English

Technology

Spheripol Process
and Services
Production of PP
Homopolymer, random copolymer, heterophasic impact copolymer
2
 3

A True Polyolefin
Perspective

1. An Introduction to Basell

Basell is the worlds largest Advanced Polyolens Business,

producer of polypropylene and
advanced polyolens products, a
leading supplier of polyethylene
and catalysts, and a global leader
in the development and licensing
of polypropylene and polyethylene
processes.
which consists of polypropylene
compounds and other specialty
products, and
Polyolens Business, which
comprises polypropylene and
polyethylene.

Basell, together with its joint ventures,
has manufacturing facilities around
the world and sells products in
more than 120 countries. With
research and development activities
in Europe, North America and
the Asia-Pacic region, Basell is
continuing a technological heritage
that dates back to the beginning of
the polyolens industry. Basell is
committed to innovation both through
improvements of its processes
and a continuous extension of the
properties of its polyolens portfolio.
Basell has its corporate centre in The
Netherlands and has regional oces
in Belgium, Germany, the United
States, Brazil and Hong Kong, as well
as sales oces in the major markets
around the globe.
For further information on Basell,
please see separate leaets in the
pocket-page in the back of this
brochure or visit the companys
web site: www.basell.com.

The company is organised in three

businesses:

Technology Business, which

includes licensing, catalysts
development and sales, R&D
and new projects;
4

2 Your Partner in the World of Polyolefins Technology

2.1 Leading the Technology Race

The history of Basell and its prede-
cessors is one of continuing achieve-
ments and breakthroughs in cata-
lysts, process and product develop-
ments in the field of polyolefins.
It began with the discoveries in poly-
olefins technology and catalysts by
Karl Ziegler and Giulio Natta, reward-
ed with the Nobel Prize in 1963, and
has continued through five revolu-
tionary generations of Ziegler-Natta
catalysts to the development of a
new metallocene-based polypropy-
lene catalyst family and products.
and cost-effective solutions that
meet the changing requirements of
our customers.
Thanks to the close integration be-
tween our marketing, R&D and man-
ufacturing, new developments of cat-
alysts, processes and products are al-
ways focused on meeting market de-
mands and commercialised quickly
in a responsible manner.

From the first industrial polypropy-

lene and polyethylene processes to
our latest multi-zone circulating re-
actor developments, Basell and its
predecessors have delivered state-
of-the-art polyolefin catalysts, tech-
nologies, and products to customers
world-wide.
For us, creating innovative poly-
olefin products is a way of life, deliv-
ering both superior performances

2.2 A Licensing Portfolio for
Any Producers Needs
Basell is the only licensor offering
process technologies for production
of all PP and PE product families. Our
technologies are some of the most
reliable, efficient and cost-effective in
the world, and can meet both the di-
verse needs of performance plastics
manufacturers and those of com-
modity-oriented polyolefin produc-
ers.
Basells licensing portfolio of process-
es and services includes the following
technologies:
Spheripol, the worlds leading tech-
nology for the production of
polypropylene homopolymer plus
random and heterophasic copoly-
mers
Spherizone, this new manufactur-
ing platform with a multi-zone cir-
culating reactor system that cre-
ates polypropylene and novel,
propylene-based polyolefinic ma-
terials with outstanding quality
Hostalen, the leading low-pressure
slurry process technology for the
production of bimodal HDPE
5
Spherilene, the dual reactors swing
gasphase process technology for
the production of LLDPE and HDPE
Lupotech G, the fluidised bed gas-
phase technology for the produc-
tion of chromium type HDPE and
MDPE or ZN based HDPE / LLDPE
Lupotech T, the high pressure tubu-
lar reactor process technology for
the production of LDPE homopoly-
mers and EVA-copolymers
Some of the processes can be easily
upgraded in capacity and capability
to produce more sophisticated prod-
ucts, if required.
Basells Avant catalyst range covers
titanium, chromium and zirconium-
based polymerisation and is the opti-
mal solution for the process tech-
nologies we offer. Avant catalysts
can also be used in most other types
of polyethylene and polypropylene
process technologies.
6

PP consumption trend 1975 - 2005

45,0
40,0

35,0
30,0

25,0
kt/a

20,0

15,0
10,0

5,0

0,0
1975

1977

1979

1981

1983

1985

1987

1989

1991

1993

1995

1997

1999

2001

2002

2005
Source: TECNON, Basell

3 Technology
3.1 Introduction to Spheripol Technology

Global demand for polypropylene This includes Exxon, Dow, Borealis,

(PP) has grown quickly over many Showa Denko, Hyundai and Sinopec,
decades. There are three major rea- to name but a few. Today, products
sons for this: from the Spheripol process are rou-
tinely sold in over 100 countries, and
As a well-established plastic resin future licensees will certainly benefit
with a broad application range, PP from this wide acceptance and prod-
usage has grown in line with the uct standardisation.
overall economy.
During their transition phase, de-
veloping countries experience
rapid growth in their per capita PP
consumption.
There is huge untapped technical
potential in PP resins, which con-
tinues to extend their usage into
market segments of traditional ma-
terials like glass, wood, paper,
metal, etc., other plastics and, in
some cases, even engineering
plastics.

