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UNIPOL

Polypropylene
Technology

Simple and Reliable


Broadest Product Range
Low Investment Cost
Low Operating Cost
Easy To Operate
Outstanding Profit Potential

UNIPOL Polypropylene Technology

A Smart Choice for Profitable


Polypropylene Production
If you are evaluating options for
large-scale polypropylene
production, you know there is
more to consider than just the
unit operations of the process
technology itself. Successful resin
producers understand the need
for a process that delivers a broad
range of market-leading products;
low operating costs to help ensure
sustainable profitability; ease
of operation, and continuous
technology advancements and

Setting the standard


for polypropylene process
technology.
By any measure, including process design
and operation, catalyst performance,
products produced, economics and value
as well as technology advancement
and licensee support, the UNIPOL
Polypropylene Technology is considered an
industry leader worldwide. Here are the
reasons why:
Simple, Reliable, Proven Technology
the UNIPOL Polypropylene Technology is an
all gas-phase technology that is stable and
predictable, and that has been designed
to have fewer moving parts and less
equipment than any competing technology.

The simple process design leads to lower


capital costs and lower operating and
maintenance costs.
Although mechanically simple, the
underlying technology enables the
production of homopolymers or random
copolymers in a single reactor plant
design regardless of capacity. The same
plant can also produce impact copolymers
with the addition of a second reactor of
identical technology. This feature of the
UNIPOL Polypropylene Technology enables
producers exceptional flexibility to easily
change their product mix to meet market
demands both now and as markets develop
in the future.
The simple, reliable design of the
UNIPOL Polypropylene Technology,
coupled with SHAC Catalyst Systems,
offers another significant economic
benefit the ability to operate the plant
above nameplate capacity.

support to keep them competitive


and market leading year after year.
It is for those reasons,
and more, that leading
resin producers
around the world have
chosen the UNIPOL
Polypropylene Technology,
marketed and supported
worldwide by The Dow
Chemical Company.

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

Plants utilizing the UNIPOL Polypropylene


Technology routinely run above nameplate
capacity, delivering even higher return on
the original investment. Exceptional onstream time and aim-grade performance
further enhance the capacity of the UNIPOL
Polypropylene Technology.
Broadest Product Range the UNIPOL
Polypropylene Technology can make
the broadest range of polypropylene
products available. From commodity raffia
grades, to market leading BOPP (biaxially
oriented polypropylene) grades for todays
high-speed lines, to unrivalled random
copolymers, to high-performance impact
grades for automotive and aerospace
applications, the UNIPOL Polypropylene
Technology offers both market-leading
and competitive products that are proven
performers.
And of equal importance is the fact that
every licensee has access to the full
complement of improved products as they
are developed. As a producer, you have
the ability to tailor your product selection
to meet the demands of your customers in
your markets, helping maximize your return
on investment in the UNIPOL Polypropylene
Technology.
Catalyst Portfolio experienced
polypropylene producers recognize the
importance of the catalyst system in the
operation of the process. The portfolio
of SHAC Catalyst Systems includes a
range of catalyst and donor products that
enable efficient, economical production of
our broad product line.
Consistent catalyst performance that
translates to product consistency, our unique
morphology-controlled catalysts that deliver
high productivity with excellent operating
reliability, and the Dow commitment to
advancing the science of catalysis are
additional benefits that come with a UNIPOL
Polypropylene Technology license.

Industry-leading Economics a simple,


reliable design coupled with efficient,
consistent catalyst systems result in both
low investment costs and low operating
and maintenance costs for the UNIPOL
Polypropylene Technology. A small plant
footprint, low number of moving parts
and a streamlined process help keep land
costs, as well as equipment fabrication and
installation costs, lower than competing
processes.

The UNIPOL Polypropylene


Technology your best choice.
The information on the pages that follow
details many of the important features
and benefits that make the UNIPOL
Polypropylene Technology your best choice
for polypropylene production. Please
contact your Dow representative or the
sales office nearest you for additional help,
or visit www.dow.com/licensing.

