My Turn – Dr. Balaji B. Singh –
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Basell sells 50th Lupotech T technology license to QAPCO for a 250 KT PE plant in Qatar
Qatar Petrochemical Co. Ltd (QAPCO), a joint venture of Industries of Qatar and Total Petrochemicals, has chosen Basell’s Lupotech T technology for a new 250 KT per year low-density polyethylene (LDPE) plant to be built in Mesaieed, Qatar. The start-up of the new plant is expected in 2011.
According to Basell, the Middle East requires world-scale plants to take full advantage of the abundant availability of feedstock for petrochemicals. Scale is one of the advantages offered by Basell’s Lupotech T technology, in combination with demonstrated product capability, thus offering excellent manufacturing economics and a broad range of high-quality products. Key features in the selection of Lupotech T technology include low manufacturing costs, fast start-up and grade changes, and a high on-stream factor which make it today’s technology of choice for the production of LDPE.
Lupotech T is the leading high-pressure tubular reactor process for the production of LDPE homopolymers and EVA-copolymers. With 14 Lupotech T plants licensed since 2000 and a total of more than seven million tons per year of licensed capacity, Lupotech T has established itself as the clear front-runner in high-pressure LDPE technology.
Comments: There are very few licensors providing LDPE technology. Basell is one of the major licensors of tubular LDPE technology and has been quite successful. Due to advances in LDPE technology the tubular plants have become cost competitive. The newer plants offer economies of scale and efficiencies that enable a cost reduction. From the market side, LDPE has always maintained a premium over LLDPE making LDPE the highest-margin polyethylene. The industry has been disciplined in adding new LDPE capacity and this has created favorable supply-demand dynamics. The inherent advantage of LDPE is that, in addition to the commodity LDPE grades, the tubular/autoclave reactors allow the licensees to develop specialty grades in the future.
The movement to specialties though is currently the focus of most advanced countries, will become a logical choice for most developing countries because of the Global migration of basic R&D, technology, and catalyst development – e.g., China, India, Saudi Arabia, Thailand, Korea, etc., These nations are far more suited for specialty development in terms of both potential markets and the future intellectual capital.
Dow Chemical and Libya’s National Oil Corporation to form JV to expand petrochemical complex in Libya
National Oil Corporation of Libya (NOC) and Dow Chemical Company have announced their plans to participate in a joint venture to operate and expand the Ras Lanuf petrochemical complex in Libya.
The Country (Libya) recently embarked on a policy of attracting foreign expertise and investments which will lead to further reintegration into the global economy. Dow is the first global chemical company to participate in the economic development of the Libyan petrochemical industry.
The investment supports the Libyan government’s economic policy of diversifying its domestic economy by expanding its downstream industries; including petrochemical and basic product manufacturing. Enhancements at the Ras Lanuf petrochemical complex on the Mediterranean coast will position the joint venture for future growth as a world-class supplier of polyethylene and polypropylene.
Through the joint venture, Dow will help upgrade and modernize existing assets to develop more high-skilled jobs in the country and stimulate investments in associated industries by utilizing its technical capabilities.
The joint venture agreement encompasses the Ras Lanuf site’s existing naphtha cracker, two polyethylene production facilities, and associated infrastructure. The project will include refurbishment and expansion of the existing units, followed by the construction of an ethane cracker and additional polyethylene and polypropylene facilities. The later phases will include the construction of additional hydrocarbon, plastics, and chemical production facilities based on natural gas.
Comments: The search for cost-advantaged feedstock continues as producers of developed countries leave no stone unturned. As the usual suspects such as Saudi Arabia, Kuwait, and Qatar get crowded, new countries are considered. The current move by Dow to move into Libya may turn out to be a very successful strategy. Libya has been silently improving its economy and privatizing to become more efficient. Libya has hired none other than the strategy guru from Harvard, Michael Porter, to manage this change since 2004. Since meeting one of Muammar al-Qaddafi’s sons at the World Economic Forum in Davos, Switzerland, in 2004, Porter and a group of Western consultants have become deeply engaged in overhauling the Mediterranean petro-state. Qaddafi’s son, Seif al-Islam (Sword of Islam), is making a career of trying to reform what is by many measures one of the world’s most backward economies. Now, thanks to his relationship with Porter and Monitor Group, a consulting firm with which Porter is affiliated, a roadmap for restructuring is emerging.