Basell's Spheripol process is the most

widely licensed technology ever de-
veloped for the production of
polypropylene. Since 1982, proof of
its enduring worldwide success is
the number of leading polypropylene
producers choosing this technology.

3.1.1 An overview of Spheripol Technology development
Todays Spheripol process is the re-
sult of forty years of continual im-
provement. However, to truly appre-
ciate the unique capabilities of this
technology, it is helpful to under-
stand the evolution of the polypropy-
lene industry and the breakthroughs
that led to the discovery of the
Spheripol process.
In the 1960s, polypropylene processes
employed first generation low yield
catalysts (<1,000 kg PP/kg catalyst) in
mechanically stirred reactors filled with
an inert hydrocarbon diluent. Polymer
produced with these catalysts had un-
acceptably high residual metals, and
contained 10 % atactic polypropylene,
which required separation. Removal of
catalyst residues and atactic PP in-
volved treatment of the polymer with
alcohol, multiple organic and/or water
washings, multistage drying and elabo-
rate solvent, amorphous and catalyst
separation systems. These processes
were costly and difficult to operate,
and also required extensive water
treatment facilities, and catalyst residue
disposal systems.
7
In the 1970s, the discovery of se- morphology, isotacticity and molecu-
cond-generation high yield catalysts lar weight, and continually challeng-
(6,000 kg PP/kg catalyst) eliminated ing new frontiers in the development
the need for catalyst residue re- of propylene polymers.
moval, but atactic was still unaccept-
ably high. This simplified the wash- Due to its low density, good physical
ing but did not eliminate the atactic properties and easy processability,
recovery steps. polypropylene is the worlds fastest
growing thermoplastic.
In the 1980s, third generation high
yield, high selectivity (HY/HS) cata-
lysts (30,000 kg PP/kg catalyst) elim-
inated the need for catalyst and atac-
tic removal. This further simplified
the process and improved product
quality. Other breakthroughs oc-
curred in the process design,
through the refinement of gas-phase
and bulk polymerisation reactors
that led to the development of
Spheripol technology in 1982.
Today, the capabilities of the
Spheripol process are further en-
hanced by the current catalyst gene-
ration, which has the ability to pro-
duce new families of reactor-based
products with improved properties.
They offer even greater control over
8

3.2 Spheripol Key Characteristics

The Spheripol process offers li-
censees a simple and economical
method of producing a wide range of
PP products of the highest quality.
Today, more companies are using the
Spheripol process than the technolo-
gies of the three closest competitors
combined.
The unmatched success of Spheripol
technology is a result of our focus on
polyolefins and a commitment to
continuous improvement.
Safety & Loss prevention
Basell has a safety record among the
best in the industry. To date, Basell
technologies have achieved nearly 7
million operating hours without any
major incident.
self), recovery and recycling of unre-
acted monomers, and the absence of
undesired by-products from the reac-
tion.
Reliability
At the end of 2002, a year-on-year
analysis of operating records from
over 80 Spheripol process plants
worldwide, showed the average
overall operability rate is about 98 %.
Of an average 2 % downtime, less
than 1 % is due to process features.

Reducing Resource Intensity

Spheripol technology includes fea-
tures that reduce both resource con-
sumption and emissions from the
process. These include use of high
yield, highly stereospecific catalysts,
the absence of solvents in the
process to suspend the polymer (the
suspension agent is the monomer it-

