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Chemicals For Beginners Deutsche Bank May 13, 2011
Chemicals For Beginners Deutsche Bank May 13, 2011
Company
Chemicals Bulk
Industry Update
13 May 2011
For beginners (and experts)
Chemicals for
You have just been allocated the chemical
sector and perhaps now regret sitting at
Global Markets Research
Beginners
while the chemical industry is a minefield
of products and processes with all sorts
of wonderful and sometimes complex
names and applications, we’ve put
together this easy to read yet informative
overview of the major product areas, their
applications, size and prospects.
13 May 2011
Industry Update
Chemicals for Beginners
The Vth edition
Tim Jones Martin Dunwoodie, CFA Virginie Boucher-Ferte Oliver Reiff
Research Analyst Research Analyst Research Analyst Research Analyst
(+44) 20 754-76763 (+44) 20 754-72852 (+44) 20 754-57940 (+44) 20 754-76663
tim.jones@db.com martin.dunwoodie@db.com virginie.boucher-ferte@db.com oliver.reiff@db.com
Table of Contents
Petrochemicals ................................................................................ 15
Ethylene .................................................................................................................................. 15
Propylene ................................................................................................................................ 19
Butadiene................................................................................................................................ 23
Benzene .................................................................................................................................. 27
Ethylene Oxide........................................................................................................................ 30
Ethylene Glycol ....................................................................................................................... 32
Methanol................................................................................................................................. 34
Phenol ..................................................................................................................................... 36
Styrene.................................................................................................................................... 38
Paraxylene (PX) ....................................................................................................................... 41
Purified Terephthalic Acid (PTA).............................................................................................. 42
Acrylic Acid ............................................................................................................................. 45
Acetic Acid.............................................................................................................................. 48
Acrylonitrile ............................................................................................................................. 50
Caprolactam............................................................................................................................ 53
Melamine ................................................................................................................................ 57
Solvents.......................................................................................... 104
Surfactants ..................................................................................... 106
Agribusiness................................................................................... 181
Agrochemicals ...................................................................................................................... 181
Herbicides............................................................................................................................. 191
Insecticides ........................................................................................................................... 194
Fungicides............................................................................................................................. 196
Seed Treatment .................................................................................................................... 198
Conventional seeds............................................................................................................... 200
Agricultural Biotechnology / Genetic Modification (GM) ....................................................... 202
Fertilizers........................................................................................ 207
Nitrogen ................................................................................................................................ 210
Potash ................................................................................................................................... 219
Phosphate ............................................................................................................................. 224
The chemical market sells into a broad range of end uses. While some of these products are
used in markets that are mature (textiles) and GDP dependant (construction, autos) there are
also a number which go into markets with fast growth (electronics) or with a more stable
demand outlook (food and beverage, industrial gas).
Figure 1: End product breakdown for the European chemical industry 2011E
Basic Inorganics
12%
Specialties
26%
Consumer
Chemicals
14%
Polymers Petrochemicals
23% 25%
Figure 2: End market breakdown by sector for the EU chemical industry 2009
Others
16%
Consum er
Elec. Goods 31%
4%
Paper
5%
Construction
5%
Autom otive
Services
5%
17%
Textile & clothing Agriculture
6% 6%
Regional breakdown
Figure 3: Regional breakdown of chemical output, 2010
RoW
Latam 3%
7%
Asia
33%
North America
26%
Europe
31%
From a regional perspective Asia is now the leading producer of chemicals with
approximately 33% market share. Europe currently has 31% market share and a turnover of
approximately Euro 600bn per year (2.4% of European GDP). The largest production regions
are Germany, France, Italy and the UK. From a size perspective the EU is followed by North
America which accounts for 28% of global sales. However, the position of the EU and North
American manufacturing bases, while strong, has been eroding over time. In the past 10
years Asia, and China in particular, have taken an increasing share of global chemical
production (higher domestic rate of growth, greater focus on manufacturing rather than
service etc). This has also been seen in the Middle East where the abundance of
petrochemical raw materials has provided cost advantages.
