Nexant, Inc.
Polypropylene
Keywords: information, forecast, market, demand, supply, report, developments, energy


Full Report Price: $6,500.00
Sections: starting at $100.00
Delivery: Immediate Online Access
Publication Date: 14-AUG-03

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Report Description

Polypropylene developments are occurring across a wide front, reflecting the versatility of the polymer. Two of the areas of intense activity are in metallocene-catalyzed resins and in heterophasic or impact copolymers. The objective of the impact copolymer developments is to improve the stiffness/impact strength balance. Improvements are achieved through better control of the atactic polypropylene content of the base polymer matrix and good distribution of the rubber phase within the matrix.

Metallocene-catalyzed polypropylene is gaining better market acceptance as a result of availability from multiple producers, giving better security of supply. Areas where the metallocene catalyst brings particular benefits are in fibers and in clarity applications, where polypropylene has the opportunity to displace higher cost polymers such as the styrenics and PET.

The most notable change in polyolefin process technology is the continued increase in plant scale, which is a factor across all technology areas and appears, in Nexant Chem Systems' view, set to continue. In addition to this overall trend a number of process highlights appear.

  • Evolution of new technologies - notably BORSTAR from Borealis, which brings slurry and gas phase technologies together in a novel way, with a new, supercritical, operating regime. Initially developed for the production of polyethylene, this technology has been subsequently applied to the production of polypropylene. Borealis has recently adopted a more selective approach to process licensing opportunities in order to better represent the technical capabilities of the process.

  • Step-out technologies - Basell began commercialization of its Multi-Zone Circulating Reactor (MZCR), trademarked SPHERIZONE, which offers the prospect of dual reactor type polymer structures from a single piece of equipment. It is hoped that improved polymer performance and reduced investment cost will result.

  • Key patent expiration - Another factor that is likely to lead to technology development in the short to medium term, is the expiration in 2003 of the condensing mode patent, which applies to fluidized bed gas phase polyolefin technologies. This will give technology developers wider freedom to develop their platforms. The freedom to operate in a condensing regime facilitates higher rates of heat removal from the gas phase and potentially improves the temperature stability of the reaction system. The improved heat removal capability can be particularly beneficial when operating with very high activity catalyst, such as the latest Ziegler-Natta, metallocene and post-metallocene systems.

For this report, Nexant Chem Systems evaluated many state-of-the-art polypropylene processes that are available for license. The evaluation provides:
  • Recent developments, highlighting key developments relating to the process technology.
  • Background on the technology, including general product capabilities, and a list of licensees where applicable.
  • Process description with simplified flow sheets.
  • Investment and cost of production (COP) estimates for a grassroots facility.

The focus is on the various gas phase, bulk, and slurry processes that are well-established, commercially practiced technologies for the production of polypropylene homopolymer and copolymer resins.

In addition to the technology and cost of production analyses, regional supply/demand forecasts out to 2010 are presented.