Versatility
In comparison with any gas-phase
technology, a Spheripol process
plant offers on a single polymeriza-
tion line the widest range of ho-
mopolymers, random copolymers
and terpolymers, as well as het-
erophasic impact and specialty im-
pact copolymers covering all PP ap-
plication fields. Intense efforts in
product application development
for all the major market areas in the
world, ensures Basell's PP products
keep a leading position in most
profitable market segments, with
excellent results in PP specialties
and "high quality" demanding appli-
cations development.
Quality
Spheripol technology delivers un-
matched quality with minimum
property variation due to excellent
process stability and the consisten-
cy of Basell's catalysts performance.
9
Design flexibility Dedicated support
A range of single line capacities The experience of Basell's dedica-
from 40 450 kt/a are available for ted technology team is made avail-
homopolymer, random copolymer able to Spheripol process licensees
or heterophasic impact copolymer, to ensure the highest degree of suc-
either using polymer or chemical cess during project implementation
grade monomer. and plant operation.
Modular installation
By a modular installation, Spheripol
process technology is easily adapt-
ed to meet changing market re-
quirements when new business op-
portunities arise for licensees. This
flexible modular design has virtual-
ly no impact on initial investment
costs. On existing plants, expan-
sions of up to 30 - 40 % of the ini-
tial capacity have been achieved
through minor adjustments.
Low capital and operating costs
Capital costs for the Spheripol
process are competitive with cur-
rently available PP processes. The
technology also offers the lowest
operating costs and excellent plant
reliability and transition efficiency.
10
3.3 Process Description
The Spheripol process, using high
yield/high selectivity (HY/HS) catalysts
supplied by Basell, has the unique abil-
ity to produce polymer spheres direct-
ly in the reactor. Spherical polypropy-
lene differs considerably from the
small, irregularly shaped, granular par-
ticles produced with some other tech-
nologies and provides significant ad-
vantages in terms of process reliability.
The Spheripol process is a modular
technology. In its most widely adopted
configuration the polymerisation sec-
tion involves the following main units:
Catalyst feeding
Polymerisation
- Bulk polymerisation (homopoly-
mer/random copolymer and ter-
polymer)
- Gas-phase polymerisation (het-
erophasic impact and speciality
copolymer) - option (gas-phase
copolymer unit can be added at a
later stage without affecting initial
plant configuration or involving
significant implementation costs)
Finishing
Bulk polymerisation employs tubular
loop reactors filled with liquid propy-
lene to produce homopolymer and
random copolymer or terpolymer.
The catalyst, liquid propylene and
hydrogen for molecular weight con-
trol are continuously fed into the
loop reactor. Residence time in the
reactor is lower than other technolo-
gies because of the high monomer
density and increased catalyst activi-
ty. The loop reactor is used because
it offers low cost, high heat transfer
and maintains uniform temperature,
pressure and catalyst distribution.
The low residence time also results
in short transitions during grade
changes, while the complete filling of
the reactors eliminates any risk of
contamination between different
grades due to the presence of an in-
terface between the actual reaction
volume and disengagement.
 11

Spheripol process

Propylene
+ Hydrogen

Steam

Catalyst

Ethylene

Nitrogen

To polymer handling
Propylene + Hydrogen and extrusion
Ethylene
12
A homogeneous mixture of poly-
propylene spheres is circulated in-
side the reactor loop. If the produc-
tion of random copolymer or terpoly-
mer is desired, ethylene and/or
butene-1 are introduced in small
quantities into the loop reactor. This
process achieves very high solid con-
centration (>50% by weight), excellent
heat removal (by water circulation in
the reactor jacket) and temperature
control (no hot spots). The resulting
polymer is continuously discharged
from the reactor through a flash
heater into a first-stage de-gassing
cyclone. Unreacted propylene from
the cyclone is recovered, condensed
and pumped back into the loop reac-
tor.
For the production of impact and
specialty impact copolymers, poly-
mer from the first reactor is fed to a
gas-phase fluidised bed reactor that
operates in series with the loop reac-
tor (this gas-phase reactor is by-
passed when homopolymer or ran-
dom copolymer is produced). In this
reactor, an elastomer
(ethylene/propylene rubber) formed
by the introduction of ethylene is al-
lowed to polymerise within the ho-
mopolymer matrix that resulted from
the first reaction stage. The carefully
developed pores inside the polymer
particle allow the rubber phase to de-
velop without the sticky nature of
the rubber to disrupt the operation
by forming agglomerates.
Fluidisation is maintained by ade-
quate recirculation of reacting gas:
reaction heat is removed from the re-
cycled gas by a cooler, before the
cooled gas is recycled back to the
bottom of the gas-phase reactor for
fluidisation. This type of gas-phase
reactor is efficient because it main-
tains a high degree of turbulence in
order to enhance monomer diffusion
and reaction rates, and offers an effi-
cient heat removal system.
Some speciality products, incorpora-
ting two different ethylene content
copolymers, require a second gas-
phase reactor in series.
In impact copolymer production, at
least 60% of the final product is pro-
 13

duced in the first-stage loop reactor.

In addition, since ethylene is more re-
active than propylene, the gas-phase
reactors are smaller than would be re-
quired if this design were to be used
for homopolymer production. Spheri-
cal morphology ensures high reliabili-
ty and elimination of fouling phenom-
ena, which frequently disrupt other
gas-phase systems.

Polymer discharged from the reactors

flows to a low-pressure separator and
subsequently to a steam treatment
vessel where catalyst residues are
neutralised and the dissolved
monomer is removed, recovered and
recycled back to the reactor system.
From the steamer, polymer is dis-
charged into a small fluidised-bed
dryer with a hot nitrogen closed loop
system to remove the moisture.