The UNIPOL Polypropylene Technology,


combined with the comprehensive
Dow technology transfer services and
support, result in swift and efficient
project execution, putting licensees in the
marketplace quickly.
The mechanical simplicity of the process,
coupled with exceptional process stability
and catalyst consistency, and further
enhanced by UNIPOL UNIPPAC
Advanced Process Control technology helps
keep operating costs among the lowest in
the industry.
New process, product and catalyst
developments are designed to drop into
existing units to give licensees the ability
to move with the market of the future while
minimizing capital costs.
Unmatched Licensee Support
comprehensive ongoing licensee support is
a vital part of Dows commitment to helping
you succeed. Support starts with expert
advice and counsel from Dow process
experts during the evaluation stage, and
continues during design, construction,
startup and beyond.
Dow is committed to advancing the
UNIPOL Polypropylene Technology in
every way we can, from new products
and catalysts to ongoing operator training
and process improvements. We share our
advancements regularly with licensees
through our Global Technology Exchange
Meetings, frequent contact with our
licensees, as well as customized technical
service and training sessions.

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

Products

The ability to produce a wide range


of polypropylene resins must be a key
consideration as you evaluate the process
technology you will choose. Experienced
resin producers have identified three
important product-related questions to ask
when comparing the various technologies:
What is the breadth and depth of the
product offerings?
Does the process offer flexibility to
allow easy and economical changes in
the product mix being produced?
Does the process have favorable economics
across the entire product range?

Licensees of the UNIPOL Polypropylene


Technology know from their experience
that they can produce the broadest range
of products with the greatest flexibility and
compete in any global market.

The industrys most


complete product capability
It isnt just how many types of products
can be produced using the UNIPOL
Polypropylene Technology. Equally
important is the depth in each product
family that enables our licensees to
compete in all major market applications.
Licensees of the UNIPOL Polypropylene
Technology have access to more classes
of products, and grades within those
classes, than is available from any other
commercial technology.

Figure 1: Product Line Markets Served


End Use Applications

Random Copolymers
77
Impact Copolymers
72

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

Thermoforming
& Blow Molding

Rigid
Packaging

TWM

Extrusion

Melt
Blown

Spun
Bond

Staple
CF & BCF

Monofilament
& Raffia

Homopolymers
137

Durable &
Industrial Products

Textiles

TWQ

Cast

BOPP

Film

Injection
Molding

Product Family

Keep margins high


Meet market demands
through production flexibility The UNIPOL Polypropylene Technology
Producers who cant easily and
economically vary their product mix are
at a disadvantage in meeting customer
demands in fast-changing markets. The
simple, proven technology that allows
production of both homopolymer and
random copolymer products in the same
reactor, and impact copolymers with
an additional identical reactor, enables
exceptional flexibility.

sets the standard for low investment


cost and low operating cost across all
product types. The UNIPOL Polypropylene
Technology will help make you competitive
in your most important markets.

UNIPOL UNIPPAC Advanced Process


Control software enables operators to
optimize product line changes.

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

SHAC Catalyst Systems

SHAC Catalyst Systems and donors are


complementary components designed
specifically for the UNIPOL Polypropylene
Technology. SHAC Catalyst Systems are
easy to use, consistent and contribute to
the low operating cost of the process. The
entire family of SHAC Catalyst Systems is
regularly updated, and licensees benefit
from the commitment of Dow to advancing
the science of catalysis.

A versatile catalyst family


A range of SHAC Catalyst Systems enables
the producer to choose the best catalyst
and donor combination to meet specific
requirements as shown in Figure 2.

Figure 2: Versatility of SHAC Catalyst Systems


Product Family
Homopolymers 137

Catalyst System
SHAC 201 Catalyst or SHAC 320 Catalyst + ADT or NPTMS Donor

Random Copolymers 77

SHAC 205 Catalyst + ADT or NPTMS Donor

Impact Copolymers 72

SHAC 320 Catalyst + ADT or DCPDMS Donor

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

Simple to use
An important advantage of SHAC
Catalyst Systems is ease of use. Unlike
some competitive technologies, SHAC
Catalyst Systems can be fed directly
as shipped into a reactor employing
UNIPOL Polypropylene Technology,
which helps to keep operating costs low.
No pretreatment required
No activation required
No pre-polymerization required

Morphology-controlled
catalysts offer advantages
Catalyst particle size and shape directly
translate to polymer particle size and
shape. The portfolio of SHAC Catalyst
Systems includes controlled morphology
catalysts with spherical particles that are
consistent in size.
Compared to traditional catalysts, these
high-performance systems produce
powder-stage resins that are more uniform
in shape. The result is higher powder
flow rates and higher powder settled bulk
density that enables plants to achieve the
highest production rates.

