Introducing and Supporting Speciality Polymer (EVA) Applications GPCA PlastCon 7-9 April 2013 FINAL 8-4-13

Introducing and supporting speciality polymer [EVA] applications
Dr. Trevor J. Hutley

General Manager - Sipchem Technology
4th GPCA PlastCon - Dubai, UAE - Monday 8 April 2013
Sipchem Sipchem EVA ethylene-vinyl acetate Sipchem PADC Product & Application Development Centre Product & Application Development Sipchem
4th
GPCA PlastCon - Dubai, UAE - Monday 8 April 2013
Sipchem Sipchem EVA Sipchem PADC Product & Application Development Sipchem
4th
Sipchem is
- a growing, private, Saudi petrochemical company
- established in December 1999; start of operations 2004; IPO 2006
- 5 world-scale plants in Jubail, making 8 products - producing 2.4 m tons of petrochemicals ~ 1000 employees - 2011 revenue: $0.88 bn - market capitalisation: ~ $2 bn
tools & dies
methanol acetic acid acetic anhydride butanediol carbon monoxide maleic anhydride tetrahydrofuran vinyl acetate monomer VAM
- 5 plants under construction, 1 in the pipeline

ethyl / butyl acetate LDPE & EVA wire & cable compounds EVA photovoltaic encapsulation lm xxx polymer
MAP 1:
COUNTRIES WHICH CONDUCTED SURVEYS IN 2000
Turkey
Tunisia Morocco Algeria Libya Egypt Saudi Arabia Lebanon OPT * Syria ** Iraq Jordan Kuwait Bahrain Qatar UAE Iran
Oman Sudan *** Djibouti DHS data MICS 2 Data No 2000 data Middle-East & North Africa Yemen
MENA
Bahrain, Djibouti, Iran, Iraq, Israel, Jordan, Kuwait, Lebanon, Oman, Palestine, Qatar, Saudi Arabia, Syria, United Arab Emirates, Yemen; Algeria, Egypt, Libya, Morocco, Tunisia
* For OPT, the data is presented separately for the Palestinian refugee camps. See tables for details ** A separate survey has been conducted for the Palestinian population of Syria. See tables for details Bahrain, Kuwait, Oman, Qatar, for details *** A separate survey has been conducted for Southern area of Sudan. See tables Saudi Arabia, United Arab Emirates
GCC
Source: MICS 2 and DHS
Gulf Cooperation Council
Sipchem Jubail Industrial City
Sipchem HQ Al-Khobar
Sipchem Asset Por>olio:
Sipchem plants Jubail Industrial City
100 km
Sipchem PADC Dhahran
2 km
Sipchem HQ Al-Khobar
Sipchem PADC - Product & Application Development Centre

King Abdullah bin Abdulaziz Science Park [KASP] Dhahran Techno-Valley [DTV] King Fahd University of Petroleum & Minerals [KFUPM]
PADC conceptual design - acrylic model
Corporate Structure
Sipchem
Business & Strategic Development
Institutes KACST HIPF Universities KFUPM KAUST
IMC IDC IGC IAC IVC SCC IPC

MeOH
International Methanol Company 1000k+ t 65 %
PADC
Product & Application Development Centre
SM
Sipchem Marketing
MAn BDO THF

International Diol Company 75k t 54 %
CO
International Gases Company 345k t 72 %
AA AAn
International Acetyl Company 460k t 76 %
VAM
International Vinyl Acetate Company 330k t 76 %
EA W&C
Sipchem Chemical Company 100k t 25k t 100 % 50 %
EVA
International Polymers Company 200k t 75 %
Aectra
Singapore
4th
May 2009 Sipchem became the 9th licensee of the ExxonMobil high-pressure tubular technology for EVA and LDPE A 200,000 ton plant is under construction........ start-up: 4Q13
Sipchem
LDPE branching crystallinity density PE 0.853 PE 1.004

A X
short-chain branching
15- 25 short-chain branches per 1000 carbon atoms
long-chain branching
ethylene
poly (ethylene)
Sipchem
Global polyolen demand:

EVA ethylene - vinyl acetate copolymer
polymer LDPE HDPE LLDPE UHMWPE PP EVA TOTAL
demand 2011 (000,000 tons) 18.5 34.7 22.9 0.2 52 3.4 132 Sipchem 76.30
4th
since PE is so successful, why do we need EVA ? no polymer is perfect - co-monomers modify the properties of LDPE - VAM [vinyl acetate monomer] modies the properties of LDPE - polarity - crystallinity adhesive elastomeric / tough
heat-seal; impact puncture exibility
transparency clarity
compounding
Sipchem
LDPE EVA
0 high-pressure polymerisation % vinyl acetate monomer [VAM] in LDPE emulsion polymerisation
PVA VAE
100
poly ethylene
poly (ethylene - co - vinyl acetate)
poly vinyl acetate
LDPE manufacturing process EVA

ethylene co-monomer
VAM
Reactor
This chain transfer mechanism leading to long chain branching increases with rising reactor polymer concentration, with higher reactor temperatures, particularly above 200 C, and lower reactor pressures. Long chain branching particularly influences the solution and melt rheological properties of polymers.
3.2.1.2 Short Chain Branching
initiator
chain-transfer agent
Short chain branches are made by a unimolecular, intramolecular process known as the Roedel Back Biting Mechanism. In this rearrangement, the growing end of a polymer chain can form a six-membered cyclic transition state thereby allowing the primary radical at the chain end to abstract a hydrogen atom from the carbon atom at position 5, as shown in fig. 3.2.4. This new secondary radical can propagate further resulting in a butyl side branch. In reality, several sequential back biting mechanisms can take place before propagation recommences thus producing a number of very specific short chain branches:
LDPE EVA
schematic process
free-radical initiated addition polymerisation chain
16-PR-00-TM-001 Rev 0
high-pressure (2000 - 3000 bar)

Page 99 of 438
Sipchem
4th

This chain transfer mechanism leading to long chain branching increases with rising reactor polymer concentration, with higher reactor temperatures, particularly above 200 C, and lower reactor pressures. Long chain branching particularly influences the solution and melt rheological properties of polymers. 3.2.1.2 Short Chain Branching
41%
of installed capacity is
autoclave
Short chain branches are made by a unimolecular, intramolecular process known as the Roedel Back Biting Mechanism. In this rearrangement, the growing end of a polymer chain can form a six-membered cyclic transition state thereby allowing the primary radical at the chain end to abstract a hydrogen atom from the carbon atom at position 5, as shown in fig. 3.2.4. This new secondary radical can propagate further resulting in a butyl side branch. In reality, several sequential back biting mechanisms can take place before propagation recommences thus producing a number of very specific short chain branches:
59%
tubular
of installed capacity is
1,670 m x 60mm
16-PR-00-TM-001 Rev 0 Page 99 of 438
Sipchem

ethylene
The global demand mix in 2011 by EVA resin type:

EVA type % vinyl acetate typical applications 2011 demand (000 tons)
very low
>1 up to 7
Commodity lms; bakery bags, ice bags, frozen food bags, overwrap and fresh produce wrap
499
low
7 up to17
Blow molding, foam applications, extrusion / lamination, injection molding, industrial stretch wrap and wire & cable
886
mid
17 up to 25
Footwear, Extrusion coating, injection molding, lamination lm, coextruded lms, heat seal layers, hot melt adhesives, agricultural lms
1458
high
25 - 35
Carpet backing, hot melt adhesives, injection molding, wax blended coatings, extrusion, solar panels and photovoltaic cells
577 very high 36 - 45

Hot melt adhesives, coating, polymer modication, grafted polymers
3.4m tons
Townsend Solutions
MFI melt ow index
860
100
Y Axis Axis Y
10
0.1 0.1
0 0
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
12 12
13 13
14 14
15 15
16 16
17 17
18 18
19 19
20 20
21 21
22 22
23 23
24 24
25 25
26 26
27 27
28 28
29 29
30 30
license limit
31 31 32 32 33 33
34 34
35 35
36 36
37 37
38 38
39 39
40 40
41 41
EVA products
% vinyl acetate monomer
X X Axis Axis
provisional Sipchem EVA grade range:

Sipchem EVA LD 2023 EVA 2005 EVA 2009 EVA 3514 EVA 2018 EVA 3522
(2.16 kg / 190C)
MFI 2 2 2 3.5 2 3.5
VAM % 0 4.5 9 14.4 18.2 22
4th
Global R&D Funding Forecast Battelle Memorial Institute

Scientists & Engineers per million people
0.5
1.0
R&D as % of GDP
8000 Americas 7000

Scientists & Engineers/Million People people Scientists & Engineers per million
Finland Singapore
2011
Asia Europe Other
6000 Norway United States 5000 Greece New Zealand Canada Portugal Russia Ireland UK Belgium France Netherlands Taiwan Austrailia Austria
Denmark
South Korea
Sweden
Japan Germany
4000
3000
Spain
Switzerland
Czech Republic 2000 Poland Argentina 1000 Saudi Mexico Romania Arabia Malaysia 0.5 Turkey Brazil South Africa Italy Hungary
Israel China
Indonesia
India 1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
R&D as % of GDP
R&D as % GDP
polymer processing is an integral part of the design of the PADC
Design Elements
Sipchem PADC
Final Design
Sipchem PADC
Final Design
Dhahran TechnoValley
NOV09
Progress of Construction
Progress of Construction
177 m 94 m site of Sipchem PADC 142 m
MARCH 2010
PADC
11 May 2011
PADC
19 May 2011
27 September 2011
15 November 2011
March 2012
1 July 2012
TJH ofce
Sipchem PADC
Product & Application Development Centre
Overview
design intent: collaboration, open, interaction, integration 10 800 m2 of constructed area 3 oors + open basement + central atrium novel polymer faade state-of-the-art IT, instruments & equipment 39 Laboratories 7 expansion spaces 8 facilities for Teaching 40+ ofces
PADC is a mission-driven technical centre, focussed on delivering value to Sipchem
PADC Pathways
Establishing PADC
2013 - 2014
Engaging with and Developing the downstream [plastics processing] industry in the Kingdom Product Development Development Application Development Customer Development [Technical Service] Process Development Training & Teaching Research - creating the future through science, technology and creativity Corporate & Strategic Development [includes Project Development]
4th
Product & Application Development
establishing the PADC building capability in polymer technology
engaging with the industry
Sipchem
establishing the PADC Application Focus

4th
adhesives, ink and paint [coatings] packaging lms wire & cable footwear photo-voltaic encapsulation lm lms for agriculture & horticulture Sipchem
understanding LDPE and EVA structure / property relationships
Sipchem
LDPE EVA
0 high-pressure polymerisation % vinyl acetate monomer VAM 100
poly ethylene
poly (ethylene - co - vinyl acetate)
28
86
Y = 47.683 - 1.034x
R2 =0.9936
50 40 % crystallinity 30 20 10
22 mole%
46.12
10
15 20 25 30 vinyl acetate (weight %)
35
40
45
An algorithm for the accurate prediction of the detailed polymer architecture [2010]

4th
understanding LDPE and EVA structure / property relationships
engaging with the industry understanding market needs developing Products & Applications Sipchem
Engaging with & Developing the downstream [plastics processing] industry in the Kingdom
understanding the local EVA demand identifying opportunities for collaboration innovate invent discover
di
putting science in to the application
NAPCO
Sipchem Technology
one step ahead of the innovators

Introducing and Supporting Speciality Polymer (EVA) Applications GPCA PlastCon 7-9 April 2013 FINAL 8-4-13

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Introducing and Supporting Speciality Polymer (EVA) Applications GPCA PlastCon 7-9 April 2013 FINAL 8-4-13

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Introducing and supporting speciality polymer [EVA] applications

Dr. Trevor J. Hutley

4th GPCA PlastCon - Dubai, UAE - Monday 8 April 2013