The final product is conveyed to an

extrusion unit, where it is mixed with
additives and extruded to pellets.
14

3.4 Safety and Environment

Basell has a safety record among the

best in the industry. To date, Basell
technologies have achieved nearly 7
million operating hours without any
major incident.

Spheripol process plants are built ac-

cording to the Basell Safety Design
Criteria and must undergo Safety Au-
dits prior to commissioning and
start-up.
All licensed sites receive visits from a
team of specialists experienced in di-
verse fields, including:

Safety and Loss Prevention

Health & Environmental
Process Operations
Instrument/Electrical/Mechanical
design

This team verifies and ensures that

the plant is built according to the
Basell Safety Design Criteria, and as-
sists the licensee with any safety,
health or environmental concerns re-
garding the process and related faci-
lities.
 15

3.4.1 Intrinsic safety 3.4.2 Spheripol: Technology

of the process
The design of each Spheripol process
plant includes a number of safety
features, such as:
Proprietary Catalyst Deactivation
System, which immediately stops
all reaction
Computer controlled emergency
shutdown systems
Uninterruptible Power Supply (UPS)
for computer control and critical
instrumentation control
Instrument air emergency buffer
Emergency Blowdown System to
empty the plant quickly, in the
event of an emergency
Gas detectors which instantly de-
termine and highlight (on a graph-
ic easy-to-read board) the source
of any hydrocarbons in the event
of leakage into the atmosphere
Automatic fire protection systems
designed to lower
environmental impacts
Spheripol process units are config-
ured so that unreacted monomers
are recovered and recycled. If neces-
sary, other discontinuous hydrocar-
bon purges can be sent to "off-gas
recovery for use as a fuel supply or
to a flare system.
The Spheripol process does not use
hydrocarbon diluents nor contami-
nant chemicals and the only waste-
water is released from the steam-
ing/drying section of the plant which
contains steam condensate and a
small amount of inert polymer fines,
which are recovered by a separator.

Depending upon the severity of the

situation, the plant can be shut down
manually in a step-by-step, con-
trolled fashion, more rapidly by both
manual and computer control, or by
instant automatic shutdown.
16

3.5 Process Capability

3.5.1 Design Flexibility

Spheripol process plants are de- a later date to produce heterophasic

signed to meet the particular require- impact and speciality impact copoly-
ments of individual licensees, yet mers. Impact copolymers are more
they are flexible enough to be easily specialised products, which require
expanded to meet future needs as additional capital investment and
the business develops. Two critical technical support.
design elements that are easily ex- The simple design of a Spheripol
panded include capacity and product process plant does not require
range. mandatory equipment or instru-
ment/electrical vendor lists. There is
Spheripol process facilities have been also a list of suitable suppliers and
designed with capacities ranging designs for critical equipment, en-
from 40 - 450 kt/a. This wide capaci- abling purchasers to benefit from the
ty range and the modular installation most economic pricing available.
approach allows, within limits, easy
debottlenecking. This minimises ini-
tial capital costs and allows new ca-
pacity to be added later when re-
quired.
The product range can also be easily
expanded. Often new entrants to the
polypropylene business will build a
plant to produce only homopolymer
and random copolymer products as
these are the least expensive, are
easy to operate and their products
account for 75% of all polypropylene
sold in the world. A basic homopoly-
mer plant can be easily expanded at

