New developments in Polypropylene grades Polypropylen Innovativ 05.-06.05.04 Würzburg Ben Raven SABIC EuroPetrochemicals Technical Marketing PP Moulding & Extrusion

Contents Basic facts SABIC Developments in polypropylene grades Evolution of MFR Application of nucleators Multi-functional PP grades Conclusions

SABIC: Saudi Arabian Basic Industries Corporation Started from scratch in 1976, produced first tons in 1983 World wide 16.000 employees in 22 countries Turn-over of € 11,4 bln in 2002 Is 70% owned by Saudi government and 30% by private sector 100% owner of SABIC EuroPetrochemicals Basic Chemicals Intermediates Polymers Fertilizers Metals

SABIC EuroPetrochemicals Geleen site Gelsenkirchen site SABIC’s first major acquisition outside Saudi Arabia

West-Europe PP/PE Supply 2003

Developments in polypropylene grades Increasing MFR shorter cycle times thinner wall thicknesses Nucleation Multi functional PP grades

Increasing MFR - evolution of grade portfolio block-copolymers 100 1980 Notched Izod impact (kJ/m²) 10 Sheet 18 If we translate these customer needs into a general direction of wanted development of PP properties, the following picture emerges. Here the dependency of the IZOD impact strength and the melt flow rate of PP is shown: it is clear that if the melt flow rate of the material improves, the IZOD impact strengths deteriorates. The preferred development direction is indicated by the red arrow: more impact strength at higher melt flow rates. Over time we see a gradual improvement of the balance of these properties.   In the next few slides I will show you some recent Stamylan P developments that support this preferred development direction and add to improve the property balance of the Stamylan P portfolio. 1 0,1 1 10 100 Melt flow rate (g/10 min)

Increasing MFR - evolution of grade portfolio block-copolymers 100 1980 1990 Notched Izod impact (kJ/m²) 10 Sheet 18 If we translate these customer needs into a general direction of wanted development of PP properties, the following picture emerges. Here the dependency of the IZOD impact strength and the melt flow rate of PP is shown: it is clear that if the melt flow rate of the material improves, the IZOD impact strengths deteriorates. The preferred development direction is indicated by the red arrow: more impact strength at higher melt flow rates. Over time we see a gradual improvement of the balance of these properties.   In the next few slides I will show you some recent Stamylan P developments that support this preferred development direction and add to improve the property balance of the Stamylan P portfolio. 1 0,1 1 10 100 Melt flow rate (g/10 min)

Increasing MFR - evolution of grade portfolio block-copolymers 100 1980 1990 2000 Notched Izod impact (kJ/m²) 10 Sheet 18 If we translate these customer needs into a general direction of wanted development of PP properties, the following picture emerges. Here the dependency of the IZOD impact strength and the melt flow rate of PP is shown: it is clear that if the melt flow rate of the material improves, the IZOD impact strengths deteriorates. The preferred development direction is indicated by the red arrow: more impact strength at higher melt flow rates. Over time we see a gradual improvement of the balance of these properties.   In the next few slides I will show you some recent Stamylan P developments that support this preferred development direction and add to improve the property balance of the Stamylan P portfolio. 1 0,1 1 10 100 Melt flow rate (g/10 min)

Increasing MFR - evolution of grade portfolio block-copolymers 100 1980 1990 2000 2010 ? SABIC® PP Notched Izod impact (kJ/m²) 10 Sheet 18 If we translate these customer needs into a general direction of wanted development of PP properties, the following picture emerges. Here the dependency of the IZOD impact strength and the melt flow rate of PP is shown: it is clear that if the melt flow rate of the material improves, the IZOD impact strengths deteriorates. The preferred development direction is indicated by the red arrow: more impact strength at higher melt flow rates. Over time we see a gradual improvement of the balance of these properties.   In the next few slides I will show you some recent Stamylan P developments that support this preferred development direction and add to improve the property balance of the Stamylan P portfolio. 1 0,1 1 10 100 Melt flow rate (g/10 min)

Increasing MFR - processing advantages (example MFI 15 vs Increasing MFR - processing advantages (example MFI 15 vs. MFI 35 grade) 140 120 100 80 Traditional grade Index figure 60 High MFR grade 40 20 Flow Mould Cycle time Output pressure rate

Increasing MFR – reduced wall thicknesses (example MFI 15 vs Increasing MFR – reduced wall thicknesses (example MFI 15 vs. MFI 35 grade) 800 700 600 500 Traditional grade Flow length (mm) 400 High MFR grade 300 200 100 0,5 1,0 1,5 2,0 Wall thickness (mm)