Catalyst productivity
equals economy
Excellent uniformity and high catalyst
productivity help lower catalyst cost per
unit of resin produced.

Figure 3: Controlled Morphology SHAC


Catalyst and Effect on Polymer Particle

Controlled Morphology Catalyst

Focusing on catalyst
development
Catalysis is a core science for Dow across
a wide range of chemical and polymer
fields. Applying Dows world class skills
and facilities, development programs for
SHAC Catalyst Systems bring benefits to
licensees of the UNIPOL Polypropylene
Technology as new products and
technology platforms are developed.
Examples include:

Polymer

Catalysts for high crystallinity


homopolymers and blends
Advanced Donor Technology (ADT) to
maximize reactor operating time
through superior reliability while
producing advantaged polymer products.

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

UNIPOL Polypropylene Technology


Simple to Build, Operate and Maintain
Simplicity
is a key characteristic of the
UNIPOL Polypropylene Technology:
Fewer moving parts and less
equipment overall compared to
competing systems
Smallest Inside Battery Limits
(ISBL) footprint in the industry
Easy access to key plant
equipment for simplified
maintenance
The result of our simple, common
sense design approach is that the
licensee will enjoy low capital

The core facility for the UNIPOL


Polypropylene Technology requires a small
footprint of 60 meters by 65 meters or a
total of 3,900 square meters. This includes
the Purification, Reaction, Purging, Vent
Recovery, Additive Addition, and Pelleting
operations.

Figure 5: State-of-the-Art Process


Technology with Mechanical Simplicity

The total Inside Battery Limit (ISBL)


occupies 14,000 square meters measuring
approximately 115 meters by 120 meters.
The ISBL area includes the Core facility
plus the Alkyl Supply, Catalyst Storage,
Laboratory, Control Room, and Motor
Control Center.
The UNIPOL Polypropylene Technology
is state-of-the-art technology, yet it is
mechanically simple and easy to operate.
A minimal amount of major equipment
is required. There are only three to four
pieces of major rotating equipment.
A single reactor is used to produce
homopolymers and random copolymers,
plus one additional reactor in series to
produce impact copolymers irrespective of
plant capacity.

costs and the low operating costs


compared to competing systems.

Figure 4: Minimal Land Requirement

20
SCALE (METERS)

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

40

Other benefits of the UNIPOL


Polypropylene Technology include:
Up to 550 KTA single line capacity for
full homopolymer, random and impact
grade product mix
Up to 650 KTA single line capacity for
selected product mixes
Uses readily available industry-standard
equipment
Least expensive standard materials
of construction widely used due to
non-corrosive process
No mechanical agitation in the reactors
Only polypropylene process which can
remain agitated during power outage
Close-coupled pelleting eliminating the
need for intermediate resin storage

The simplicity of the UNIPOL Polypropylene


Technology offers several additional
benefits because competitive technologies
require additional processes and
components.
Other processes require some or all of these:
Multiple processes to coordinate and
control as many as three in a series
Multiple reactors needed for large
capacities or advanced products
as many as five in a series
Pre-polymerization and/or catalyst
pretreatment
Additional purification

The simplicity of the homopolymer/random


copolymer system is mirrored in the impact
copolymer stage, which operates with the
same gas phase fluidized bed process in a
slightly smaller reactor. For each reaction
stage there are just three main pieces
of equipment: the reactor, the cycle gas
compressor and the cycle gas cooler.
With active catalyst entering from the
first stage, there is no need for additional
catalyst feed to the impact reactor. The
critical rubber component is polymerized
directly in the growing polypropylene
particles, achieving optimum rubber
dispersion and morphology that results in
the highest impact performance.