Spheripol Process Capability
MFR (g/10)
Xylene Insolubles (%)
Particle size (mm)
Melting point (C)
Flexural Modulus (MPa)
IZOD impact at 23C (J/m)
3.5.2 Versatility
Spheripol technology's versatility is
demonstrated by its easy process op-
eration and ability to deliver a pro-
duct range that includes all standard
polypropylene grades, and many
unique, special products.
Key to this versatility is the applica-
tion of Basell's high yield / high se-
lectivity Avant catalysts:
High polymerisation activity
(mileage over 40,000 kg PP/kg cat-
alyst), resulting in extremely high
polymer purity
Stereospecificity control of poly-
mer
Morphology control of particle
size, shape and distribution
Molecular weight distribution con-
trol
Use of polymer or chemical grade
monomer
Homopolymer, random copolymers
and terpolymers, heterophasic im-
pact and speciality impact copoly-
mer production
17
0.3 to > 1600
90 to 99 %
0.3 to 5.0
130 to 165
600 to > 2400
30 to 1000
3.5.3 Advanced Process
Control
Although the standard control sys-
tems are highly capable of control-
ling the process reliably and effi-
ciently, Advanced Process Control
software can be made available to
Spheripol licensees in order to fur-
ther benefit from the process capa-
bilities.
3.5.4 Simulation /
Operator Training
program
A special developed simulation pro-
gram is used for training and deve-
lopment purposes, and can be made
available to Spheripol licensees. The
program allows training for start-up,
steady state, grade-change and shut-
down operations, and can assist in
optimising your Spheripol plant.
18
3.5.5 Technology Summary
The Spheripol process is the most cost effective technology for whole PP family production
Other Processes
Conventional gas-phase design suffers from equip-
ment size scale up problems and constraints in
plant operation economics due to monomer losses
and mechanical weakness.
Gas-phase operating window is limited in terms
of hydrogen response and heat removal.
Spheripol technology ensures better product quality and reproducibility
Other Processes
Polymer morphology may affect process reliability
and represent a constraint to finishing efficiency
and complete monomer recovery.
Catalyst system distribution and process parame-
ters control is more critical.
Hydrogen response is limited and reactors cascade
operating mode (bimodal operation) is not available.
Spheripol Process
Spheripol process operation is not affected by the
presence of critical machines. Complete monomers
recovery is possible even in case of chemical grade
monomer use. Catalyst yield is higher.
Plant configuration is modular in order to optimise
investment costs to product slate requirements, loop
reactors design allows for better scale up efficiency
(single line over 400 kt/a does not imply any critical-
ity in equipment sizing or reactors configuration)
Hydrogen response is higher. Loop reactors design
and liquid monomer operation grants extremely effi-
cient heat removal and temperature control.
Spheripol Process
Controlled morphology of the polymerising particle
(independently from average particle size) improves
finishing efficiency and eliminates risk of fouling
when producing impact copolymers even at high
ethylene content.
Polymerisation conditions are completely homoge-
neous and can be reproduced exactly any time by
simple parameter selection.
Hydrogen response is very high, catalyst system ca-
pabilities and bimodal operation mode allows for ac-
curate control of product quality in a wide range of
properties.

Spheripol technology provides the easiest and cheapest grade change
Other Processes
Cumbersome product transition from grade to
grade, especially when switching to or from copo-
lymers. Presence of an interface between polymer
bed and disengagement section increases risk of
product contamination.
Off-grade material associated with each cam-
paign takes up a recognisable portion of the pro-
duction.
Spheripol technology has reduced environmental impact to negligible levels
Other Processes
Conventional approach.
Lower efficiency associated with hydrocarbons
polluted nitrogen stream recovery and polymer
residual volatiles.
19
Spheripol Process
The switch from one grade to another is particularly
easy, quick, and low cost because hydrogen composi-
tion can be adjusted immediately without reducing ca-
pacity and impact copolymer production can be star-
ted by just feeding homopolymer to copolymer reac-
tor.
Very low residence time, allowed by extremely high
reactivity conditions, minimise transition material.
Full reactors avoid product contamination .
Spheripol Process
Extremely high attention to environmental and safety
considerations due to the "liquid phase hydrocarbons
culture".
All monomer residues are recovered to the polymeri-
sation thanks to the unique "live steam stripping
which ensures a complete polymer "finishing.
20

3.6 Process Economics

3.6.1 Reliability and operability

The Spheripol process has proven to
be extremely reliable. In use since
1982, it has been continuously re-
fined and optimised. Yearly world-
wide surveys of operating Spheripol
process lines reveal an average on-
stream operability of around 98%.
Key contributors to this remarkably
high operability include:
A simple, straightforward process
design with simple and reliable
equipment
Easy on-line product change
Rapid restart after shutdown
No scheduled maintenance down-
time for cleaning or inspection
purposes
Products from the Spheripol process
are superior in quality. The Spheripol
process was designed around the
catalyst to minimise property varia-
tions and to ensure consistent results
with regard to:
Particle size and shape
Crystallinity and stiffness
Melt flow
Molecular weight distribution
Comonomer distribution
Physical and optical property per-
formance
High catalyst mileage results in ex-
tremely low residual metal content.

3.6.2 Quality

In addition to high operating rates,

products produced with the
Spheripol process maintain consis-
tently high quality from one run to
the next. Products are identical from
different plants, wherever located.
 21

3.6.3 Consumptions

Spheripol process plant capital and

operating costs are among the low-
est in the industry as a result of:

Smaller reactor volumes

Minimum transition time
Lowest monomer consumption
Utilisation of low cost chemical
grade or polymer grade monomer
Low steam and electric power con-
sumption

Typical specific consumption (per

1000 kg of PP produced)

Homopolymer Impact Copolymer

(1)
Monomers (kg) 1002 1002
3) (2)
Hydrogen (Nm 0.01-0.5 0.01-0.5
(3)
Catalysts & Chemicals ($) 22-25 23-26
(4)
Electric power (kWh) 250-270 280-300
(5)
Steam (kg) 280 280
3) (6)
Cooling water (m 110 120
Nitrogen (Nm3) 15 15