Table of Contents: Polypropylene
TABLE OF CONTENTS
Technology Review
INTRODUCTION
Figure 2.1 Polypropylene Capacity (Installed) by Technology
GAS PHASE PROCESSES
BP (INNOVENE)
Table 2.1 Polypropylene Plants Using INNOVENE Gas Phase Technology(1)
Chisso
Table 2.2 Polypropylene Plants Using Chisso's Gas Phase Technology(1)
Dow (UNIPOL PP)
Table 2.3 Polypropylene Plants Using UNIPOL Gas Phase Technology(1)
Polypropylene Plants Using UNIPOL Gas Phase Technology(1)
Novolen Technology Holdings (NOVOLEN)
Table 2.4 Polypropylene Plants Using NOVOLEN Gas Phase Technology(1)
Sumitomo
Table 2.5 Polypropylene Plants Using Sumitomo's Technology
Table 2.6 Sumitomo's Polypropylene Grades
BULK PROCESSES
Basell (SPHERIPOL)
Table 2.7 Polypropylene Plants Using SPHERIPOL Technology
Mitsui Chemicals (HYPOL II)
Table 2.8 Polypropylene Capacity Based on HYPOL Technology
Borealis (BORSTAR)
IMPROVED SLURRY PROCESS
Recent Developments/Background
Process Description
Technology Developments
PRODUCT PERFORMANCE
PROCESS TECHNOLOGY
Figure 3.1 SPHERIZONE and SPHERIPOL Property Envelopes
PROCESS CHEMISTRY
Economic Analysis
RAW MATERIALS AND UTILITIES
Table 4.1 Raw Material and Utility Prices and Labor Rates
TECHNOLOGY ASSESSMENT
Homopolymer
Table 4.2 Cost of Production Estimates for Homopolymer Polypropylene
Figure 4.1 Cost of Production Comparison for Homopolymer Polypropylene
Impact Copolymer
Table 4.3 Cost of Production Estimates for Impact Copolymer Polypropylene
Figure 4.2 Cost of Production Comparison for Impact Copolymer Polypropylene
Commercial Analysis
GLOBAL OVERVIEW
Demand
Table 5.1 Global Polypropylene Demand by Region
Figure 5.1 Global Polypropylene Demand by Region
Table 5.2 Global Polypropylene Demand by End-use
Figure 5.2 Global Polypropylene Demand by End-Use, 2002
Supply
Table 5.3 Global Polypropylene Capacity(1) by Region
Trade
Table 5.4 Global Polypropylene Net Trade by Region
Figure 5.3 Global Polypropylene Capacity by Region
Figure 5.4 Global Polypropylene Regional Trade Pattern
Supply/Demand and Trade Balance
Table 5.5 Global Polypropylene Supply/Demand and Trade Balance
Figure 5.5 Global Polypropylene Supply/Demand and Trade Balance
UNITED STATES
Demand
Table 5.6 U.S. Polypropylene Demand by End-Use
Table 5.7 U.S. Polypropylene Demand by End-Use
Supply
Table 5.8 U.S. Polypropylene Capacity
Table 5.9 U.S. Polypropylene Capacity
Supply/Demand and Trade Balance
Table 5.10 U.S. Polypropylene Supply/Demand and Trade Balance
Table 5.11 U.S. Polypropylene Supply/Demand and Trade Balance
WESTERN EUROPE
Demand
Table 5.12 West European Polypropylene Demand by End-Use
Supply
Supply/Demand and Trade Balance
Table 5.13 West European Polypropylene Capacity
Table 5.14 West European Polypropylene Supply/Demand and Trade Balance
JAPAN
Demand
Table 5.15 Japanese Polypropylene Demand by End-Use
Supply
Table 5.16 Japanese Polypropylene Capacity
Supply/Demand and Trade Balance
Table 5.17 Japanese Polypropylene Supply/Demand and Trade Balance
ASIA PACIFIC
Introduction
Demand
Table 5.18 Asian Pacific Polypropylene Demand by End-Use
Table 5.19 Asian Pacific Polypropylene Demand by Country
Supply
Table 5.20 Asian Pacific Polypropylene Capacity by Country
Supply/Demand and Trade Balance
Table 5.21 Asian Pacific Polypropylene Supply/Demand and Trade Balance
Table 5.22 Asian Pacific Polypropylene Net Trade by Country
Table A.2 Cost of Production Estimate for: Homopolymer Polypropylene Process: Chisso, Gas Phase, 2 Lines
Table A.3 Cost of Production Estimate for: Homopolymer Polypropylene Process: Dow, UNIPOL, Gas Phase
Table A.4 Cost of Production Estimate for: Homopolymer Polypropylene Process: NTH, NOVOLEN, Gas Phase
Table A.5 Cost of Production Estimate for: Homopolymer Polypropylene Process: Sumitomo, Gas Phase, 2 Lines
Table A.6 Cost of Production Estimate for: Homopolymer Polypropylene Process: Basell, SPHERIPOL, Bulk
Table A.7 Cost of Production Estimate for: Homopolymer Polypropylene Process: Mitsui, HYPOL II, Bulk
Table A.8 Cost of Production Estimate for: Homopolymer Polypropylene Process: Borealis, BORSTAR, Slurry/Gas Phase

 

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