Stirrers or scrapers in the reactors


Solid separation equipment
Vent dryer recovery
Membrane separation unit for reactor
vent gases
Intermediate storage and conveying

Figure 6: Simplicity of the Impact Reactor

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

Global Resources to Support


You Wherever You Operate
The polypropylene industry is truly global,
with resin producers and converters
operating in every major market around
the world. As a global Company, Dow
has invested in resources to support its
licensees no matter where they operate.

Our investments in strong local resources


are helping licensees succeed.

Figure 9: Serving Global Customers With Extensive Resources

Dow A strong
business resource
From facilities and people in
every corner of the globe, to
an R&D budget approaching
$1 billion, Dow is focused on
delivering ongoing business
success to its licensing customers.
Dow is a science and technology

UNIPOLTM Polypropylene Technology


METEORTM EO/EG Process
LP OxoSM Technology
QBISTM Technology
PTA Technology

leader that supplies over


3,500 products to customers
in 175 countries. As a licensee
of the UNIPOL Polypropylene
Technology you can be assured
that the strength and skills of
this market-leading organization
and its people are behind you in
every possible way.

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

Technology Transfer, Training and


Ongoing Support to Help You Succeed
Our goal is to help each licensee become
as successful as they can be. We focus
our resources on your success from the
first meeting, through plant construction
to training, start-up and commissioning,
and long-term support using experienced
Dow personnel at every step.

Plant design and


technology transfer
The UNIPOL Polypropylene Technology
is thoroughly documented in manuals that
cover the underlying scientific knowledge,
a comprehensive process design package
containing the basic engineering information
from which an engineering contractor
can work and a manual of typical plant
operating procedures. An experienced
multifunctional client team works closely
with each licensee throughout the process
of turning the basic technology into a
new plant, and maintains support through
start-up and beyond.

Training
Licensees are trained in all facets of the
UNIPOL Polypropylene Technology from
process theory to practical experience.
Initial orientation courses, covering both
process and product technology, are held for
technical staff and the project team. Plant
staff receive thorough operations training in
advance of start-up. In this comprehensive
program, licensee personnel from plant
operations, maintenance and laboratory
groups attend Dows university-like training
center in Houston, Texas, USA, joining
a population of graduates that already
numbers over 1500.

Coursework in the classroom is supplemented


by training using the UNIPOL
UNIPPAC Virtual Plant Simulator, a
computer-based plant simulator that
reproduces the behavior and control room
displays of an actual plant using the UNIPOL
Polypropylene Technology. Learning is
greatly accelerated as the simulator models
steady operation, grade changes and even
unexpected events like utility upsets in real
or speeded-up mode. Trainee responses
can be replayed for study and correction
if needed. Scale models are incorporated
to teach plant layout and maintenance
techniques, and trainees receive manuals
to retain for continuing reference.

Putting It
All Together

Start-up assistance

Streamlined and proven gas


phase technology with the
lowest investment costs

An experienced team of Dow people,


including a chief commissioning engineer
and several operating specialists,
provide comprehensive, on-site support,
assisting with the commissioning and
start-up activity of each licensees new
plant. As testimony to the exceptional
technology transfer and process simplicity,
plants using the UNIPOL Polypropylene
Technology usually achieve nameplate
rates and aim-grade production within
hours of initial start-up.

Ongoing support through


technology improvements
Licensees can participate in a technology
exchange program that extends over
several years after their plant begins
operation, and will receive process and
product technology improvements. This
program includes our highly regarded
Global Technology Exchange Meeting, held
annually to encourage licensees to share
best practices in a group setting. Licensees
also have opportunities for one-on-one
sessions with Dow experts.

