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Metallocene Technology

Univations success story still being told

T
he opening chapter of our metallocene Tougher, clearer and easier to process than
success story began with a major competing resins, the high-performing
breakthrough that set the benchmark metallocene linear low-density polyethylene
for others to follow. In the early 1990s, (mLLDPE) resins produced using XCAT catalysts
Exxon Chemical Company, now ExxonMobil provide the primary ingredient for a wide
Chemical Company, developed revolutionary range of products. Among them: Flexible
single-site metallocene catalysts for use in a packaging, pallet stretch wrap, collation
subsidiary of Dow Chemicals gas-phase shrink-films, general-purpose and carrier bags,
UNIPOL PE Process. Environmentally friendly heavy-duty bags, and food-packaging and
and safety oriented, this low-pressure process agricultural films.
has provided a perfect platform for developing
metallocene technology. Our metallocene technology redefined the
performance limits of polyethylene, enabling
Building on that success, The Dow Chemical Company producers to create precisely tailored resins
and ExxonMobil Chemical Company formed a joint that open the door to new and differentiated
venture, Univation Technologies, which introduced global markets.
XCAT Metallocene Catalysts to the market.
Our Portfolio Distinguishes Us ene resins. The industrys broadest range
as the Industry Leader of product capabilities. Extreme versatil-
Today, we offer a broad portfolio of metallo- ity, enabling resin producers to change their
cene technologies that distinguish us as grade slate with the changing markets.
a leader in our industry: That powerful combination has resulted in a
m LLDPE films and very low-density films record number of licenses being issued re-
(mVLDPE) that provide excellent dart impact cently and increasing commercialization
and puncture resistance, tensile strength of our technology by third parties.
and heat-sealing performance.
S econd generation easy-processing A History of Innovation for
mLLDPE, the first mLLDPE to compete Metallocene Catalyst Production
effectively with high-pressure, low-density Univation Technologies has developed and
polyethylene for shrink-film applications. fully commercialized metallocene catalysts
These resins produced via XCAT catalyst for producing polyethylene resins that offer
offer a unique balance of easy processing, significant value over resins produced with
excellent shrink properties and outstanding conventional catalysts. Our XCAT Metallocene
optical characteristics. Catalysts result in exceptionally uniform
Engineered catalyst technology to produce PE metallocene polymers with narrow molecular-
resins with bimodal molecular-weight weight and composition distributions.
distribution in a single UNIPOL PE reactor They produce resins with tailored molecular
a milestone achievement that eliminates more designs, reliable production and impressive
costly two-reactor configurations. performance and processing properties that
Univation technology has many advantages non-metallocene catalysts or conventional
to offer. Improved operating economics. Ziegler-Natta catalyzed materials cannot provide.
Tougher, clearer, better-performing polyethyl-
Our XCAT Metallocene Catalysts give our customers Our second generation XCAT Metallocene Cata-
products a clear-cut competitive advantage: lyst is designed for making easy-processing (EZP)
Outstanding toughness with improved tensile mLLDPE. This catalyst system produces a poly-
strength, impact resistance and puncture ethylene that is extremely tough and provides an
performance improved-strength replacement for LDPE/LLDPE
Excellent optics with better clarity and higher blends and pure high-pressure LDPE products
gloss for more appealing packaging while matching the processing ease of LDPE
Less odor and off-taste in high-volume blown film applications. The XCAT
Higher recycle and reclaim incorporation rates EZ 100 catalyst was designed to replace
for less waste LDPE/LLDPE blends, so high pressure is eliminated.
Lower heat-seal initiation temperatures and
higher hot-tack strength for faster line speeds For converters, these resins offer easier, more
and excellent seal integrity efficient extrusion and conversion with less block-
ing, less waste and less downtime compared to
Univation has created a variety of solutions to meet conventional resins. Plus, theres no need to retool
our customers diverse requirements. Our first existing conversion equipment.
generation solution involves our XCAT HP Catalyst.
This catalyst system produces polymer molecules Overall Operability is Critical
with a more uniform molecular-weight distribution We have developed reactor continuity additives
compared to conventional Ziegler-Natta catalyzed to enhance our XCAT Metallocene reactor oper-
LLDPE. This leads to higher performance capability ability. These additives keep the plant running
but reduces processability, which can be longer without fouling the system or producing
improved by blending XCAT mLLDPE with high- agglomerates, which can lead to plant shutdown.
pressure polyethylene.
A New Generation of
Metallocene Technology

In recent years, Univation has expanded


its operating experience and strength-
ened its understanding of the subtleties
of running a PE plant. As a result, we built
on the market success of our first-gener-
ation high-performance resins (HPRs) by
introducing second-generation EZP tech-
nology that helped open up new markets
and applications, such as shrink wrap.

These two technologies provide a perfect


complement to each other in the PE
In addition, Univation has successfully developed
field, where there are often trade-offs
several process-related technologies that result in
between a plastics performance and its
smooth operation of metallocene-based catalysts
processability. Narrow molecular-weight
and production of superior products for many
distribution makes the product harder to
applications. Some of the process-related tech-
nologies that were developed and successfully process. With broader weight distribu-

implemented include: tion, processability improves, but product


Use of advanced detection and monitoring tech- performance drops.
niques for early detection of discontinuity events
Advanced control strategies and algorithms
Our latest technology, PRODIGY Bimodal
Catalyst delivery for optimized particle morphology
Catalyst, comprises two active species
Defined procedures and reaction models for
with a metallocene catalyst making up
smooth operation during critical stages and
the low molecular-weight fraction. This
steady state
new technology gives resin producers

