Supreme Petrochem to commence Phase-I of ABS production by March 2025

Supreme Petrochem Ltd (SPL), the market leader in polystyrene and expanded polystyrene with market share exceeding 50 percent, is planning to commence commercial production on the first phase of mass Acrylonitrile Butadiene Styrene (ABS) project by March 2025. Along with ABS project, the Rajan Raheja group company is also working on enhancing Compounds and Masterbatches and expanded polystyrene (EPS) capacities at its Amdoshi plant.

According to company sources, SPL is setting up a mass ABS project with a cumulative capacity of 140,000 metric tonnes per annum (MTPA) at Amdoshi plant. The project is proposed to be set up in two phases with 70,000 MTPA each. However, the first phase of 70,000 MTPA is expected to come on stream by March 2025, with the second phase to be commenced at a later date.

Rakesh Nayyar, Executive Director and Chief Financial Officer of SPL, stated, “The implementation of the first phase of mass ABS project, with a capacity of 70,000 tonnes per annum is expected to be completed by March 2025. For the financial year 2024-25, the company has chalked out an investment of Rs 380 crore.”

SPL has acquired 96 acres of land in Haryana and started pre-project activities including the environment clearances, impact assessment and other approvals which are needed. So, all that work is going on, it is a long drawn process, which will take another six to eight months before the company can really start the work there. Total expenditure on the Haryana project is estimated at Rs 800 crore. SPL proposes to manufacture polystyrene and expandable polystyrene and derivatives components of PS, EPS, 3D Panels, PS sheeting Lines in phases over 36 to 48 months post receipt of statutory clearances. The entire project cost is proposed to be funded through internal accruals.

Products and applications
ABS is a thermoplastic polymer, made up of three monomers including acrylonitrile, butadiene, and styrene through emulsification, a process that combines products that don't normally combine. It is a tough, durable, and impact-resistant plastic with good surface finishing. Additionally, ABS is resistant to chemicals and aging. It is used in many industries, including for computer keyboard keys and LEGO bricks.

Expanded polystyrene (EPS) is a rigid, white foam plastic material. It's made from solid polystyrene beads that contain pentane gas, which expands when heated to create a closed-cell foam. EPS is a versatile, cost-effective, and widely used material with many applications, including packaging (for chilled produce boxes and other packaging), construction (in buildings for insulation, structural integrity, and energy efficiency. It can also be used as an aggregate in lightweight concrete, decorative tiles, and molding, and other uses (in bicycle helmets).

Mass ABS process is clean and environmentally-friendly compared to conventional emulsion process, due to elimination of water pollution. The company has entered into an agreement for license and basic engineering design with Versalis-Eni Chemicals Group for Phase I. The total project cost is estimated at Rs 850 crore for both the phases. Additionally, the company is also undertaking capital investment for enhancing compounds and masterbatches and EPS capacities at its Amdoshi plant to cater to the additional demand.

Compounds
These are ready to use grades wherein specific / custom stated properties are introduced into the polymer by use of functional minerals & additives. Various formulations are produced in GPPS, HIPS, SAN, ABS, PP and Nylon. Properties include resistance to fire & UV light, toughened / impact modified, low shrinkage, improved load bearing capacity & high heat resistance Its benefits include proprietary grades specific to the customer/applications can be formulated. Lot to lot consistency is guaranteed for all physical properties and regulatory compliances.

Custom colour grades with UV stabilisation are used in appliances like Air conditioners, Washing Machine, TV, Water heaters, Water purifiers and Kitchen appliances. Flame retardant grades are used in Electrical switch accessories, Automotive & Industrial Battery. Mineral & Glass filled grades are used in Automotive exterior & interior parts, under the hood parts, Blower & fan impellers, and textile bobbins.

Masterbatches
These are concentrates of colourants, speciality minerals and performance additives which are used for enhancing specific characteristics of polymers, as demanded by the end application. It is beneficial in the final product, Masterbatches help in reduction of material & energy cost, improves aesthetic properties like colour, brightness & surface finish; and enhances properties like resistance to UV & thermal degradation, blocking & printing, resistance to static electricity & fire, resistance to fouling due to microbes.

White and additive masterbatches are used in packaging of dairy, oil & ghee, pulses & grain, cereals & juices, medical, cosmetics, fertiliser & pesticides. black masterbatches, in pipes & films, are predominantly used in Agriculture & Irrigation applications. Colour masterbatches are used to improve the aesthetic appeal in various Appliances, Automotive parts, Electrical switch accessories, Kitchenware, tableware, gift, toys & stationery, geotextiles.

The humble beginning
SPL was formed as a joint venture between the Supreme Industries Ltd. and the well diversified Rajan Raheja Group. The company commenced operations in 1995 with a 66,000 metric tonnes per annum polystyrene plant located in Amdoshi, Maharashtra. This plant has grown into a 422,000 MTPA styrenics complex, producing a range of advanced materials, including: polystyrene, expandable polystyrene (EPS), Specialty Compounds & Masterbatches, Extruded Polystyrene Insulation Board (XPS).

The company operates a second EPS manufacturing plant at Manali New Township, located near Chennai with a capacity of 33,000 MTPA. It operates India’s first and only plant of Extruded Polystyrene Insulation Foam Board (XPS) reinforcing its leadership role in promoting the Green Building Movement. This initiative supports energy-efficient construction and helps reduce carbon emissions.

First phase of Mass ABS project and EPS Phase II expansion when completed will take overall capacity at Amdoshi complex to 522,000 MTA. In line with its commitment to sustainability, SPL has set up a 12.5 MW solar power plant in joint venture with Tata Renewable Energy Ltd. to reduce its reliance on conventional energy sources.


DILIP KUMAR JHA
Editor
dilip.jha@polymerupdate.com