(1) Net consumption of 100% monomers / co-monomers included

(2) Depending of reactor gas composition, according to polymer MFR
(3) Typical General Purpose stabilisation
(4) Extrusion included, consumption depending on product MFR
(5) Low pressure steam, high pressure steam consumption for extruder die plate or barrels heating is excluded
(6) At T = 10C
22
3.7 Products and Applications
Isotactic polypropylene is well suited
for a variety of end uses, ranging
from flexible and rigid packaging to
fibres and large moulded parts for
automotive and consumer products.
Polypropylene is recyclable, an im-
portant consideration in many pack-
aging and automotive applications,
and it can be incinerated without
toxic emissions. It can be processed
using most methods including extru-
sion, extrusion coating, blow mould-
ing and stretch blow moulding, injec-
tion moulding, and thermoforming.
Its physical properties can be easily
enhanced through the addition of
fillers such as calcium carbonate or
talc. Polypropylene has excellent
chemical resistance and electrical in-
sulating properties.
Typical applications for polypropy-
lene products produced in the
Spheripol process include fibres and
filaments, oriented and cast film, in-
jection-moulding items, blow-mould-
ed bottles and parts, and thermo-
formed containers.
Random copolymers can be pro-
duced with excellent optical proper-
ties and sealing initiation tempera-
tures in compliance with the U.S.
Food and Drug Administration (FDA)
regulations for food contact.
Heterophasic copolymers with out-
standing low-temperature behaviour,
high-impact strength and enhanced
stiffness can be obtained in the
widest range of melt viscosities.
As a global average, homopolymer
accounts for 65-70 % of all
polypropylene, random copolymer
and terpolymer for 10-15 % and het-
erophasic copolymer for 15-20 %.
Film and fibre are the two largest
segments in the global PP market,
but injection/blow moulding and ex-
trusion account for significant quan-
tities. Typical polypropylene fabrica-
tion processes and end uses include
the following major fields:
 23

By courtesy of SIMONA

Fabrication Process Markets/End Uses

Film Extrusion BOPP film / WQB film / cast film/ (flexible packaging for tex-
tiles, confectionery, bakery and cigarette wrap)

Multifilaments woven sacs (raffia)/fibrillated tape for carpet backing, geotex-

tiles, rope and twine, upholstery and cigarette tow

Nonwovens geotextiles, medical application

(meltblown and spunbonded)

Injection moulding automotive, appliances, houseware,

furniture, consumer products, packaging (crates, cases, caps
and closures, thin walled and transparent containers)

Blow moulding packaging

Profiles extrusion pipes, conduits, corrugated sheet, wire and cable extrusion
coating, lamination.

Basell Avant catalysts are capable of
manufacturing products with virtually
unlimited combinations of physical
properties to meet the increasing de-
mands of customers in new and more
challenging applications.
In comparison with any competitor
gas-phase technology, a Spheripol
process plant is making available on a
single polymerization line the widest
range of PP products, including ho-
mopolymers, random copolymers and
terpolymers, as well as heterophasic
impact and specialty impact copoly-
mers covering all PP application fields.
Extensive product application develop-
ment has enabled products from the
Spheripol technology to keep a leading
position in most market segments
worldwide, and particularly in PP spe-
cialties and applications demanding
high quality levels, where excellent re-
sults have been achieved.
For better evaluation of the capabili-
ties of the Spheripol process, and to
demonstrate its superiority to any
competing technology, listed overleaf
are some of the Spheripol process
products which ensure Basell's leading
position in specialties and high perfor-
mance PP market segments:
24
Homopolymers
Very high processability BOPP, for
application on very fast tenter ma-
chines (over 300 m/min).
Single and multi-layer cast film
produced on high-speed lines
using new grades particularly suit-
able for thin gauges.
Fine denier continuous filament
and non-woven fabrics products
for disposable clothing, lining,
medical hygienic, feminine care,
diapers, crop protection in agricul-
ture.
High clarity gamma ray resistant
for syringes injection grade.
In addition, a number of new com-
mercial grades have been successful-
ly introduced to the market for very
high stiffness homopolymers (Flexur-
al Modulus higher than 2300 MPa)
for injection and thermoforming.
..
Copyright Citroen Communications
Random copolymers and
terpolymers
A new family of very high clarity ran-
dom copolymers of propylene and
butene-1 with less hexane extracta-
bles (very important for food con-
tact) is under commercial develop-
ment. Uses will include high perfor-
mance cast film application with dif-
ferent stabilization package as well
as for extrusion applications, such as
thermoforming, blow molding, sheet
extrusion and blown film.
 25