The monitor has pored over the Libyan economy and mapped out a strategy for the next decade or so, focusing on energy, tourism, trade, and construction. U.S. companies that were forced by the U.S. government to give up their properties in Libya in the 1980s have been coming back to the country. Among those that have returned is Occidental Petroleum, which says it now has the most oil and gas acreage of any foreign company operating in Libya, with some 30 million acres. Oxy regained its concession in the Sirte Basin in 2005 after a 19-year absence, and it has been an aggressive bidder in auctions held by the Libyans for exploration tracts. Marathon, ConocoPhillips, and Hess also have negotiated a return to concessions they worked under the Oasis Group label. The largest foreign oil operators in Libya now are Italy’s ENI, with 255,000 barrels per day, and Germany’s Wintershall, with 145,000 barrels per day. By comparison, Oxy now produces about 23,000 barrels per day.
Slowly the spoils of reforms are trickling from the petroleum industry to the petrochemical industry as Dow plans to start its venture in Libya.
Basell to expand polypropylene capacity at Bayport, Texas by restarting a unit
Basell announced its plans to expand capacity at Bayport, Texas site by restarting a polypropylene plant that has been inactive since 2001. The company currently operates two Spheripol process plants at Bayport with a combined annual nameplate capacity of 530 KT.
The plant to be restarted also uses the Spheripol process and has a nameplate capacity of 220 KT. This plant will be fully refurbished and upgraded with state-of-the-art innovations. The start-up is scheduled for the second quarter of 2008.
According to the company, restarting the Bayport plant is an extremely cost-effective way to add capacity, and the synergies from operating multiple production lines at the same site will reduce unit fixed costs for all three lines and improve its overall cost position.
In North America, Basell also operates two polypropylene lines in Lake Charles, Louisiana as well as plants in Sarnia, Ontario, and Varennes, Quebec. Basell’s joint venture in Mexico, Indelpro, operates a Spheripol process line and is building a new 350 KT Spherizone polypropylene plant at Altimira which will start up in 2008.
Comments: Basell’s decision to restart their Spheripol plant is in line with the current situation in North America. There hasn’t been any new polypropylene capacity that has come up in North America for the last 10 years. A gradual increase in demand for polypropylene during this time has resulted in the demand approaching capacity. Currently, the average capacity utilization in North America is close to 90% with the demand in 2006 at 8,330 KT.
Spheripol has been one of the most successful technologies for polypropylene licensing by Basell. The company has been very successful in licensing its latest Spherizone technology for manufacturing polypropylene. Basell claims that Spherizone technology is economical and can produce all products (and more) that Spheripol can. It is possible to convert a Spheripol plant to Spherizone. It will be interesting to see if Basell will convert one of its older Spheripol plants to Spherizone to take advantage of the new technology.
Braskem and Pequiven enter into an agreement to develop Jose petrochemical complex in Venezuela
Braskem, a leading company in the petrochemical sector in Brazil, and Pequiven, the main petrochemical company in Venezuela, signed an agreement with a view to constituting two “joint ventures” to develop and implement in that country the most modern and competitive integrated petrochemical project of the Americas, in the Jose Complex. One of the projects provides the construction of an ethane “cracker” from natural gas with a capacity of 1.3 million t/year of ethene, integrated into the production of 1.1 million t/year of polyethylene and other petrochemical products.
The second project refers to the construction of a polypropylene plant with a capacity of 450 thousand t/year, previously announced to El Tablazo and that now will be developed within the Jose Complex. Even more integrated, the complex will have its competitiveness enhanced through the utilization of the synergies in implementation and operation, among other factors. The new polypropylene unit will begin to operate at the end of 2009, while the ethane cracker and the other units will be put in operation at the end of 2001.
As a result of the availability of one of the most plentiful oil and natural gas reserves in the world, Venezuela offers important competitive advantages for the development of petrochemical projects, in agreement with its governors’ objectives to transform the country into a relevant player in the international petrochemical sector.
The investments for the implementation of the ethene production unit and the polyethylene units are estimated at US$ 2.5 billion. Braskem and Pequiven have also evaluated the possibility to invest in PVC and sodium hydroxide units.