Figure 4: Contribution of the chemical industry to the Figure 5: Geographical breakdown of EU chemical
EU economy 2011E industry sales 2011E
Others
12% Germany
IE
Rest of 25%
5%
Industry
17%
Belgium
7%
Chemicals
1% ES
Agriculture Services & 8%
2% Admin France
73% Netherlands 15%
Construction
8%
7%
UK Italy
10% 10%
Source: CEFIC and Deutsche Bank estimates Source: CEFIC and Deutsche Bank estimates
Over the past decade, Asia has gone from being a net importer of many chemical products,
to being a net exporter of many products and has significantly expanded into other products
particularly specialty chemicals. Countries such as Korea now regularly sell product into the
Americas. The exception is China, for now, which is a key importer (both for the region and
the world). The major global chemical companies wish to be manufacturers within Asia rather
than exporters into it. Consequently, significant percentages of their total capital expenditure,
continues to be deployed in the region.
Figure 7: Growth in chemical and manufacturing growth Figure 8: Production growth in the EU chemical industry
(%) by sector
20%
Inorganics
Polymers
Chemicals
Chemicals
Chemicals
Petrochemicals
Consumer
Specialty
-20.0%
Basic
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
Companies have consistently sought to reduce the cyclicality of their operations by a variety
of means, these include: more gradual addition of new production capacity, focus away from
sensitive and cyclical market sub-segments, and the better management of inventory and
customer ordering.
Figure 9: Volume growth in the European Chemical Figure 10: …and pricing is often lagged to volumes
sector is volatile…
30% 14%
20% 10%
6%
10%
2%
0% -2%
-10% -6%
-20% -10%
-14%
-30%
Q1 11E
Q1 00
Q1 01
Q1 02
Q1 03
Q1 04
Q1 05
Q1 06
Q1 07
Q1 08
Q1 09
Q1 10
Q1 11E
Q1 00
Q1 01
Q1 02
Q1 03
Q1 04
Q1 05
Q1 06
Q1 07
Q1 08
Q1 09
Q1 10
Cost structures
While cost structures vary notably for different companies some relevant general comments
can be made about the industry. External purchases generally account for 55-60% of total
sales. Raw materials represent by far the largest element of this amount (estimated 40-50%),
with direct energy costs broadly accounting for another 9-10%. Payroll costs represent 15-
20% of sales on average although this level has been declining over recent years. One should
note that both petrochemical and industrial gas manufacturers have a proportionately higher
fixed cost element with lower payroll and marketing costs. The opposite is of course true for
the specialty chemicals where service levels comprise a greater component of overall costs.
Figure 11: Breakdown of average costs for a chemical Figure 12: Global ethylene cash costs: regional averages
company 2011E at $80/bbl oil
Trading
cost
7%
Gross
operating Other cost
surplus 69%
11%
Labour cost
13%
* Gross operating surplus = value added - labour cost (payroll) - profit before taxes, financial charges and Source: CMAI
depreciation; ** Including raw materials, capex and R&D
Source: CEFIC and Deutsche Bank estimates
Figure 13: R&D to sales in the chemical industry Figure 14: Capex/sales in chemical industry by region
6.0% 7.0%
5.0% 6.0%
4.0% 5.0%
4.0%
3.0%
3.0%
2.0% 2.0%
1.0% 1.0%
0.0% 0.0%
1991
1993
1995
1997
1999
2001
2003
2005
2007
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
EU 13 USA Japan EU NAFTA Japan
Figure 15: EU chemicals industry energy consumption Figure 16: EU manufacturing industry breakdown of
by source labour cost per employee
Furniture manufacturing
90 Food products and beverages
80 Recycling
Fabricated metal products, except machinery and equipment
70 Other non-metallic mineral products
20 Basic metals
Medical precision and optical instruments, watches and clocks
10 Office machinery and computers
0 Tobacco products
Radio, television and communication equipment and apparatus
Electricity
Renewables
Oil
Heat
Coal
Gas
Others
Organic chemicals
All organic chemistry is based upon hydrocarbons (carbon-based molecules) and derivatives
of oil or natural gas. Organic chemicals account for approximately 85% of all substances
produced in the chemical industry and form the basis of the chemical industry from upstream
petrochemical products through to downstream compounds such as pharmaceutical
intermediates. These products play a significant role in all our daily lives.