Heterophasic impact copolymers In addition, heterophasic copolymers

Improved impact/stiffness balance with very high creep resistance are
copolymers for corrugated pipe, now available for pipe applications.
injection and thin wall injection- There are also a whole family of high
moulding applications. These rigidity "ultra" grades for fast injec-
grades have been recently intro- tion applications, and high clarity im-
duced on a commercial scale and pact grades for cosmetic packaging
made available to the Spheripol and houseware.
process licensees.
Very high MFR impact copolymers
for thin wall injection (MFR 70 and
100 g/10' pelletised commercial
grades are regularly produced in
Basell's Spheripol process plants).
Specialty impact heterophasic
copolymers for bumpers present-
ing extremely high impact resis-
tance even at very low tempera-
tures. These reactor grades were
developed in the Spheripol
process to the requirements of all
major car manufacturers in Eu-
rope.
High impact for special applica-
tions such as a low MFR grade free
of fish eyes for film and tape or
extrusion and blow moulding.
26

4 Licensing Customer Services

During the development of a project also described. Payment conditions

and throughout the operation of the vary from lump sums to running roy-
plant, experts from the Licensing De- alties, or an appropriate combination
partment and the Technology Trans- of both these elements.
fer Centre will be dedicated to the li- Further sections of the License
censees needs in the following areas Agreement stipulate the project as-
of activity: sistance, particularly during commis-
sioning and start-up of the plant and
Licensing process the performance testruns, by Basell
Prior to the granting of a license, experts in process design, polymeri-
Basell will actively participate in the sation, extrusion and quality control.
definition of the project, based on Other more formal chapters cover se-
the product and marketing expecta- crecy, liability, patent issues, force
tions from the customer. This stage majeure, applicable law, etc.
defines the optimal technology and
particular design features - such as Business start-up support
capacity, reactor configuration, cata-
lyst system, etc. - under a confiden-
tiality agreement.
Once the scope of the plant has been
jointly identified, a draft License
Agreement will be prepared and ne-
gotiated; the agreement will contain
articles that define the type and ca-
pacity of the plant, the product grade
slate, etc. The supply of the Process
Design Package, the extent of the
granting of the license, the license
fee and the payment conditions are

Basell is open to discuss possible sup-
ply of resins from Basell production for
pre-marketing of resins by the li-
censee, and use the Basell marketing
and sales organisations to support the
licensee in the development of the
polyolefins business, by agreement on
defined off-take volumes of resins
until the licensee can market the entire
production volume itself.
Process Design Services -
Engineering
The Process Design Package (PDP)
provided by Basell Process Design
contains a comprehensive technical
description of the entire process, and
is adequate to allow for the prepara-
tion of the engineering of the plant,
application to authorities for environ-
mental licenses, and the preparation
of the operating manual. Typical PDP
content is:
Process description
Process flow diagram (PFD) with
heat and material balances
Piping and instrument diagrams
(PIDs)
27
Equipment list + data sheets
Instrument list + data sheets
Safety valve list + data sheets
Plot plans
Safety design criteria
Emergency flaring load
Fluid list and piping classes
Environmental information
Guidelines for the operating manu-
al
Etc.
Ideally the Basic Engineering may be
provided by a contractor with a
proven record of the Basell technolo-
gy. Alternatively this can be done by
another contractor on the basis of
the PDP.
The Detailed Engineering at least in
part - is typically done by a local en-
gineering company in the region of
the license plant.
Experts from Basell Process Design
can assist the engineering activities.
28
Technology Transfer:
Besides some initial support during
the licensing process, the main ser-
vices provided to the Licensees by
Technology Transfer are in agree-
ment with the Licensing Agreement,
and consist of the following:
Training
Prior to the start-up, highly experi-
enced trainers at Basells training
centres (Ferrara, Italy / Bayport,
Texas, USA / Aubette, France) will
train licensees experts on Opera-
tions, Quality Control, Maintenance,
Applications and Safety. Comput-
erised dynamic process simulators
are available to enable licensees per-
sonnel to train for start-up, steady
state, grade-change and shutdown
operations.
Courses are tailored to fit the specific
needs of the customer, not only with
regard to content, but also accom-
modation, interpretation, transporta-
tion, visas, etc.
Start-up support and guarantee
testruns
A start-up team, consisting of Basell
expert operators, will provide assis-
tance during pre-commissioning and
commissioning of the plant.
After completion of the commission-
ing, Basell HSE experts will partici-
pate in a Plant Safety Audit to verify
the adherence to the Safety Design
Criteria, with special attention to
health and environmental concerns.
The start-up team will assist during
the start-up, in order to obtain a safe
and reliable start-up, and normally
remain until the performance guaran-
tee testruns have been finalised.

