contributor to growth.
H H
n C = C catalyst CH2 CH2
H H n
ethylene polyethylene
Polyethylene are classified as
• Low Density Polyethylene (LDPE)
• Linear Low Density Polyethylene (LLDPE)
• High Density Polyethylene (HDPE)
Polyethylene
• Present Polymer demand is at 5 MMT. • Growth in Last 5 years has been at ~9.3% per annum. • Indian Polymer Market to grow at ~8.1% per annum from 2017
to 2021. • Indian Polymer Demand in 2021 estimated at 7 MMT. • Capacity in 2021 estimated at 6.8 MMT • India’s consumption will surpass capacity
Present: ~4.5 MMTPA ~5.5 MMTPA
GoI Infrastructure Development Push
I
N
D
I
A
SWACH BHARAT
SMART CITY
AMRUT
HRIDAY
NAMAMI GANGE
DIGITAL INDIA
Targets & Responsibilities
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N
D
I
A
Design Innovations
Weight Reduction
Better Strength to Weight Ratio
Chemical & Stress Cracking Resistance
Product Life Cycle
GoI Infrastructure Development Push
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N
D
I
A
Opportunity Created
Water & Waste Management
Products : Water & Septic Tanks, Manholes, Chambers
• Light weight
• Resistant to chemicals
• Ease of installation
• Custom built Unlike concrete tank.
• Easy to clean
• Different colours
Advantages
GoI Infrastructure Development Push
I
N
D
I
A
Opportunity Created
Water & Waste Management
GoI Infrastructure Development Push
I
N
D
I
A
Opportunity Created
Automobile & Transport related
Products : Barriers, Signage, Bins, Toilets
• Light weight
• Ease of Installation
• Customized Designs
Advantages
GoI Infrastructure Development Push
I
N
D
I
A
Opportunity Created
Automobile & Transport related
• Corrosion resistant
• UV stabilised
• Ranging in capacities from 500 - 10,000 litres
• ‘Tank within a tank’ construction offers integral
protection from leakage & overfilling
• Overfill prevention device
• Covered bund prevents collection of rain water
Advantages
GoI Infrastructure Development Push
I
N
D
I
A
Opportunity Created
Automobile & Transport related
Toys for Entertainment for kids
I
N
D
I
A
Opportunity Created
Recreation & Related
• Safe
• Aesthetic
• Corrosion free
GoI Infrastructure Development Push
I
N
D
I
A
Opportunity Created
Recreation & Related
IOCL New High Density Grade
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D
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A
Technical Characteristics of LLDPE 040R40A/U
Easy Processability
MFI ~ 4.0 gm/10 min
High Rigidity
Density ~ 0.940 gm/cc
Good Impact Strength
Izod ~ 220 J/m
High Stiffness
FM ~ 9000 Kg/cm2
Recommended Applications:
Septic Tanks
Rainwater Tanks
Underground Tanks
Manholes & Chambers
Insulated Containers
Automobile Parts
Oil-Grease Traps
Material Handling Equipments
Sr. No Plant No. of Lines Capacity per Line (KTA) Technology/ Licensor
1 Polypropylene 2 300 Spheripol II – Basell
2 Dedicated HDPE 1 300 Hostalen – Basell
3 HDPE / LLDPE Swing 1 350 Sclairtech - Nova
Polypropylene Plant Dedicated HDPE Plant Swing Plant
Spheripol Hostalen Sclairtech
With 1.95 Million MT capacity, IOCL is the second largest Polyolefin producer in India
IOCL Polymer Plants & Technology
Tanks
34%
Toys Novelties &
Sporting Goods
25%
Containers
18%
Transportation
12%
Others
11%
Global Rotomolding Market
Indian Rotomolding Market
Rotomolding End Use Representation
32 / 68
Advantages of Rotomoulding Process
• Stress Free Parts
• No Weld Lines
• Design Freedom
• Large Parts
• Little Process Scrap
• Inexpensive Molds
Roto Molding – Capacity vs Cycle time
Product Capacity Weight Heating Time(Min) Total Cycle time(Min)
500 Litre (DW) 10.6 Kg 19 28
500 Litre (TW) 15.0 Kg 23 35
1000 Litre (DW) 19.4 Kg 19 28
1000 Litre (TW) 24.0 Kg 23 35
1500 Litre (DW) 30.6 Kg 17 25
1500 Litre (TW) 37.0 Kg 21 32
5000 Litre (DW) 99.0 Kg 19 28
5000 Litre (TW) 123.0 Kg 25 38
Resin Used in RM
PE
84%
PVC, PC, PP,
Nylon
15%
Others
1%
PE Resins Used
LLDPE
90%
XLPE
5%
HDPE
4%
LDPE
1%
Global look at resin used % volumes & types
Resin choice for Rotomolding
Desirable Resin Properties for Rotomolding