For the two projects already defined, the modeling forecast an increase of about 30% by Braskem and Pequiven, in equal proportions, and of about 70% through project finance with an exclusive warranty of the project’s assets themselves, financed by multilateral credit agencies to exports, development banks, and private banks.
In parallel to the projects, Pequiven will build a propane dehydrogenation unit for a production of 465 thousand t/year of propene, while the PDVSA Gás will build units to extract 1,800 thousand t/year of ethane. Besides, Pequiven will make complementary investments in the Jose Complex infrastructure, increasing the total value of investments to more than US$ 5.0 billion.
Comments: Braskem had announced its intentions to become a top 10 petrochemical company. The company has been working towards this goal via acquisitions, joint ventures, and other growth opportunities. The JV between Braskem and Pequiven was anticipated as talks regarding this JV started last year. South America is one of the regions with opportunities from both the demand side and the supply side. The region is projected to show strong economic growth, especially in Brazil, and the region has a good feedstock position in Venezuela. The JV between the two companies is essentially a JV between the countries with an advantage for supply and demand.
This joint venture was originally sketched out in 2004 between ExxonMobil and Pequiven. In Feb. 2006 ExxonMobil said that Pequiven had suspended a preliminary development agreement (PDA) for a planned 50-50 joint venture to develop a $3 billion olefins plant in the eastern Venezuela city of Jose. After this, in April 2006 there was the announcement that Pequiven was considering a JV with Braskem. Braskem and Pequiven announced in April 2006 that over the next six months, they will study the operational, technological, marketing, financial, and strategic details of the project.
Basell launches two new Purell® LDPE resins for medical applications
Basell is introducing two new low-density polyethylene grades, Purell PE 2420 F and Purell PE3020H. The resins have been produced in conjunction with a medical protocol tailor-made to address the specialized requirements of customers in medical blown film applications. Basell’s Purell family of select polyethylene and polypropylene grades brings advantages in terms of design, regulations, and functionality that the medical and pharmaceutical markets will appreciate. Interested customers are expected to be producers of packaging for syringes and diagnostics equipment.
According to the company, the new products surpass the performance capabilities of conventional polyethylene, particularly when it comes to their high level of purity. The company said that this eliminates the problem of small amounts of additives migrating into the application, which can occur with conventional resins. In addition to their high level of purity, the new grades provide good puncture and tear resistance and their mechanical behavior has demonstrated resistance to the usual variations encountered on industrial processing lines. The new grades complement the existing Purell family of grades used by customers in injection and blow molding applications, and mark the first step for Basell into PE film applications used in the medical industry. The resin is currently manufactured in Europe and is available for export.
Comments: This is a step in the right direction for Basell to enter into a new market – PE film applications used in the medical industry. By bringing these new grades, Basell is also enriching its existing Purell products portfolio that is used by customers in injection and blow molding applications. These resins have been produced in conjunction with a medical protocol tailor-made to address the specific requirements of customers in medical blown film applications. Basell’s Purell family of selected PE and PP grades brings advantages in terms of design, regulations, and functionality that the medical and pharmaceutical markets will appreciate. By having no additives, these new products eliminate the problem of small amounts of additives migrating into the application, which can occur with conventional resins.
All Purell materials are listed in US FDA’s Drug Master Files (DMF). Specific Purell grades meet the requirements of both US/European Pharmacopeia and the Medical Devices Directive (MDD). As an extra mile effort, Basell offers customers a clear set of support services for the entire “Purell” portfolio of products, – letting them know what to expect and to develop new applications with confidence.
Kraton Polymers receive FDA approval to use SEBS polymers with foods containing free fats and oils
Kraton Polymers LLC announced that the Food and Drug Administration (FDA) has cleared the Kraton styrene-ethylene-butylene-styrene (SEBS) products for use in fatty food applications. These Kraton polymers are listed with the FDA as CAS Reg. No. 66070-58-4. This product line has been cleared for use in non-fatty food applications for 30 years.
All current FDA-grade Kraton SEBS products can now be used for all types of food packaging in all conditions of use as defined by the FDA. This will allow Kraton’s customers the flexibility of using our SEBS polymers in direct contact with food containing free fats and oils. Kraton SEBS products offer impact and puncture resistance, clarity, flexibility, and toughness which are unmatched in the industry.