Technical support after start-up
While the full commercial operation
of the plant will soon become a rou-
tine business of the licensee, devel-
opments in the world of polyolefins
will continue.
Safety information about Basell, its
joint ventures and/or licensees will
be directly shared unconditionally, in
order to continue to improve the
safety standard of our technologies.
In order to further benefit from
Basells technical knowledge and de-
velopments, licensees can enter into
a Technical Support Agreement (TSA)
with Basell, typically comprising the
following elements:
Explanation and details of technical
improvements within the scope of
the original License Agreement
Non-confidential information on
Basells R&D progress that goes be-
yond the current license
Further training sessions
Optimisation of plant efficiency:
trouble shooting / trial for new
products / new catalyst implemen-
tation, provided with technical assis-
tance at the customers site
29
Advice on maintenance and quality
control procedures
Marketing exchange
New product development or adjust-
ments to local markets
Periodical Technical Exchange
Meetings with focus on licensees
issues
Periodical seminars / conferences
with focus on safety, best practice
and breakthrough in process and
catalysts
Engineering services
If market conditions change, and the
capacity of the plant needs to be in-
creased, or a variation in the product
grade slate needs to be made, Basell
can assist in the engineering activi-
ties needed to upgrade the plant ac-
cordingly.
30

Source: Nasa

Basell Technology Licensing

Conclusion
Basell is unique in providing excel-
lent process technologies for all
polyolefin production for all fields of
product applications. This, together
with our drive for customer satisfac-
tion, continuing R&D developments,
and the support from the organisa-
tion of the world leader in poly-
olefins, will make Basell technology
the optimum choice for your poly-
olefin production, now and in the fu-
ture.
31
 Corporate Centre North America Regional Oce Australia Sales Oce
Before using a Basell product, customers and other users should make their own independent determination that the product is suitable for the intended use. They should also ensure that they can

employee. Unless otherwise agreed in writing, the exclusive remedy for all claims is replacement of the product or refund of the purchase price at Basells opinion, and in no event shall Basell be li-
ranty of merchantability or fitness for a particular purpose. No one is authorized to make such warranties or assume any liabilities on behalf of Basell except in writing signed by an authorized Basell
use the Basell product safely and legally. (Material Safety Data Sheets are available from Basell at www.basell.com). This document does not constitute a warranty, express or implied, including a war-

Basell B.V. Basell North America
Hoeksteen 66 Regional Oce and
2132 MS Hoofddorp Research & Development Centre
The Netherlands 912 Appleton Road
Tel. +31 20 4468 644 Elkton, Maryland, USA 21921-3920
Fax +31 20 4468 649 Tel. +1 410 996 1600
Fax +1 410 996 1660
045 LC e 06/05
Basell Australia Pty. Ltd.
Level 2, 199 Toorak Road
South Yarra VIC 3141
Melbourne
Australia
Tel. + 61 3 9829 9455
Fax + 61 3 9829 9431

Europe Regional Oce Basell North American For more information on Basell
Advanced Polyolens Business licensing services, Spheripol
Basell Polyolens Company B.V.B.A. and Technical Centre technology, or engineering,
Woluwe Garden 2727 Alliance Drive technical and marketing
Woluwedal 24 Lansing, Michigan, USA 48910 services, please contact:
1932 Zaventem (Brussels) Tel. +1 517 336 9600 licensing@basell.com
Belgium Fax +1 517 336 9611
Tel. +32 2 715 80 00 You can nd out more about
Fax +32 2 715 80 50 Basell by visiting our website at:
South and Central America www.basell.com
Main European Sales Oces* Regional Oce
Avant, Catalloy, Hostalen,
Advanced Polyolens Basell Brasil Ltd. Lupolen, Lupotech G, Lupotech T,
Basell Deutschland GmbH Estrada Samuel Aizemberg, 1707 Spherilene, Spheripol and
Industriepark Hoechst Sao Bernardo do Campo Spherizone are trademarks owned
Building B 852 09851-550 or used by Basell. Hostalen,
65926 Frankfurt am Main Sao Paulo, Brazil Lupolen and Spherilene are
Germany Tel. + 55 11 4343 3461 registered in the U.S. Patent and
Tel. +49 69 305 85800 Fax + 55 11 4343 3464 Trademark Oce.
Fax +49 69 305 85803
Copyright 2005 Basell Service Company BV.
All rights reserved.
Polyolens Europe Asia-Pacic Regional Oce
Basell Deutschland GmbH
able for special, consequential, punitive, or exemplary damages.

Bruehler Strasse Basell Asia Pacic Ltd.

50389 Wesseling 22/F Hennessy Centre
Germany 500 Hennessy Road
Tel. +49 2236 726000 Causeway Bay
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