• Cold Temperature (-40C) Impact Strength
• High ESCR for Chemical Tanks and IBC's
• High Flexural Modulus for Chemical Tanks and ICB's
• Consistency of Color and Basic Properties (MI and Density)
• Consistent Warpage and Shrinkage Properties
• Narrow MWD
Lower Low Shear Viscosity for Good Processing
Application
• Tanks- fuel tanks,shipping tanks,oil tanks
• Automotive-door armrest,instruments panel
• Containers-planters ,airline container
• Toys and Leisure-balls ,ride on toys, hobby horses
• Marine Industry-dock floats,pool liners,docking fenders
Value Added Rotomoulding Grades
High Productivity Grade
Product Textile Processing Container
Weight 13 kg, Single Layer,
Machine Naroto Make
Reduction in cycle time 9.5%
Productivity increased by 4 tanks per day ~ 6 $ savings per shift
Product 500 Lit, 15.200 kg , 3 layer tank
Machine Naroto 3- Arm Roto molding
Reduction in cycle time 3 min
High Productivity Grade
High Density LLDPE
Development of High Stiffness grade PROPEL 042R35A High stiffness PROPEL 042R35A is a modified grade specially designed for application segment like underground septic tanks, grease traps, inspection manhole/ chambers etc. High stiffness PROPEL 042R35A is having 28% higher flexural modulus in comparison to conventional rotomoulding grade. The density of this modified grade is high compare to conventional roto grades which results in better rigidity and mechanical properties of the said applications. Modified PROPEL 042R35A improves the product performance and service life.
Indian Oil has recently introduced high stiffness, high performance rotomoulding grade 042R35A in the market.
Key attributes
• Upto 0.942gm/cc Higher density
• Around 28 % higher than the conventional roto grades
Higher flexural modulus
Grade Benchmarking Trial : IOCL New High Density Roto Grade Vs Existing Domestic Eq.
Manhole : 2400 mm Height
Product : Single piece rotomoulded manhole of height 2400 mm and diameter 1000 mm having outer ribbed surface and inner
smooth surface.
Parameter / Process Condition Existing Domestic RM
IOCL New Roto Grade
Compounding S S
Pulverization S S
Rotational Moulding
Process Temp. S S
Color Dispersion S S
De-Moulding S S
Cycle Time S S
Product Weight S S
Product Dimension S S
S Satisfactory / Within Spec. at standard parameters
Success Story of High Stiffness PROPEL 042R35A
Manhole (2.4 Mtr Height, 1 Mtr diameter); Weight: 110 kgs
Material Combo 042R35A 96% + Black MB 4 %. Key Attributes Smooth processing of material. No changes in processing parameter.
Double layer underground tank 5000 litres; Weight - 180 kgs
Material Combo Black : 042R35A 93% +Black MB 4% + UV MB 3% White : 042R35A 96% + White MB 4%
Key Attributes Uniform dispersion of material.
Smooth Processability.
Product meeting all quality requirement.
Success Story of High Stiffness PROPEL 042R35A
Opportunity in Indian Oil Retail outlets
• HDPE Pipes
• Fuel Transportation
• Replacing MS Pipes
• Less then 1/8th Weight
• LLDPE (with liner) Storage Tanks
• Fuel Storage HSD & MS
Retail Outlets
Business Development Initiatives – Indian Oil
Rotomoulding Tanks (20KL) requirements – Petrol & Diesel Retail Outlets
Name of Company No of Outlets
IOCL 25000
HPCL 14000
BPCL 13500
ESSAR 2100
RIL 1400
Shell 100
Total 56100
Replacement opportunity 4000 X 4 per annum Weight of tank is 600 kg Overall requirement of material is 960 MT
Product Application and Development Centre (PADC)
PADC is set up near Panipat Naphtha Cracker Complex.
State of Art Technology Centre with sophisticated Plastic Processing & Characterisation equipments
DSIR Recognized
Application Development Lab
Injection Moulding Blow Moulding Rotational Moulding Pipe Plant
TQPP Film Plant Monolayer Film Plant Multilayer Film Plant Twin Screw Extruder
PADC – Testing Lab Facilities
PADC – Testing lab
• Physical Testing
• Thermal Testing
• Rheological Testing
• Mechanical Testing
• Chemical lab
• Optical testing
PADC – Testing Lab Facilities
Confidential 42