Kraton is a leading global engineered polymer company and, we believe, the world’s largest producer of styrene block copolymers (SBCs), a family of products whose chemistry was pioneered by us over forty years ago. SBCs are highly engineered thermoplastic elastomers, which enhance the performance of numerous products by delivering a variety of attributes, including greater flexibility, resilience, strength, durability, and processability. Kraton polymers are used in a wide range of applications including adhesives, coatings, consumer and personal care products, sealants, lubricants, medical, packaging, automotive, paving roofing, and footwear products. Kraton has the leading position in nearly all of its core markets and is the only producer of SBCs with global manufacturing capability. Its production facilities are located in the United States, The Netherlands, Germany, France, Brazil, and Japan.
Comments: Kraton Polymer is the largest producer of SEBS globally and in North America. It has the highest market share with over 65% of the total consumption. Currently, Kraton Polymers’ SEBS grades are used in applications such as adhesives, coatings, consumer and personal care products, sealants, lubricants, medical, packaging, automotive, and others. The North American demand for SEBS is close to 170 million pounds and growing at 5.0 %.
Kraton Polymers’ FDA approval of their SEBS grade will further increase the range of end-use applications in the food packaging market. The food packaging application is a high-growth market in North America and Kraton Polymers will be able to take advantage of this situation.
Metabolix and ADM to commercialize production of Mirel™ – biobased and fully biodegradable plastic
Metabolix Inc. and ADM announced their plans to jointly produce Mirel™ Natural Plastics. Mirel is a family of high-performance natural plastics that are biobased, sustainable, and completely biodegradable. Metabolix and ADM are commercializing Mirel through their joint venture, Telles™, named for the Roman goddess of the Earth. Telles is now building its first commercial-scale plant in Clinton, Iowa. This plant is expected to start up in 2008 and will produce Mirel at an annual capacity of 110 million pounds.
Mirel is a versatile brand of natural plastics produced from renewable resources like corn sugar that provides an alternative to traditional, oil-based plastics. But unlike oil-based plastics, Mirel will biodegrade harmlessly back to nature in a wide range of environments such as soil, compost, rivers, and oceans. Mirel can be used as an alternative to petroleum-based plastic in a wide variety of conversion processes, including injection molding, paper coating, cast film and sheet, blown film, and thermoforming. Metabolix is currently working with more than 40 prospective customers on more than 60 applications, including consumer products, packaging, single-use disposables, and products used in agriculture and erosion control.
Comments: Polyhydroxy alkanoates (PHAs) are renewable plastics that can be produced in a variety of ways using sugar and lipids as feedstock. PHA natural plastics are a broad and versatile family of polymers that range in properties from rigid to elastic, and they can be converted into molded and thermoformed goods, extruded coatings and film, blown film, fibers, adhesives, and many other products. They have excellent shelf life and resistance even to hot liquids, greases, and oils, yet they biodegrade in aquatic, marine, and soil environments and under anaerobic conditions such as those found in septic systems and municipal waste treatment plants. They can be both hot and cold composted. Further, they do not require the addition of a plasticizer to modify their glass transition temperature to below 0°C.
In the early 2000s, Metabolix developed its proprietary enzyme-catalyzed polymerization technology for the production of high-purity PHAs for biomedical applications. Later they worked on using E. Coli to reduce production costs and simplify purification. In 2003, it announced an initial one-year research collaboration with BASF to investigate the material technology and processing properties of its PHA resins. Later in 2004, ADM and Metabolix expressed their intention of entering a JV to commercialize this technology (protected by over 130 patents) at Clinton, Iowa, close to one of ADM’s corn wet milling sites. This meant that the proposed plant will utilize starch from the mill’s existing corn grind capacity as raw material for PHA production resulting in synergies.
Biodegradable plastics are gaining market momentum, especially in Europe as a result of government regulations promoting the composting of biodegradable materials. The EU market for bioplastics in 2000 was 23,000 tons and is expected to grow to 454,000 to 907,000 tons by 2010, and 3-5 million tons by 2020. Polymers made from renewable resources derived from starch and sugar are expected to account for 60% of the market for EU biodegradables in 2010, in part because of their greater cost advantage over biodegradable synthetic polymers made from petrochemicals. Although some has not been the case in the US, it is fast catching up with growing environmental concerns. An additional concern in the US has been the influence of using corn for ethanol and chemical production on grain prices. This has recently been reflected in the cost of meat and poultry with more corn-based ethanol capacities being added.
