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Borealis Sirius catalyst
technology – enabling factor for
sustainable growth
Dr. Nora Vaarne
Catalyst Scale-Up and
Production Manager
Borealis at a glance
2 |
EUR 7.5billion
sales revenuein 2017
(>EUR 9 billionwith Borouge)
Operates in over 120 countries
on 5 continents
Head officein Vienna,
Austria
EUR 1.095
million
net profitfor 2017
Production and sales of polyolefins,
base chemicalsand fertilizers
Ownership structure
Mubadala, UAEOMV, Austria
2nd largest polyolefin producer
in Europe
Borouge operates world’s largest
integrated PO site in Ruwais, UAE
6,600employees
+3,500 in Borouge
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
3 |
We strive for zero incidents
in health and safety
We consider our local and
global responsibility for the
environment in our decisions
We do business according
to high ethical standards
and lead by example
We trust and involve people
and communicate openly,
respectfully and in a timely
manner
We collaborate, support and
help each other to develop
for the best of Borealis
We build on diversity for
better results as “One
Company”
Our values guide our business decisions and drive
every action we take
Responsible Respect Exceed Nimblicity™
We win through Excellence
and deliver beyond
expectations
We commit to making joint
decisions and follow through
We give feedback and make
“Connect–Learn–Implement”
and “Continuous
Improvement” a natural way
of working
We are fit, fast and flexible
and seek smart and simple
solutions
We encourage decisions on
all levels of the organisation
to increase ownership and
speed to realisation
We welcome change and
manage it to shape our
future
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
World class safety standards
16,3
14,8
10,19,5
8,36,9
4,0 3,82,4
1,7 1,7 1,7 1,6 0,7 1,0 1,6 1,5 1,5 1,3 1,4 0,9 1,1
9,9
8,3
7,47,0
3,03,1
2,5 2,5 1,8
1,21,4
2,5 2,11,7
2,2 2,4
1,3 1,3
0
2
4
6
8
10
12
14
16
18
1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017
TRI total TRI Own TRI Contractors
Note: TRI being defined as total recordable incidents per million hours worked
TRI frequency - Own vs. Contractors 1996 – 2017
Our Core Values drive our Actions
4 | Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
Borstar process
Multimodality of Borstar® PP
Key feature to tailor end product properties
5 |
− Borstar® process gives freedom in molecular design resulting in highly differentiated PP
− Multimodality for advanced properties (e.g.: strength and processability, clarity and toughness)
− Stiffness control through MWD design, Borealis nucleation technology and catalyst
− High EPR incorporation (RTPO’s)
Borstar® PP – A unique technology platform
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
Catalyst
Macrostructure
Borealis Sirius catalyst technology –
Key to advanced PP products with Borstar®
6 |
− High degree of control on the catalyst nano and micro
structure allowing fine-tuning of polymer properties
− Excellent control of internal and external morphology for an
optimal polymerisation behaviour
− Versatile catalyst chemistry allowing flexibility in the choice of
modern donor technology
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
Requirements for a Catalyst used in Borstar®
Kinetics matchingprocess window
Good particle morphology & homogeneity
Good polymerstructure control
High productivity
IPRCatalyst
manufacturingHSE
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 20197 |
Borealis Sirius: Sustainable Basics
1. Borealis Proprietary Sirius technology: IPR in place
2. No phthalates – No other questionable chemicals either
3. Catalyst manufacture designed to be highly contolled for reproducibility of quality –
Still flexible enough for making several types of Borealis Sirius catalysts
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 20198 |
IPRCatalyst
manufacturingHSE
Borealis Sirius – Meeting Borstar® operability
requirements
9 |
Catalyst kinetics matching
process
Flexibility to adjust the
reactor split to get
different products
High enough catalyst productivity
Different reactors and conditions
Good morphology and
homogeneity of catalyst
and polymer
Operability in different
reactors & conditions
PP powder from Borstar®
PP plant
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