Trademark of The Dow Chemical Company (Dow) or an affiliated company of Dow

Every way you look at it, a license


for the UNIPOL Polypropylene
Technology is your best choice,
bringing you all the elements you
need for a successful polypropylene
project:

Excellent operating economics


and reliability
Widest product flexibility
with market leading grades in
key applications
SHAC Catalyst Systems
optimized for gas phase
process operation
Superior technology transfer
services and long-term support
Continuing technology
development backed by the
commitment and resources
of Dow

10

Dow Technology Licensing


your leading resource for petrochemical
process technology
UNIPOL Polypropylene Technology
A process for the production of a comprehensive
line of polypropylene resins, including
homopolymers, random copolymers, and impact
copolymers. This process utilizes a broad line
of SHAC Catalyst Systems, engineered by
Dow specifically for the UNIPOL Polypropylene
Technology.
LP OxoSM Technology A process for the
manufacture of alcohols by low-pressure
hydroformylation. The LP Oxo Technology,
marketed in collaboration with Davy Process
Technology, Ltd., is the most widely used
technology in the industry, with 26 licensed
facilities operating in 16 countries.
METEOR EO/EG Process and Catalyst
Process and catalysts for the production of
ethylene oxide and ethylene glycol. This
unique technology combines high performance
catalysts with a streamlined process design
that uses a single EO reactor to deliver output
capacities up to two times higher than other
available commercial technologies.
QBIS Technology A process for the
production of bisphenol-A for use in melt-phase
and interfacial polycarbonate resins and
epoxy resins. The QBIS process, using QCAT
Catalysts, is a highly reliable, simple process
that features high raw material utilization and
low energy requirements.
PTA Technology A process for the
production of Purified Terephthalic Acid for use
in the manufacture of PET resins. The process
features low raw material consumption and has
shown high reliability and trouble-free operation
in over 30 years of commercial use, as well as
optimized energy savings for standard plant
capacity beyond 600 ktpa.

For information on any technologies offered by Dow Technology Licensing, please contact
the office nearest you. For specific information on the UNIPOL Polypropylene Technology,
please use the North America contact information:
US, Canada, Mexico
The Dow Chemical Company
Customer Information Group
4520 E. Ashman Rd.
Midland, MI 48642-1206
Telephone: + 800 447 4369
Toll: +989 832 1542
Fax: +1 989 832 1465
Europe
Dow Customer Information Group
Prins Boudewijnlaan 41
B-2650 Edegem
Belgium
Telephone Europe toll free: +800 3 694 6367
Toll: +32 3 450 2240
Fax: +32 3 450 2815
Italy: 800 783 835
Moscow Office
Dow Europe GmbH
17/23, Taganskaya Street
109147 Moscow Russia
Telephone: +7 495 258 56 90
Fax: +7 495 258 56 92

India, Middle East, Africa


Dow Export GmbH
Level 22
Kendah House
Sheikh Zayed Road
Dubai
United Arab Emirates
Telephone: +971 4 332 8866
Fax: +971 4 332 8280
Asia Pacific
Dow Chemical (China) Investment Co. Ltd.
Room 1101, Tower W3, Oriental Plaza
No. 1 East Chang An Avenue
Dong Cheng District,
Beijing 100738, China
Telephone: +86 10 85183399
Fax: +86 10 85183999
Latin America
Dow Brazil S.A.
CIG Latin, 3C Floor
Rua Alexandre Dumas, 1671
Chacara Santo Antonio
04717-903
Sao Paulo, Brazil
Telephone: +55 11 5188 9000
Fax: +55 11 5188 9887

Visit our web site:


www.dow.com/licensing

NOTICE: No freedom from infringement of any patent owned by Dow or others is to be inferred. Because use conditions
and applicable laws may differ from one location to another and may change with time, the Customer is responsible for
determining whether products and the information in this document are appropriate for the Customers use and for ensuring
that the Customers workplace and disposal practices are in compliance with applicable laws and other governmental
enactments. Dow assumes no obligation or liability for the information in this document. NO WARRANTIES ARE
GIVEN; ALL IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ARE
EXPRESSLY EXCLUDED.
Published July 2007

Dow Technology Licensing

Trademark

of The Dow Chemical Company (Dow) or an affiliated company of Dow


mark of The Dow Chemical Company (Dow) or an affiliated company of Dow
Dow Technology Licensing is a business unit of Dow that markets technologies owned
by The Dow Chemical Company, Union Carbide Corporation, and their subsidiaries.
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Printed in U.S.A.
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SMG 11107