These new metallocene operability enhancements the swing capability to produce both

facilitate UNIPOL PEs well established ability to LLDPE and HDPE and, more importantly,
operate at higher throughput. These advantages to compete with bimodal HDPE products
have allowed Univation licensees to produce large in the global market without investing
volumes of high value products.
capital in a two-reactor system.
More Technology Breakthroughs The potential of VP technology is limited only by the
on the Horizon imagination, and we believe it will become the single
Univation continues to be committed to major catalyst that goes far beyond the film markets to fit a
research and development programs in metallocene very broad range of applications. Our success story
catalyst systems. Unquestionably, our customers will continue to unfold with more exciting chapters
needs drive our focus. We are investing in discovery that reveal our continued ability to accommodate
research wherever we see promise for our licensees. the polyethylene market of the future.
Our developmental XCAT VP-100 (Versatile
Performance) next generation catalyst, which is Our Metallocene Technology
being developed to broaden the scope of metal- Potential is Unlimited
locene applications, provides a stellar example Over the past 15 years, millions of tons of MCN
of our dedication to meeting customers needs. polyethylene resins have been produced using our
It is useful not only in film applications, but in UNIPOL PE Process and XCAT technology. Univa-
injection and rotational molding applications tion has become the leading global supplier of proven
and other medium-density applications. metallocene PE technology, which continues to have
The versatility is achieved by adjusting reaction robust double-digit annual growth worldwide. Our
conditions to make this range of products with XCAT technology has been commercialized globally.
a single-catalyst system. Clearly, we have a success story worth telling.

While the earlier generation of metallocene prod- Proven to deliver. Designed to adapt. That is the Uni-
ucts (XCAT HP-100 and EZ-100) continue to prove vation promise that has made us an industry leader.
successful in the high-strength commercial market,
the XCAT VP 100 technology promises to cover all
high-performance mLLDPE film applications.
XCAT Catalysts Make for Easy
Plant Retrofit

Customized for the UNIPOL PE gas-phase


process, XCAT Metallocene Catalysts can
be added easily to existing UNIPOL PE
plants. Univation brings strong technical
know-how, unsurpassed licensing experi-
ence with gas-phase PE process technology
and successful production and market
experience with metallocene-based resins to
each metallocene-catalyst plant retrofit.

A retrofit solution with XCAT Metallocene or


PRODIGY Bimodal Catalysts usually requires
minimal modification and little disruption to
I consider the metallocene retrofit to be a very successful licensees current production schedules.
project. Univation personnel, with longtime metallocene expe-
Customers also find that a conversion to
rience, supported us through technology transfer, operational
XCAT Metallocene Catalyst, coupled with
training and plant modifications for our metallocene operation.
The modifications were very minor. The entire preparation Univation expertise, allows you to further
process took about three months. And within three commercial increase output (via higher condensing) while
scale campaigns, we were off producing products successfully producing a higher value product.
on our own without Univations assistance. We now have
nearly five years of commercial run experience with metallo-
Clients who are constructing a new facility
cene technology from Univation.
will assess whether they intend to produce

Eduardo Carnaba, Lead Engineer, Braskem these resins initially or at a later time. If
Camaari Project included in the initial design, there will be
minimal impact on the overall constructabil-
ity of the plant as footprint and equipment
The process of readying the UNIPOL PE process plant for
requirements can be taken care of in an
producing metallocene LLDPE resins went very smoothly,
thanks to the advice of Univations Engineering and Manufac- optimal manner.
turing specialists. They provided us with excellent technical
support from start to finish.

Mr. Claudio Abreu, Production Plant Manager,


Quattor (formerly Rio Polimeros), Duque de Caxias, Brazil
The foregoing is intended to be only an introduction,
and is not an offer, express or implied, of general
or specific licensing warranties, patent warranties,
performance guarantees, profitability guarantees, or
other terms which are to be found only in and deter-
mined only by a fully executed licensing agreement.

The information contained herein is based upon


data believed to be reliable and relates only to the
matters specifically contained herein. ALTHOUGH
SUCH INFORMATION IS, TO THE BEST OF OUR
KNOWLEDGE AND BELIEF, ACCURATE AND RE-
LIABLE AS TO THE DATE HEREOF, WE MAKE NO
REPRESENTATION, WARRANTY (EXPRESS OR IM-
PLIED), AS TO MERCHANTABILITY, FITNESS, USE
OR OTHERWISE, OR GUARANTEE OR AS TO THE
SUITABILITY, ACCURACY, RELIABILITY OR COM-
PLETENESS OF THE INFORMATION CONTAINED
HEREIN. IT IS THE USERS RESPONSIBILITY TO
SATISFY ITSELF AS TO THE MERCHANTABILITY,
FITNESS, SUITABILITY, ACCURACY, RELIABILITY,
AND COMPLETENESS OF SUCH INFORMATION
FOR ITS PARTICULAR USE. UNIVATION TECH-
NOLOGIES SHALL NOT BE LIABLE FOR ANY LOSS,
DAMAGE OR INJURY THAT MAY OCCUR FROM
THE USE OF THIS INFORMATION.

UNIVATION, XCAT, PRODIGY, and the stylized U


are registered trademarks (Reg. U.S. Pat. and Tm. Off.
and in other countries.) of Univation Technologies.

UNIPOL and UCAT are registered trademarks (Reg.


U.S. Pat. and Tm. Off. and in other countries.) of The
Dow Chemical Company or an affiliated company
of Dow. UNIPOL and UCAT are licensed for use to
Univation Technologies.

Univation Technologies, LLC


5555 San Felipe, Suite 1950
Houston, Texas 77056-2723
Phone: +1 713.892.3700
Fax: +1 713.892.3760
Web: www.univation.com

2003-2008 Univation Technologies, LLC. All rights reserved. 08-2008

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