HIGH DENSITY LLDPE FOR INFRASTRUCTURE APPLICATIONS Dhananjay Sahoo

DGM- Tech IndianOil Corporation Limited

CONTENTS

1. PETCHEMICALS AND POLYMER - A GROWTH ENGINE

2. INFRASTRUCTURE – A NEW OPPORTUNITY

3. INDIANOIL PLANT AND TECHNOLOGY

4. VALUE ADDED HIGH PRODUCTIVITY AND HIGH STIFFNESS RESINS

5. OPPORTUNITY IN RETAIL PUMP STATIONS FOR FUEL TANKS

6. PRODUCT APPLICATION AND DEVELOPMENT CENTER

Natural Resources

• Crude Oil

• Gas

• Coal

Chemical Intermediates

• Naphtha

• Kerosene

• LPG

Basic Chemicals

• Olefins

• Propylene

• Ethylene

• Aromatics

• Benzene

• Toluene

• Xylene

Petrochemicals

• Polymers

• Polypropylene

• Polyethylene

• HDPE

• LLDPE

• PTA

• Glycols

• LAB

End Use Sectors

• Automotive

• Textiles

• Packaging

• Appliances

• Construction

• Healthcare

• FMCG

• Agriculture

• Infrastructure

Petrochemical Industry Value Chain

3

Global Polymer Market – 260 MMT

4

Global Polymer Market

Source: IHS

Net Import of Chemicals & Petrochemicals: Rs 80436 crore in 2015-16

World average

Per capita Polymer Consumption

Per capita Polymer Consumption shall reach world average of 32 by 2040 at CAGR of 5.6%. However current growth is 8%

Polyethylene

• Present Global demand is estimated at 92 MMT

• World capacities matching demand at the moment

• Global Polyethylene Market to grow at ~4.3% per annum from 2017 to 2021

• Growth in Last 5 years has been at ~3.6% per annum .

• Emerging economies are major contributor to growth.

H H

n C = C catalyst CH2 CH2

H H n

ethylene polyethylene

Polyethylene are classified as

• Low Density Polyethylene (LDPE)

• Linear Low Density Polyethylene (LLDPE)

• High Density Polyethylene (HDPE)

Polyethylene

• Present Polymer demand is at 5 MMT. • Growth in Last 5 years has been at ~9.3% per annum. • Indian Polymer Market to grow at ~8.1% per annum from 2017

to 2021. • Indian Polymer Demand in 2021 estimated at 7 MMT. • Capacity in 2021 estimated at 6.8 MMT • India’s consumption will surpass capacity

Present: ~4.5 MMTPA ~5.5 MMTPA

GoI Infrastructure Development Push

I

N

D

I

A

SWACH BHARAT

SMART CITY

AMRUT

HRIDAY

NAMAMI GANGE

DIGITAL INDIA

Targets & Responsibilities

I

N

D

I

A

Design Innovations

Weight Reduction

Better Strength to Weight Ratio

Chemical & Stress Cracking Resistance

Product Life Cycle

GoI Infrastructure Development Push

I

N

D

I

A

Opportunity Created

Water & Waste Management

Products : Water & Septic Tanks, Manholes, Chambers

• Light weight

• Resistant to chemicals

• Ease of installation

• Custom built Unlike concrete tank.

• Easy to clean

• Different colours

Advantages

GoI Infrastructure Development Push

I

N

D

I

A

Opportunity Created

Water & Waste Management

GoI Infrastructure Development Push

I

N

D

I

A

Opportunity Created

Automobile & Transport related

Products : Barriers, Signage, Bins, Toilets

• Light weight

• Ease of Installation

• Customized Designs

Advantages

GoI Infrastructure Development Push

I

N

D

I

A

Opportunity Created

Automobile & Transport related

• Corrosion resistant

• UV stabilised

• Ranging in capacities from 500 - 10,000 litres

• ‘Tank within a tank’ construction offers integral

protection from leakage & overfilling

• Overfill prevention device

• Covered bund prevents collection of rain water

Advantages

GoI Infrastructure Development Push

I

N

D

I

A

Opportunity Created

Automobile & Transport related

Toys for Entertainment for kids

I

N

D

I

A

Opportunity Created

Recreation & Related

• Safe

• Aesthetic

• Corrosion free

GoI Infrastructure Development Push

I

N

D

I

A

Opportunity Created

Recreation & Related

IOCL New High Density Grade

I

N

D

I

A

Technical Characteristics of LLDPE 040R40A/U

Easy Processability

MFI ~ 4.0 gm/10 min

High Rigidity

Density ~ 0.940 gm/cc

Good Impact Strength

Izod ~ 220 J/m

High Stiffness

FM ~ 9000 Kg/cm2

Recommended Applications:

Septic Tanks

Rainwater Tanks

Underground Tanks

Manholes & Chambers

Insulated Containers

Automobile Parts

Oil-Grease Traps

Material Handling Equipments

Sr. No Plant No. of Lines Capacity per Line (KTA) Technology/ Licensor

1 Polypropylene 2 300 Spheripol II – Basell

2 Dedicated HDPE 1 300 Hostalen – Basell

3 HDPE / LLDPE Swing 1 350 Sclairtech - Nova

Polypropylene Plant Dedicated HDPE Plant Swing Plant

Spheripol Hostalen Sclairtech

With 1.95 Million MT capacity, IOCL is the second largest Polyolefin producer in India