Dow introduces lower-yellow-index thermoplastic polyurethane (TPU) elastomers
Dow Chemical has introduced a family of lower-yellow-index Thermoplastic Polyurethane (TPU) elastomers, to be commercialized under the PELLETHANE™ brand, by year-end 2007. These new experimental products offer “best-in-class” color performance, and deliver significant aesthetic, weather ability, and processing benefits.
According to the company, this new family of elastomers was specifically developed to address market demand for TPU products with a lower yellow index. Dow will offer both ether and ester grades at various hardness levels.
The “best-in-class” color performance of the new Low-YI elastomers delivers a variety of additional advantages, including (1) increased color consistency of final fabricated parts; (2) cost savings via a reduction in the need for UV stabilizers; (3) better weather ability; and (4) improved thermal stability for higher-heat applications as well as those that use regrind.
Comments: Dow Chemical is one of the major producers of TPU in North America. The North American demand for TPU in 2006 was close to 140 million pounds and grew at close to 4%. The main application for TPU includes (1) automotive, (2) Film, (3) mechanical goods, (4) medical, (5) wire & cable, (6) hoses & tubes, (7) footwear, (8) wheels & casters, (9) coatings, (10) adhesives and others.
Dow Chemical’s move to introduce low-yellowing TPU will target markets that require coloring. This would allow it to target low-end aliphatic TPU applications which cost more than twice the cost of aromatic TPU and expand end-use applications where coloring is required. Aromatic TPU has an inherent tendency to yellow on exposure to sunlight creating a discoloration of the product. Aliphatic TPU is used where clarity and coloration are required.
Owens-Illinois forms two plastics joint ventures in Mexico to produce containers
Owens-Illinois, Inc., (OI) announced that its plastics packaging business has finalized two joint ventures in Mexico.
O-I HealthCare Packaging de Mexico has entered a 50/50 joint venture, O-I Pavisa S.A. de C.V., with Pavisa Industries, a leading Mexican plastics packaging company, to manufacture and sell plastic healthcare containers in Mexico and certain other Latin markets.
Additionally, O-I de Mexico has entered a 50/50 joint venture, O-I Mega S.A. de C.V., with Bepensa Industries, a leading Mexican soft drink producer, to manufacture and sell compression-molded, plastic carbonated soft drink (CSD) closures to Bepensa and other customers in Mexico.
Through its three divisions, Grupo Pavisa designs manufactures, and sells glass and plastics packaging, as well as crystal glassware products. Latino Americana de Vidrio, Pavisa’s glass container division, is a leading manufacturer of high-value-added specialty glass containers in Mexico. Pavisa Industries, Pavisa’s plastic container and closures division, has been a leading Mexican manufacturer of plastic packaging for over 30 years. Nouvel Studio, Pavisa’s glass tableware division, designs and produces innovative crystal glass products sold around the world.
Bepensa Industries has been a leading producer of soft drinks in Mexico for over 50 years. Bepensa is the exclusive bottler of Coca-Cola products in the Yucatan Peninsula-the Mexican states of Yucatan, Campeche, and Quintana Roo. Bepensa is the largest bottler in Consorcio Orion de Bebidas A.C., an alliance of nine midsized and small Coca-Cola bottlers in Mexico. In addition to selling Coca-Cola products, Bepensa also produces and sells a number of other proprietary beverage products, including Bevi and Friolin, and bottles and sells Cristal, a purified water product in the states of Campeche, Yucatan, Quintana Roo, Tabasco, Veracruz, and Chiapas.
Comments: Headquartered in Toledo, Ohio, Owens–Illinois (OI), Inc. is an international manufacturer of rigid glass and plastic containers for consumer goods packaging products. The predominant segment is glass containers (89% of company sales) serving brewers, wine vintners, distillers, food producers, and, outside the United States, soft drink bottlers. The company is the leader in glass containers in each of the geographic markets in which it competes, including Europe, North America, South America, Australia, and New Zealand, through its 82 glass manufacturing facilities. The plastics packaging segment (11%) consists of healthcare and prescription containers as well as plastic closures. OI operates this segment primarily in North America with container customers including Cardinal Health, Johnson & Johnson, Pfizer, and Walgreens. Plastic closure customers also include Coca-Cola Enterprises, Cott Beverages, and Procter & Gamble. OI also licenses its glass and plastic container technology to numerous companies, including competitors, across the world.
