Hyperzone PE Process Technology

Dr. Gerben Meier

Associate Director, Hyperzone Technology Development and Commercialization
February 26, 2019

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Our company has developed new products and technologies that are
the bedrock of the chemical industry

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Hyperzone PE technology extends our differentiation

New Hyperzone PE investment for high density polyethylene (HDPE) offers

resins with:
 Combination of LyondellBasell PE and PP technical expertise
 Light weighting by optimizing stiffness, stress crack resistance and strength
 Enhancing sustainability by using less material for same functionality
 One catalyst chemistry covering full range of HDPE

Synthesis of
1st HDPE at
low pressure
1st bimodal
Hostalen Launch of
benchmark PE
100 pipe grade 1st Hostalen
ACP
1st Hyperzone
PE plant

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HDPE markets have evolved due to capabilities of different catalyst
technologies

■ Narrower processing window ■ Excellent ESCR/impact balance

compared to Cr grades (Film, SBM)
■ Very good processability
■ Superior mechanical properties
compared to Cr grades ■ Multimodality is key – cascade
setup
■ Single/multimodal reactor setup

■ Excellent processability ■ Excellent processability

■ Poor mechanical properties (film) ■ Excellent surface quality
■ ESCR/impact balance inferior to ZN ■ Medium ESCR/impact balance
grades (SBM)
■ Single reactor setup
■ Single reactor setup

Based on our ZN catalyst technology the Hyperzone PE process will be able to serve all markets

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Hyperzone PE is based on 70 Years of LyondellBasell knowledge

LyondellBasell Process Knowledge

• Hostalen ACP
• Multimodal reactors Hyperzone PE
• Spherilene
• FBR reactor operation
• Spherizone PP
• MZCR design and operation

LyondellBasell Catalyst Knowledge

• Hyperzone PE is the first process Fluid Bed
able to serve ALL HDPE markets Reactor (FBR)
Multi-zone
based on using our innovative Circulating Reactor
spherical ZN catalyst technology. (MCR)

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Hyperzone PE gas phase reactor cascade for the production of
multimodal HDPE

2 Reactor
nd
Unique 3 in 2 cascade reactor setup; superior ZN product properties that can design grades
Multizone Circulation (MZCR)
with differential properties while maintaining excellent processability

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The function of the multizone circulating reactor makes the difference

One circulation cycle = about 2 minutes; residence time 2 hours2= Reactor

nd
average 60 cycles per
Multizone Circulation (MZCR)
polymer sphere; very homogeneous high molecular weight copolymer

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 The Multi Zone Circulating Reactor (MZCR) Makes the Difference –
Principle of the Barrier

HIGH H2
CONCENTRATION

STRIPPING
ZONE BARRIER
FLUID
Condensate
(>90 % propane)
Dp

LOW H2
vsolid CONCENTRATION

Bimodality in molecular weight between

riser and downer can be influenced by the barrier
(Combination of Dp, vsolid and amount of barrier liquid)
 High barrier efficiency  low H2 in downer
 strong bimodality in the
MZCR

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Spherical ZN catalyst and innovative process deliver exceptional
product homogeneity

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 Hyperzone PE plant will produce a broad range of products

Products Applications Benefits*

Gas and Water Pipes

Improved toughness and crack
Pipe
resistance

Drums and IBC

Large Excellent processability and
Blow improved crack resistance
Molding

Industrial and household bottles

Small Excellent processability and
Blow improved crack resistance
Molding

Grocery bags and can liners

Excellent processability and
Film toughness

* Based on pilot plant material

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 Hyperzone HY54907U for IBC

■ Hyperzone Large Part

Blowmolding resins
show excellent
processing
characteristics
 Outstanding ESCR/FNCT
performance
 Diameter swell very much in
line with standard monomodal
chromium catalyst blow
molding HDPEs
 Controlled weight swell
facilitating more forgiving, wider
die gaps
 Proven processability on typical
LBM extrusion blow molding
platforms
 Continuous
 Accumulator head

A new HDPE LBM resin for IBCs and other large articles

*Data based on pilot plant material

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 Hyperzone IBC HY54907U properties

Resin properties Resin impact vs stiffness

Excellent impact/stiffness balance of properties

Standard monomodal chrome-like processability with bimodal Ziegler properties

*Data based on pilot plant material

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 Hyperzone HY55430 for small part blow molding

■ Hyperzone small part blow

molding resins show
excellent processing
characteristics
■ Diameter swell very much in
line with standard
monomodal chromium
catalyst blow molding HDPEs
■ Controlled weight swell
facilitating more forgiving,
wider die gaps
■ Proven to processability on
all typical extrusion blow
molding platforms
▪ Reciprocating screw
▪ High speed wheel
▪ Continuous extrusion shuttle

A new balance in HDPE small part blow molding resins

*Data based on pilot plant material

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 Hyperzone SBM properties

Outstanding stress crack performance Excellent bottle drop impact strength

Standard monomodal chrome-like processability with bimodal ziegler properties

*Data based on pilot plant material

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 Hyperzone HY4008 for pipe

160% 160%

140% 140%

120% 120%

RCP % of L4904
PENT % of L4904

100% 100%

80% 80%

60% 60%

40% 40%

20% 20%

0% 0%
L4904 HY4008 L4904 HY4008

Introducing a new HDPE pipe resin for water, gas and industrial applications

*Data based on pilot plant material

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LYB’s Hyperzone PE Technology is timed to capture HDPE demand
Capacity Additions Demand Growth

World Scale Plants (1)

15

10
HDPE
5

2015-2017 2018-2020
Estimate

World Scale Plants (1)

15

10
LLDPE
5 La Porte, Texas

2015-2017 2018-2020
Estimate
La Porte Hyperzone PE

World Scale Plants (1)  1.1 billion pounds per year

15
 Estimated investment: ~$725 million
10
LDPE  Startup 2019
5
 Estimated EBITDA(2): $150 - $200 MM/year
2015-2017 2018-2020
Estimate

(1) Source: IHS polyethylene supply-demand data with an operating rate of 90%. World scale plant equivalents are 1.1 billion pounds.
(2) For the purpose of this slide, estimated EBITDA for Hyperzone Polyethylene is volume times average 2015-2017 margins.

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 Questions?

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