IOCL Polymer Plants & Technology

Tanks

34%

Toys Novelties &

Sporting Goods

25%

Containers

18%

Transportation

12%

Others

11%

Global Rotomolding Market

Indian Rotomolding Market

Rotomolding End Use Representation

32 / 68

Advantages of Rotomoulding Process

• Stress Free Parts

• No Weld Lines

• Design Freedom

• Large Parts

• Little Process Scrap

• Inexpensive Molds

Roto Molding – Capacity vs Cycle time

Product Capacity Weight Heating Time(Min) Total Cycle time(Min)

500 Litre (DW) 10.6 Kg 19 28

500 Litre (TW) 15.0 Kg 23 35

1000 Litre (DW) 19.4 Kg 19 28

1000 Litre (TW) 24.0 Kg 23 35

1500 Litre (DW) 30.6 Kg 17 25

1500 Litre (TW) 37.0 Kg 21 32

5000 Litre (DW) 99.0 Kg 19 28

5000 Litre (TW) 123.0 Kg 25 38

Resin Used in RM

PE

84%

PVC, PC, PP,

Nylon

15%

Others

1%

PE Resins Used

LLDPE

90%

XLPE

5%

HDPE

4%

LDPE

1%

Global look at resin used % volumes & types

Resin choice for Rotomolding

Desirable Resin Properties for Rotomolding

• Cold Temperature (-40C) Impact Strength

• High ESCR for Chemical Tanks and IBC's

• High Flexural Modulus for Chemical Tanks and ICB's

• Consistency of Color and Basic Properties (MI and Density)

• Consistent Warpage and Shrinkage Properties

• Narrow MWD

Lower Low Shear Viscosity for Good Processing

Application

• Tanks- fuel tanks,shipping tanks,oil tanks

• Automotive-door armrest,instruments panel

• Containers-planters ,airline container

• Toys and Leisure-balls ,ride on toys, hobby horses

• Marine Industry-dock floats,pool liners,docking fenders

Value Added Rotomoulding Grades

Rotational Moulding Grades

.

High Productivity Grade

Product Textile Processing Container

Weight 13 kg, Single Layer,

Machine Naroto Make

Reduction in cycle time 9.5%

Productivity increased by 4 tanks per day ~ 6 $ savings per shift

Product 500 Lit, 15.200 kg , 3 layer tank

Machine Naroto 3- Arm Roto molding

Reduction in cycle time 3 min

High Productivity Grade

High Density LLDPE

Development of High Stiffness grade PROPEL 042R35A High stiffness PROPEL 042R35A is a modified grade specially designed for application segment like underground septic tanks, grease traps, inspection manhole/ chambers etc. High stiffness PROPEL 042R35A is having 28% higher flexural modulus in comparison to conventional rotomoulding grade. The density of this modified grade is high compare to conventional roto grades which results in better rigidity and mechanical properties of the said applications. Modified PROPEL 042R35A improves the product performance and service life.

Indian Oil has recently introduced high stiffness, high performance rotomoulding grade 042R35A in the market.

Key attributes

• Upto 0.942gm/cc Higher density

• Around 28 % higher than the conventional roto grades

Higher flexural modulus

Grade Benchmarking Trial : IOCL New High Density Roto Grade Vs Existing Domestic Eq.

Manhole : 2400 mm Height

Product : Single piece rotomoulded manhole of height 2400 mm and diameter 1000 mm having outer ribbed surface and inner

smooth surface.

Parameter / Process Condition Existing Domestic RM

IOCL New Roto Grade

Compounding S S

Pulverization S S

Rotational Moulding

Process Temp. S S

Color Dispersion S S

De-Moulding S S

Cycle Time S S

Product Weight S S

Product Dimension S S

S Satisfactory / Within Spec. at standard parameters

Success Story of High Stiffness PROPEL 042R35A

Manhole (2.4 Mtr Height, 1 Mtr diameter); Weight: 110 kgs

Material Combo 042R35A 96% + Black MB 4 %. Key Attributes Smooth processing of material. No changes in processing parameter.

Double layer underground tank 5000 litres; Weight - 180 kgs

Material Combo Black : 042R35A 93% +Black MB 4% + UV MB 3% White : 042R35A 96% + White MB 4%

Key Attributes Uniform dispersion of material.

Smooth Processability.

Product meeting all quality requirement.

Success Story of High Stiffness PROPEL 042R35A

Opportunity in Indian Oil Retail outlets

• HDPE Pipes

• Fuel Transportation

• Replacing MS Pipes

• Less then 1/8th Weight

• LLDPE (with liner) Storage Tanks

• Fuel Storage HSD & MS

Retail Outlets

Business Development Initiatives – Indian Oil

Rotomoulding Tanks (20KL) requirements – Petrol & Diesel Retail Outlets

Name of Company No of Outlets

IOCL 25000

HPCL 14000

BPCL 13500

ESSAR 2100

RIL 1400

Shell 100

Total 56100

Replacement opportunity 4000 X 4 per annum Weight of tank is 600 kg Overall requirement of material is 960 MT

Product Application and Development Centre (PADC)

PADC is set up near Panipat Naphtha Cracker Complex.

State of Art Technology Centre with sophisticated Plastic Processing & Characterisation equipments

DSIR Recognized

Application Development Lab

Injection Moulding Blow Moulding Rotational Moulding Pipe Plant

TQPP Film Plant Monolayer Film Plant Multilayer Film Plant Twin Screw Extruder

PADC – Testing Lab Facilities

PADC – Testing lab

• Physical Testing

• Thermal Testing

• Rheological Testing

• Mechanical Testing

• Chemical lab

• Optical testing

PADC – Testing Lab Facilities

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