NEW DEVELOPMENTS & BUSINESS OPPORTUNITIES IN IN ROTOMOULDING - - PowerPoint PPT Presentation

“NEW DEVELOPMENTS & BUSINESS OPPORTUNITIES IN IN ROTOMOULDING”

Product Application & Research Centre RIL & IPCL

Contents

• Company profile-RIL/ IPCL
• PARC
• International Rotational Moulding Market Scenario
• Indian Rotational Moulding Industry
• Indian Rotational Moulding Industry
• Salient Features of Rotomoulding Grades Polyolefins

From Reliance Industries Limited

• Innovative Products
• New Business Opportunities

Corporate Profile Corporate Profile

• Manufacture and market internationally competitive Polymers
• Strive to develop the service, technical expertise and creativity to

address all our customers’ problems and concerns

• Commit to total Customer Satisfaction in terms of Quality & Services for

all our products

Our Mission…….

• Ensure sustained Profitability and Growth in our business operations
• Build an organization in line with our continued commitment to

excellence and innovative efforts to stay as market leaders

• Continuously upgrade our product and delivery systems to provide the

right product for every customer

Total Customer Satisfaction – a Reliance commitment…

Reliance Group - Businesses

Textiles Polyester Plastics Petroleum Products Oil & Gas Infrastructure Naroda Patalganga Hazira

Materials and energy value chains and infrastructure

Hazira Jamnagar Bombay High Suiting PSF LLDPE/HDPE LPG Crude Oil Power Shirting PFY PP Gasoline Natural Gas Telecom Furnishings POY PVC Naphtha Port Pillows P. Chips MEG ATF Roads Fabrics PTA Ethylene Kerosene OFC PX Propylene Diesel LAB VCM Petcoke EO Sulphur Ducts

About RIL

• RIL : The fastest growing private sector company
• RIL

: Amongst world’s top ten producers in petrochemicals

• RIL

: Gross turnover Rs. 75,518 crores (US$ 17,022 billion) (2003 - 04)

• RIL : First Indian company in Fortune Global 500 list

Reliance’s Polymer Business

Capacity (KTA) Global Rank PE 1000 14th PP 1300 7th PP 1300 7th Polyolefins 2300 10th All Polymers 2820 10th

……… Largest PP producer in Asia….

Post IPCL acquisition

• 500

PVC HPL 16% Others 6%

RIL- IPCL – Largest Polymer Producer in India

1160

780

PE PP

with plans for major expansions

RIL+IPCL 71% GAIL 7%

About IPCL

• IPCL : Pioneer petrochemical company now managed by

RIL

• IPCL : Heralded the growth of petrochemical industry in

India India

• IPCL : Total production of 1 million metric tons of

polymers, synthetic fibres and chemicals

• IPCL : Second largest petrochemicals company in India

in terms of sales, assets, net-worth and profits

• RIL and IPCL rank amongst tenth largest polymer

producers in the world and caters to approximately 70% of Indian market

About RIL & IPCL

• In PP alone, it has a market share of 85%

Reliance & IPCL - Manufacturing Facilities

India

Naroda - Gujarat

Textile manufacturing

Hazira - Gujarat

Petrochem & Polyester

Jamnagar - Gujarat

Refinery & Petrochem

IPCL - Baroda, Gujarat

Petrochem

Strategically located facilities in western India.

I N D I A N O C E A N ARABIAN SEA BAY OF BENGAL I N D I A N O C E A N

Patalganga-Mah

Polyester & Intermediates

Panna Mukta & Tapti

Oil & Gas Petrochem & Polyester

IPCL - Gandhar, Gujarat

Petrochem

IPCL - Nagotahne, Mah

Petrochem

IPCL : Polymer Manufacturing Facilities

• IPCL manufacturing locations at :
• Baroda
• LDPE / PVC / PP
• Gandhar
• PVC / HDPE
• Gandhar
• PVC / HDPE
• Nagothane
• LLDPE / HDPE / MDPE

Polymers Fiber Intermediates Chemicals Fibers Textiles

Reliance Group - Vertical Integration

Ducts Oil & Gas E & P Petroleum Refining Olefins Aromatics

Fully integrated value chain from well head to fabrics.

About PARC About PARC - RIL RIL

Total Technology Total Technology Total Technology & Business Solution Provider ! Total Technology & Business Solution Provider !

PARC

Established in 1990 , this centre committed to deliver value addition to polymer business by Providing technical service, Constant product up gradation and Market development

With the sole objective of total customer satisfaction

• Between business enterprises and their vendors
• Converting basic needs

into commercially viable technology

• Helping produce useful products

WE believe in building strategic relationships

• !

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Bureau of Indian Standards -Representations

• Plastics Containers PCD 21
• Test Method on plastics Containers

PCD 21.1

• Crates for Veg. & Fruits PCD 21.P1
• Method of testing of Plastics PCD 23
• Cement & fertilisers TX 23
• Textile Materials Polyolefins TX23
• Polyethylene Pipes CED 50

Member of 18 committees

• Food Packaging PCD 12.12
• Thermoplastics PCD 12.3
• Moulded Luggage PCD 12 P2
• Recycling PCD 12.17
• Plasticizers PCD 12.10
• Multilayer Films PCD 12.16
• Polyethylene Pipes CED 50
• UPVC pipes CED 50
• PVC CED 50
• Irrigation and Farm Drainage FADC 54
• Sprinkler Irrigation FADC 35-P!