Very crudely, there are three main stages in the conversion of raw materials through to final
product. The first of these is the manufacture of base chemicals (see below). These are
produced in high volumes in large facilities. Base chemicals are then converted into various
'intermediate' products (for example, ethylene glycol). Lastly, these intermediates are either
further processed or converted into goods and ‘effects’ used directly by consumers or
industry. The petrochemical portion of the industry is chiefly concerned with the first of these
three stages; the manufacture of base chemicals and their conversion into ‘downstream’
intermediates.
Base chemicals can be broadly classified into two groups: olefins and aromatics. Olefins have
chains of carbon atoms as their 'backbone' whereas aromatics contain a ring of carbon atoms
at the core of the molecule.
H H
C=C H C C H
H H
C C
H H
ethylene benzene
(Olefin) (Arom atic)
C C
C C
C=C C=C–C C=C–C=C
ethylene propylene butadiene
C C
benzene
C denotes a carbon atom: C-C represents a carbon single bond: C=C represents a carbon double bond
Source: Deutsche Bank
Naphtha and natural gas/LPGs (liquefied petroleum gases rich in ethane, propane and butane)
are the major feedstocks in olefin production. Naphtha is the dominant feedstock in Europe
while natural gas/LPG is predominant in the US. Naphtha is essentially a crude form of
gasoline and is obtained from the fractional distillation of crude oil, part of the oil refining
process.
Broadly, the principal feedstocks consumed in the main producing regions are:
Europe Naphtha
US Mainly natural gas with some naphtha
Middle East Natural gas
Japan Naphtha
Asia (excluding Japan) Mainly naphtha with some natural gas
China Naphtha, natural gas and increasingly coal
Source: Deutsche Bank
Only about 7% of naphtha (part of the gasoline pool) is actually used by the chemical
industry, the rest is consumed by the fuel industry. Consequently, the price of naphtha
virtually replicates that of gasoline, with the price being determined by the demand for fuel.
As a consequence chemical producers are often subject to wild variations in feedstock costs.
Similarly, in developed economies, like the US, consumption of natural gas by the chemical
industry is dwarfed by utility and energy demand. Therefore, natural gas-based crackers are
also subject to volatile feedstock cost swings.
Ethylene 82 44 42 29 25 25
Propylene 2 21 15 14 13 8
Butadiene 3 4 4 4 5 5
BTX 1 5 5 14 11 11
Others 13 26 35 39 44 47
Source: Business Briefing: Oil and Gas Processing Review 2006
The operations and economics of the participants in the olefin industry are heavily influenced
by the availability and cost of upstream feedstock. This in turn is often determined by the
proximity and relationship of ‘local’ refining operations or upstream reserves.
13 May 2011
Figure 22: From oil to petrochemicals
ethylene (30%)
refinery gases
naphtha
benzene
kerosene (paraffin)
toluene
Olefin Plant
crude oil Fractional Distillation AROMATICS (15%)
(Cracker)
gas oil (diesel) xylene
Others
lubricating oil
fuel oil
bitumen FUELS/GASOLINE
(35%) End products
† Liquified petroleum gases
natural gas/ LPGs †
13 May 2011
Figure 23: Organic chemistry - simplified flow diagram of the derivatives from petrochemical production
chlorine
methane ldPE
natural gas
ethane ethylene polyethylene hdPE
lldPE
isobutane isobutylene
C4 butadiene polybutadiene
butene MTBE
octene ABS
propylene polypropylene
Deutsche Bank AG/London
Styrene
acylonitrile acrylonitrile
Raw Material
Intermediate polyacrylonitrile Acylic fibres
acrylic acid
End Product
Source: Deutsche Bank and SRI
13 May 2011 Bulk Chemicals for Beginners
Petrochemicals
Ethylene
Figure 24: Ethylene at a glance
Long-term growth rate 1.25x GDP
Growth rate relative to sector Average
Supply/demand Strong in 2010 due to high outage rates supporting effective operating rates. Likely
to remain high for at least the next few years
Watch out for… Further Middle-Eastern expansions, further Chinese expansions, de-bottlenecking.