The company has set six core priorities including 1) European integration; 2) global procurement initiatives; 3) building modest growth momentum; 4) increasing liquidity and reducing leverage; 5) system cost and capital capabilities/sourcing initiatives; and 6) price increases to offset inflationary pressures.
The company has about $800 million in sales in its plastics segment and is a leader in pharmaceutical containers and a leading producer of caps and closures.
Alcoa to consider the disposition of its packaging and consumer businesses
Alcoa announced it will explore strategic alternatives for the disposition of its Packaging and Consumer segment which generated approximately $3.2 billion in revenues and $95 million in after-tax operating income in 2006, representing approximately 10 percent of Alcoa 2006 revenues and approximately 3 percent of after-tax operating income.
Businesses that will be included in the review of strategic alternatives include:
(1)Flexible Packaging, manufacturers of laminated, printed, and extruded non-rigid packaging materials such as pouch, blister packaging, unitizing films, high-quality shrink labels, and foil lidding for the pharmaceutical, food & beverage, tobacco, and industrial markets.
(2)Closure Systems International, a global manufacturing leader in plastic and aluminum packaging closures and capping equipment for beverage, food, and personal care customers.
(3)Consumer Products, a leading manufacturer of branded and private label foil, wraps, and bags.
(4)Reynolds Food Packaging, makers of stock and custom products for the food service, supermarket, food processor, and agricultural markets including foil, film, and both plastic and foil food containers.
In total, these packaging businesses have approximately 10,000 employees in 22 countries around the world. The Company anticipates the process will be completed by the end of 2007.
Comments: Alcoa has been evaluating its core and non-core businesses and has decided that the packaging and consumer segment is not one of its core businesses. The company’s business segments are divided into six categories: (1) alumina and chemicals, (2) primary metals, (3) flat-rolled products, (4) engineered products, (5) packaging and consumer, and (6) other. Its packaging & consumer segment includes beverage can sheet, bottle closures, flexible packaging, graphic products, plastic film/sheet, plastic food packaging, and consumer products including Reynolds Wrap and other Reynolds products.
Air Liquide acquired the engineering firm Lurgi
Air Liquide announced the acquisition of the engineering firm Lurgi, which is owned by Global Engineering Alliance (GEA Group AG), based on an equity value of approximately EUR 550 million, which is equivalent to an enterprise value of EUR 200 million after including the assumption of Lurgi’s cash position as well as it’s pension and other liabilities. The transaction is subject to approval by the European and American competition authorities.
This acquisition is an important step to achieve the new objectives recently announced by the Group. Notably, it will enable the acceleration of growth in the Large Industries World Business Line, strengthening our strengthening Group’s resources in hydrogen markets and giving it access to the Coal to Liquid* (CTL) and Coal to Chemicals* (CTC) sectors.
With nearly 1,300 employees and total sales of around 850 million euros in 2006, Lurgi, a German-based company, has a particularly large portfolio of technologies, from producing hydrogen and synthesis gas to biofuel production processes (bio-ethanol, and bio-diesel). Lurgi is one of the world leaders in these technologies, processes that consume large quantities of oxygen. Its main engineering centers are situated in Germany, Poland, the United States, India, and South Africa.
Comments: Air Liquide’s principal activities are the production and distribution of all industrial and healthcare gases and the provision of related services. The company designs, develops, and builds its gas production units as well as gas production units for external customers.
Lurgi is a leading technology provider for gas, coal, and biomass-based hydrogen, synthesis gas, methanol, and synthetic fuels. The company had provided the MegaMethanol® technology for the world’s first 5,000 metric ton/day plant – the Atlas Methanol plant. It had also recently signed two major coal-to-methanol and methanol-to-propylene projects in China. Air Liquide has been a regular partner with Lurgi for many years, with the most recent jointly developed projects undertaken in Saudi Arabia and Malaysia. This acquisition would double the size of the company and add value to its existing technology portfolio. The company would also be better placed to ensure the design and manufacture of larger units which are especially important in emerging technologies like gas/coal to liquids.
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