PARC

• Doctorates
• Polymer Engineers

Biggest asset - People

• Polymer Engineers
• Industrial Designers
• Polymer Chemists
• Technicians

Total Manpower : 43

Presentations

Houston

• SPO ‘97

Vancouver ISO TC/61 London

• PVC ‘98

China

• PPS

Germany

• PE ‘97

Netherland

• PPS-15

Japan

• PPS-14

Antec 2001 Addcon 2003 PPS 20

• SPO ‘97

Singapore

• WCC

Delhi Polymer’99

International conferences National conferences Presentations to OEMs Customer Meet Enviormental Meetings

PARC Facilities

ROTOMOULDING MARKETS

NORTH AMERICA MARKET: U.S. rotational moulding market place is unique in so far as fully 20% of its annual output consists of

O th e r s 2 0 % T o y s 2 0 %

annual output consists of toys (Little Tikes and Step 2) Agricultural and industrial tanks are the second largest market for North America.

T a n k s 2 0 % R e c r e a tio n a l P d ts 2 0 % A u to m o tiv e 2 0 %

ROTOMOULDING MARKETS

EUROPEAN MARKET : European moulders are involved in design concepts and products. The largest segment is the

Leisure Time 5% Toys 6% Others 11% Automobile 18%

The largest segment is the food and agriculture market at 32%. In Europe, the rotational moulding industry makes the process fit the desired design. In North America, however, the trend is to make the design fit the process.

Material Handling 10% Food & Agriculture 32% Lawn & Garden 10% Highway 8%

ROTOMOULDING MARKETS

SOUTH AFRICA MARKET : It is estimated that there are 40 companies involved in rotational

• moulding. Tanks dominate the

market (56%), although a very broad range

• f

products are

Others 4% Leisure 5% Mining 2% Industrial 7% Material Handling 8%

broad range

• f

products are manufactured. The need for building products such as septic tanks has been a big driving force. The mining industry and the expanding automotive sector has also created a demand for higher performance

• f

rotomoulded products.

Construction 12% Tanks 56% Automobile 6%

ROTOMOULDING MARKETS

INDIAN MARKET : Over 150 rotomoulders Annual consumption about 35,000 MTA 85% fo the market is Water

Others 15%

85% fo the market is Water storage tanks Rotomoulders have initiated developments in various industries like Automotives, Diary, Material handling .

Water Tanks 85%

The process comprises of the following :

• Loading the resin in the mould
• Heating fusion of the resin

ROTATIONAL MOULDING PROCESS

• Heating fusion of the resin
• Cooling and unloading the mould
• Unlike other processes, no pressure is involved and

the plastic material is heated / melted and cooled in the mould.

• Flexibility.
• Moulds inexpensive. Less lead time.
• Moulds of quite different size and shapes may be run

simultaneously on the same equipment.

ADVANTAGES OF ROTATIONAL MOULDING

simultaneously on the same equipment.

• Articles with undercuts and intricate contours can be

produced

• No weldlines or sprue marks
• wall thickness uniformity
• Inserts can be easily incorporated
• surface textures such as wood grain, leather grain etc. can

be achieved with comparative ease

ATTRIBUTES OF HOLLOW PARTS PROCESSES

Rotational Moulding Extrusion Blow Moulding Twin-Sheet Thermo - forming Shape complexity 10 8 7 Maximum size 10 5 8 Manimum size 10 9 7 Thickness uniformity 10 6 5 Moulded-in inserts 10 4 1 Moulded-in inserts 10 4 1 Material choice 6 8 10 Material scrap factor 10 8 6 Material cost 8 10 6 Machine cost 10 7 9 Mould cost 10 7 9 Labour input 6 10 7 Production rate 7 10 8 10 = Best or most common, 5 = Worth considering, 0 = Normally not done

PLASTICS IN ROTATIONAL MOULDING INDUSTRY

• Polyolefins (mainly PE) dominate the market
• Readily converted from

granules to the powder form

• Stability to withstand

long heating period

Others 5% LLDPE 61% LDPE 2% PVC 13% XLPE 8% HDPE 11%

• Liquid, fine powder or small pallet
• Optimal processing performance
• Proper stabilization

RESIN REQUIREMENTS

• Proper stabilization
• Good physical properties
• Impact
• ESCR

EMERGING APPLICATIONS

RECLAIR O35042

Reclair ER-19 is a Octene Conomoer based medium density Polyethylene grade designed for Rotational Moulding applications with optimum loading of UV Stabilizer Processing similar to Butene grades Excellent toughness and ESCR.

OCTENE ADVANTAGES

TYPICAL PROPERTIES

Property Unit Test Method Value Property Unit Test Method Value Butene Octene Tensile Strength at Yield M Pa ASTM D368 14 15 Flexural Modulus M Pa ASTM D790 480 500 Izod Impact Strength J/m ASTM D256 144 650

Indothene LL 36RA045

Reclair O35042

automotive components, fuel tanks, underground tanks (septic tanks, manholes)

• APPLICATIONS ( O 35042)

insulated crates pallets.