Improved pail grade: SABIC PP 612MK10 New Grade Old Grade 100 Notched izod impact (KJ/m²) 10 SABIC® PP 612MK10 MFR 15 MFR 35 1 0,1 1 10 100 Melt flow rate (g/10 min)

Improved high MFR multipurpose grade: SABIC PP 513MNK40 New Grade Old Grade 100 SABIC® PP 513MNK40 Notched izod impact (KJ/m²) 10 MFR 70 MFR 40 1 0,1 1 10 100 Melt flow rate (g/10 min)

Improved beaker grade: SABIC PP 313MNK40 New Grade Old Grade 100 Notched izod impact (KJ/m²) 10 SABIC® PP 313MNK40 MFI 90 grade 1 0,1 1 10 100 Melt flow rate (g/10 min)

Improved high impact grade: SABIC PP PHC26 100 SABIC® PP PHC26 75MR10 New Grade Old Grades Notched Izod impact (kJ/m²) 10 66MNK10 Sheet 22 The last example I would like to give you is that of the introduction of an improved multi-purpose high impact grade for crates, boxes and suitcases: Stamylan P PHC26, that is building on the very successful current PHC27 grade. The combination of flow properties and impact level is at a very high level and sets new standard in the Stamylan P portfolio. Moreover, these values were achieved without any compromise on surface properties and elastic recovery. Stamylan P PHC26 is excellently positioned for parts in which surface appearance, low temperature impact strength and sturdiness are of utmost importance. It also provides improved cycle time within manufacturing. Suitcases Crates & Boxes 1 0,1 1 10 100 Melt flow rate (g/10 min)

Developments in polypropylene grades Increasing MFR Nucleation increased stiffness better transparency higher crystallisation temperatures Multi functional PP grades

The influence of nucleation non-nucleated nucleated

Nucleation - increased stiffness Non-nucleated Nucleated 2000 Flexural modulus [MPa] 1500 1000 PP homopolymer PP copolymer

Nucleation - increased transparency

Nucleation - increased transparency Cross-section

Spherulitic growth in praxis In-line thermoforming Sheet thickness = 2 mm PP grade non-nucleated

New SABIC® PP grade for thermoforming PS Clarity clarified nucleated PP Stiffness possibility of down gauging

New SABIC® PP grade for thermoforming Clarity clarified SABIC® PP 523K nucleated PP Stiffness possibility of down gauging

Nucleation - higher crystallisation temperatures (Tc) Addition of nucleating agent

Nucleation - influence nucleation agent (DSC test) Tc

Nucleation - higher crystallisation temperatures; faster cycle times Required cooling time T crystallisation

Nucleation - influence Tc on cooling time; indentation test Indentation pin Mold plates Hydraulic cylinder Pressurized oil Ejection pins Injection sprue Cavity Runner (5 mm) Injection point Indentation point Crystallisation speed can be measured by the so called “indentation test”. Depth of indentation (mm) is measured during subsequent injection moulding cooling times. At longer cooling time, the indentation becomes less. Nucleated grade shows faster solidification than non-nucleated grades.

Indentation test Non nucleated PP Nucleated PP Crystallisation speed can be measured by the so called “indentation test”. Depth of indentation (mm) is measured during subsequent injection moulding cooling times. At longer cooling time, the indentation becomes less. Nucleated grade shows faster solidification than non-nucleated grades.

Developments in polypropylene grades Increasing MFR Nucleation Multi functional PP grades reduction in number of PP grades broader application range

Decreasing number of W.European COPOL PP grades 200 nr of COPOL PP grades 1997 1999 2001 2003 SABIC EPC Comp 1 Comp 2 Comp 3

Decreasing number of W.European HOPOL PP grades 300 nr of HOPOL PP grades 1997 1999 2001 2003 SABIC EPC Comp 1 Comp 2 Comp 3

Reduction in number of PP grades SABIC EuroPetrochemical’s answer: Multi-functional PP grades Broad application area Ultimate product consistency

The multi-functional block copolymer grades for injection moulding offer: Shot to shot consistency Short cycle times Acceptable stiffness / impact balance Dimensional stability Good surface appearance Low blushing performance Good organoleptics

Multi-functional block copolymers (1) Cycle time SABIC® PP 412MN40 Dimensional Stability Organoleptic Tamper evidence Impact/stiffness Balance Surface Appearance

Multi-functional block copolymers (2) SABIC® PP PHC31 Surface Appearance Impact Impact/stiffness Balance Dimensional stability Cycle time

Conclusions Increasing MFR shorter cycle times reduced wall thicknesses Nucleation increased stiffness better transparency higher crystallisation temperatures Multi functional PP grades reduction in number of PP grades broader application range