The Catalyst Value Chain
Catalyst
Design
Catalyst
Performance
Process
Development
Polymer
development
Catalyst
Pilot
Polymerisation
Pilots
Cat Scale-Up
Process
Development
Catalyst
Plant
Full Scale
Plants
PO Catalyst R&D Pilot Scale Commercial Scale
Catalyst Scale-Up
Polymerisation Scale-Up
10’s of Pilot
scale runs
100’s of lab scale tests
1 plant
test run Cost /
experiment
Probability of
discovery
Process
Development
Polymer
development
Cat Scale-Up
Process
Development
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201910 |
Catalyst scale-up from lab to plant
11 |
• Catalyst development
• Screening, DoE for conditionsLaboratory reactor
• Catalyst development
•Polymerisation, analyticsLaboratory reactor
• Scale up
• Combining chemistry with engineering practices process optimisation
Catalyst Pilot
reactors
• Catalyst production for PO plantsProduction
Sirius catalyst Plant
Batch < 1,5 g
Batch < 5 g
Batch kilograms
Batch hundreds kg
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
Polymerisation scale-up from lab to plant
12 |
• Catalyst screening
•High Throughput
Laboratory
HTE
• Catalyst Evaluation, Product Development
• Polymerisation, Polymer Analysis
Laboratory
bench reactors
• Polymer Production at Pilot Scale
• Validation, Pre-marketing testing, Operating windows, Demonstration
PolymerisationPilots
•Production Plants
• Several Borstar® in the WorldFull Scale Plants
Polymer: 300 mg – 100g
Polymer: 0,5 - 3 kg
Production Rate: 60 – 120 kg/hr
Up to 700 kt/a
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
Borealis Catalyst R&D
13 |
Parallel Catalyst Synthesis Advanced Catalyst Characterisation
High Throughput Experimentation Bench Scale Polymerisation
• Located in Finland,
Europe
• Target is to develop new
catalyst systems that
meet the PO product and
process targets
• Supported by broad
polymerisation capability
and analytical tools
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
Borealis Sirius Catalyst Technology – Mastering
polymer structure and polymerization behaviour
14 |
Intra- and inter-particle
homogeneity
Particle morphology
MgCl2 nano-crystals with
active sites
External / internal donor
chemistry
Polymer structure /
product properties
Nanostructure
ChemistryMicrostructure
Assembly of MgCl2nanoparticles
Porosity
Polymerization process
behavior
Macrostructure
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
Borealis Catalyst Pilot Plant
– Located in Finland, Europe
– Own proprietary technology
– Scope is catalyst development including Borealis Sirius
technology
– Several types of catalysts has been piloted
– High level of flexibility with a wide variety of reactors
and equipment combinations
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201915 |
Borealis Sirius Catalyst Technology – Inside the reactor
16 |
Formation of
two liquid
phases
Emulsification Solidification Final catalystWashes
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 2019
Borealis Sirius Catalyst Plant
– Located in Austria, Europe
– Own proprietary technology
– Start up year 2012
– Non-phthalate Ziegler-Natta PP catalyst manufature since 2014
– So far proven for different Borealis Sirius catalysts at the plant
– Broad range of particle sizes
– Different chemical compositions
– Different morphologies
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201917 |
Key messages
− Borealis’ Borstar® process gives freedom in molecular design resulting in highly
differentiated polymers
− The Borstar® process sets a variety of demands for the catalyst capability
− Borealis’ Sirius catalyst technology is fulfilling these demands and enables broad
product property capability
− Sirius is platform technology for all kind of Ziegler-Natta and Single Site catalysts
− Sirius emulsion catalyst technology allows unique possibilities in tailoring particle size
and morphology
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201918 |
Thank you
A project by Borealis AG. The ideas documented in
this presentation are the sole property of Borealis AG,
and are subject to current copyright laws.
Unauthorized use, reproduction in whole or in part, as
well as transmission to third parties is not permitted.
Borealis Sirius Catalyst Technology | SPE PO Conference 24 February, 201919 |
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