WHY POLYPROPYLENE (PP) ?

In order to expand into new markets, the rotational moulding industry needs materials offering good surface hardness and high temperature stability.

• Excellent chemical resistance
• Autoclavable
• High heat distortion
• Better stiffness
• Better abrasion resistance.

TYPES OF POLYPROPYLENE (PP)

• Three basic types of PP :
• HOMOPOLYMERS :
• Fibres, carpet backing, caps etc.
• RANDOM COPOLYMERS :
• RANDOM COPOLYMERS :
• Clarity, house wares,
• Clear / see through

applications

• IMPACT COMOPOLYMERS :
• Automotive, bumpers,
• Luggage

POLYPROPYLENE (PP) AS A ROTATIONAL MOULDING RESIN

• Toughness is a very major

requirement for Rotomoulded products.

• Due to inherently low stiffness of
• Due to inherently low stiffness of

LLDPE, Polypropylene is considered.

• With the advent of high activity

catalyst technology, PP impact copolymers exhibit an excellent property balance of stiffness to impact resistance.

• Parts requiring autoclaving / sterilization
• Medical bio-technology

APPLICATIONS ( PP)

• High temperature applications
• Housings of appliances -
• Automotives, Furniture.

VALUE ADDITION FROM RECLAIR LLDPE

• FR compounds for Rotational Applications
• Crosslinkable LLDPE for achanced performance
• Value addition -PE Foamed products
• Tailor-made compounds for niche markets

FR compounds for Rotational Moulding

• Requirements-
• Antistatic properties
• V-0 rating, UL -94
• FR compounds for different

flammability ratings as per UL 94 .

• Applications: Defence, Packaging,

Dust-bins, Automotive.

CROSSLINKABLE LLDPE

• Alters performance of base resin
• Increase Service temperature
• Improvement in ESCR
• Improvement in ESCR
• Increase in Toughness.
• Applications: fuel tanks,

Chemical tanks

CROSSLINKABLE LLDPE

Crosslinked materials showed encouraging results Property Unit Reclair R35042 Crosslinked R35042 Tensile Mpa 16 17 Tensile Mpa 16 17 Elongation % 260 210 Flexural MPa 710 740 Mod. Izod Impact J/m 60 240 ESCR hrs 50 >400

PE- FOAMED PRODUCTS

• Reduce Weight -Strength ratio
• Improve Rigidity
• Thermal insulation
• Eliminate post-moulding
• Eliminate post-moulding
• Better bonding ( Skin& core)
• Ease Recyclable
• Applications: Insulated

containers,Automotive components

PE- FOAMED PRODUCTS

• In-house trials have given

encouraging results

• Consistent & uniform cell

structure structure

• Increase in rigidity
• Good insulation

PE - FOAMED PRODUCTS0

• Development of insulation

containers for fishery Industry

TAILOR- MADE COMPOUNDS FOR NICHE MARKETS

• Development
• f

compound for Automotive compound to match Impact - Rigidity balance.

• Compound was designed as per the requirements of

the End user.

• In-house trials were conducted to evaluate
• In-house trials were conducted to evaluate
• Process ability
• Product properties

UNDERGROUND ROTOMOULDED MANHOLE

Manhole Developed for Reliance Telecom junctions. Total weight of the product is

100 Kgs, as compared to the

conventional Concrete manhole of 7 tons.

TESTING OF THE MANHOLE STRUCTURE

• The manhole was installed underground and soil was

compacted around the structure.

• The

pre-fabricated concrete frame and lid weighing 1.2 tonnes was placed on the Manhole.

• Various vehicles were moved on this Manhole assembly, to

simulate actual loading conditions. simulate actual loading conditions.

• This

test was carried

• ut

with different soil conditions.(Compacted, loosely packed, Dry / Wet.)

• The various Vehicles tried were :

» LMV(Car) 1.5 Tonnes » HYDRA 4.0 Tonnes » HMV(Truck) 10.0 Tonnes

TESTING OF ROTOMOULDED (UNDERGROUND) MANHOLE.

UNDERGROUND SHELTERS

Underground Shelter for Defence from Reclair LLDPE

Visualisation On ID Software

ROTOMOULDED BUS STOP SHELTER AT JAMNAGAR

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#$%&' "(

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• *
• ROTOMOULDED BUS STOP SHELTER

AT JAMNAGAR

Actual Product

ROTOMOULDED BUS STOP SHELTER AT JAMNAGAR

Reliance Industries Limited - PARC won the Plasticon Award 2000 for the above rotomoulded product

POTENTIAL APPLICATIONS

POTENTIAL APPLICATIONS: (AUTOMOTIVES/ APPLIANCES)

POTENTIAL APPLICATIONS

APPLICATIONS

APPLICATIONS

New Development Support from RIL

Development of new grades. Technical assistance- Application development. Customer support- Testing and Processing . Coordinate with OEMs and nodal agencies for approvals.