Borealis Borstar PP and Fibremod technologies Driving the unmatched success story of polypropylene in the automotive industry Maurits van Tol SVP Innovation and Technology Borealis AG SPE Houston February 2017
Table of Contents Keep Discovering.. 1. Borealis introduction 2. Impressive growth of polypropylene (PP) in automotive applications 3. Borstar PP technology for premium high-performance TPOs 4. Fibremod and Fibremod Carbon 5. PP Leading sustainability profile 6. Latest innovations in lightweighting 7. Conclusions 2
Borealis at a glance 2 nd largest polyolefin producer in Europe 6,500 employees EUR 7.7 billion sales revenue in 2015 Operates in over 120 countries on 5 continents Head office in Vienna, Austria EUR 988 million Ownership structure net profit for 2015 Sales of polyolefins, base chemicals and fertilizers IPIC, Abu Dhabi OMV, Austria 3
World-class safety standards TRI frequency - Own Employees vs. Contractors 1996 2015 18 16 14 16,3 14,8 12 10 8 6 4 2 0 10,1 9,5 9,9 8,3 16,3 7,6 7,4 14,8 6,3 7,0 10,1 9,5 8,3 2,8 2,7 3,0 3,1 6,9 2,5 2,5 1,8 2,5 2,1 2,2 4,0 3,8 1,1 1,4 1,2 1,5 1,2 1,4 2,2 2,4 1,7 1,2 1,3 2,4 0,3 0,8 1,4 0,9 1,0 1,7 1,7 1,7 1,6 0,7 1,0 1,6 1,5 1,5 1,3 1,4 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 TRI total TRI Own TRI Contractors Note: TRI is defined as total recordable incidents per million hours worked 4
Portfolio of leading Polyolefin technologies Polyolefin Technologies Borstar PE Bimodal LLD, MD & HDPE Post-Reactor Technologies Daploy HMS PP High melt strength PP Borstar PP Multimodal PP Borealis SIRIUS Catalyst Technology Fibremod Engineered Fibre Compounds Borceed Plastomers and Elastomers Borlink Wire & Cable Technology Platform 5
Polypropylene continuously advances into new applications by improved product properties High End UTB Body Panels 80 70 Weight of PP per car (kg) Bumpers Structural Carrier 60 50 IP Carrier 40 30 20 Start using plastic in automotive 1st Borealis PP Plant- Schwechat. 5.000t/year Development of moulded in color - exterior 10 Development of moulded in color - interior Polyamide 0 1940 1945 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010 2015 Breakthrough in Talc-filled PP Short and long glass fibre development 6
Advanced TPOs - Key technology enabler for ever improved automotive compounds Borealis Daplen talc compound 1990 50 100 Purity Needs 8 20 MFR 1700 1750 Tensile Modulus Borealis Daplen talc compound 2016 Ductile- Brittle Temp. 0-30 Charpy +23 C 30 50 PP compound innovation has stretched the boundaries several times following increasing automotive requirements 7
Multimodal Borstar PP Technology - Key feature to tailor end product properties Borstar process Borstar PP A unique technology platform The Borstar process gives freedom in molecular design resulting in highly differentiated PP Multimodality for advanced properties, such as strength and processability, clarity and toughness Stiffness control through MWD design, Borealis nucleation technology and high isotacticity catalyst High EPR incorporation (RTPO s) 8
Borealis Sirius catalyst technology Key to advanced PP products with Borstar High degree of control on the catalyst s nano and micro structure with subsequent fine-tuning of polymer properties Excellent control of catalyst particle internal and external morphology for an optimal polymerisation behaviour Versatile catalyst chemistry allowing flexibility in the choice of modern donor technology Macrostructure 9
Borstar PP Product portfolio for a very wide range of value added applications Cast Film Automotive BOPP Thermoforming Pipes & Fittings Energy Injection Moulding Fibre 10
Very demanding requirements in the automotive industry for advanced TPOs Surface appearance Low shrinkage / CLTE Low temperature impact strength Room temperature impact strength Elongation at break (-20 C) Elongation at break (+23 C) 11
Example: Performance of heterophasic copolymers (TPO) PP/EPR in-reactor blend P38 P45 P51 P58 P65 C3-content of XCS, wt% 38 45 51 58 65 IV of XCS, dl/g 3.2 3.2 3.2 3.2 3.2 MFR, g/10min 13 15 20 17 15 P38 (λ=2.3) P45 (λ=2.3) P51 (λ=2.3) P58 (λ=2.4) P65 (λ=2.5) Low C3 content of XCS High 12
Tensile modulus, MPa Tensile Strain at break, % Comparable stiffness, but superior tensile strain with advanced TPOs enabled by Borstar PP 1200 1000 800 Stiffness Elongation P38 (λ=2.3) P45 (λ=2.3) P51 (λ=2.3) P58 (λ=2.4) P65 (λ=2.5) 400 350 300 250 600 200 400 200 150 100 50 0 0 35 40 45 50 55 60 65 70 C3-content of EPR, wt% 13
Internal structure of dispersed phase of heterophasic copolymers P38 P65 0.5 µm 0.5 µm Homo PP matrix Amorphous EPR Semicrystalline PE inclusions 14
Borstar PP Technology Multimodal PP process for the production of superior TPO s Molecular weight / Co-monomer content 15
Price / Performance Fibremod The Engineering Plastic of the future! High Performance Plastics PI LCP Engineering Plastics MPPO PA PET TPE PP-CF PP-LGF PP-SGF Fibremod TM PC PBT PS PVC PMMA SAN Commodity Plastics PP PE Amorphous Semi-crystalline 16
Fibremod - Excellent performance / cost balance for wide range of applications Fibremod Technology Portfolio Fibremod Short Glass Fibre Fibremod Long Glass Fibre Fibremod Carbon Fibre Static loads Best performance / cost balance Dynamic loads Higher strength Less creep Excellent performance / cost balance Extreme stiffness Highest weight saving potential Outstanding weight / cost performance 17
Excellent expertise in simulation - An important pillar of our success Fibremod PP GF projects (examples) IP carriers Seat carriers Simulation at Borealis* 20 years of experience More than 5,000 customer projects Pedal supports Air intake manifold Loadings close to the material s limits Detailed Engineering for finished part needed * from conversion engineering to applications engineering
Fibremod Carbon The next PP revolution Lighter Stronger Faster 19
Weight Saving Potential [%] Specific bending stiffness Fibremod Carbon The material of choice for lightweight construction 2,5 2,0 1,5 1,0 E 1/3 / 0,8 1,5 2,1 1,6 1,4 1,8 1,8 2,3 Fibremod Carbon outperforms by 0,5 Steel 66% 0,0 Steel Aluminium Magnesium PA 6 - GF dry PA 6 - GF cond. PA 6 - CF cond. Fibremod GF Fibremod Carbon Aluminium 35% Magnesium 9% 0 0,0 PA 6 GF 35% -20 PA 6 CF 22% -40-60 -80-47,0-62,0-50,0-43,0-56,0-56,0-66,0 20
Concept study - rear frame (Husqvarna FC250) KTM KTM Borealis Challenge Solution Expected Benefit Increased driving performance Improved weight distribution Lowering of balance point Fibremod CB401SY More than 1 kg weight reduction on the frame Higher design freedom than metal construction Modularization and functionalization of part High torsion resistance 21
Emissions [kg/kg] PP PA6-GF30 PA6.6 PA6.6-GF30 PP PA6-GF30 PA6.6 PA6.6-GF30 Energy cons. [MJ/kg] PP PA6-GF30 PA6.6 PA6.6-GF30 H 2 O usage [l/kg] PP PA6-GF30 PA6.6 PA6.6-GF30 Environmental impact (cradle to the gate) Fibremod GB307HP vs Polyamide 100 500 0 PP PA6-GF30 PA6.6 PA6.6-GF30 0 PP PA6-GF30 PA6.6 5 Source: 0 CO 2 PA6-GF30 PA6.6 GHG 22
Daplen post consumer recyclate (PCR) grades - A sustainable, value adding solution Daplen PCR grades provide increased sustainability through combination of post-consumer recyclate (PCR) with virgin PP Examples: Daplen PCR grades for automotive applications: Daplen ME225SY (25% PCR) for vehicle interiors such as door trim and trunk linings Daplen MD250SY (50% PCR) for under-the-hood and exterior applications Daplen MD325SY (25% PCR) for exterior applications Daplen PCR grades produced and marketed in Europe: High performance grades in consistent quality for Borealis customers and partners 23
Award-winning Innovations by Borealis 2016 European Plastics Innovation Awards New Surfaces for Plastics Parts Daplen EE112AE is the first Borealis material for primerless paint systems Awarded in Plastics Today as one of their top five automotive technology breakthroughs of the year in 2015 24
BMW 7 bumper Light weight solution with Daplen Customer s Added Value Primerless paintable Daplen allows optimisation of painting cycle time and reduction of system cost Low density with good impact / stiffness balance enabling weight reduction 25
Key Messages 1. Polypropylene has a successful track record of 35 years in the automotive industry with a six-fold increase in volume 2. Borstar PP Enabling PP technology for superior TPOs 3. Fibremod For cost efficient high performance fibre-reinforced PP materials solutions 4. Fibremod Carbon The next step of revolutionary PP innovations 5. Borealis is committed to the automotive industry with sustainable Borstar PP, Fibremod and recycled material solutions 6. Based on the excellent sustainability profile, we believe polyolefins will continue to replace alternative material solutions 7. We welcome cooperation with external parties to further push the boundaries of polyolefin science and to grow our business through partnerships along the entire value chains we are active in 26
Thank you Unless otherwise specifically stated, this presentation, any part of it, or any information contained herein may only be copied, disclosed or used within the Borealis group of companies. Borealis AG and its affiliates give no warranty and make no representation as to the accuracy, completeness or fitness for any particular use of the information contained herein. 27