Regional profit abilities strongly impacted by gas and oil prices differentials
Source: Deutsche Bank estimates
Ethylene is the petrochemical industry’s key building block. It is the substance from which
approximately 60% of other organic chemicals are derived. The production economics and
output of an ethylene production facility are largely determined by the choice of feedstock
(raw material). Within Europe naphtha is generally used as the raw material whereas in the
US most plants use natural gas due to its ready availability. Natural gas fed facilities also
produce a far higher proportion of ethylene (approximately 80%), although the proportion of
co-products produced (propylene and butadiene and so on) is much less, when compared to
a naphtha cracker. The capital investment required for natural gas fed units is generally lower.
Figure 25: End uses of ethylene 2011E Figure 26: Ethylene capacity by region 2011E
Southeast Asia
7%
Polyethylene
Ethylene Oxide 61%
14%
West Europe
16% North America
22%
Middle East
18%
Automotive
Ethylene Ethylene Glycol Antifreeze
Oxide
Crude
Oil /
Natural Pantyhose,
Gas Ethylene Clothing,
Fibers
Carpets
Polyester
Resin
Miscellaneous
Models, Cups,
Polystyrene Insulation
Resins
Ethyl benzene Styrene
Styrene
Acrylonitrile Instrument Lenses
Resins House wares
Styrene
Adhesives Carpet Backing,
Vinyl Butadiene
Coatings, Paper Coatings
Acetate Latex
Textile/
Paper
Finishing,
Flooring Miscellaneous
Miscellaneous
Chemicals
Source: American Chemistry Council
Although the balance of supply and demand is important to predict pricing and margins,
the major determinant of the ethylene price is the cost of feedstock (this is a cost-plus
industry). Ethylene prices tend to lag changes in feedstock costs by around 1-2 months
maximum.
Ethylene demand growth reflects both global GDP and petrochemical demand due to its
position as a major petrochemical building block. Long-term demand growth is typically
1-1.5x GDP.
Over the next five years (2011-2015), we forecast nameplate global ethylene capacity to
expand by a CAGR of 2.4%. There is some risk of de-bottlenecking/capacity creep which
could increase this capacity addition rate by approximately 1-2% per annum.
Figure 30: Global nameplate supply/demand (kt/pa) Figure 31: Regional nameplate operating rate
160,000 95%
105%
140,000 100%
120,000 90% 95%
100,000 90%
80,000 85% 85%
60,000 80%
75%
40,000 80%
70%
20,000 65%
0 75%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
N. America W. Europe
Global Capacity Operating rate N. E. Asia S. E. Asia
Figure 32: Major expansions (kt/pa) Figure 33: Top producers (kt/pa) 2010
1400 12,000 8%
1200 10,000 7%
1000 6%
800 8,000 5%
600 6,000 4%
400 3%
200 4,000
2%
0 2,000 1%
ExxonMobil
Kayan
Polymers
SINOPEC
Borouge
Sichuan
OPAL
RLOC
Daqing PC
---- 0%
Wuhan
Saudi
PC
Exxon Mobil
LyondellBasell
SABIC
Ineos
NPC-Iran
Dow
SINOPEC
Abu Dhabi
Formosa
Dutch/Shell
Group
Gov't
Royal
Corp.
2011 2012 2013
Figure 34: Global ethylene cost curve 2010 Figure 35: Historical margins ($/tonne)
1,500
1,250
1,000
750
500
250
0
-250
Jan-1990
Jan-1992
Jan-1994
Jan-1996
Jan-1998
Jan-2000
Jan-2002
Jan-2004
Jan-2006
Jan-2008
Jan-2010
Figure 36: Global capacity additions (%) Figure 37: Capacity additions by region (%)
9%
100%
8%
7% 80%
6% 60%
5%
4% 40%
3% 20%
2%
0%
1%
2011E
2012E
2013E
2014E
2015E
0%
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Propylene
Figure 38: Propylene at a glance
Long-term growth rate 1.5x GDP
Growth rate relative to sector Above average
Supply/demand Remaining tight through to 2013 at least
Margin prospects Likely to remain strong due to limited supply additions
Watch out for… New capacities in Middle East/China, new technologies in Middle East (propane
dehydrogenation, metathesis) and potential product substitution (e.g. Polyethylene)
Source: Deutsche Bank estimates
In Europe, propylene is produced mainly as a by-product of ethylene. In the US, oil refineries
provide a second major source. The crude propylene stream created in a refinery can be
“cleaned up” for use as a gasoline component. Thus, when gasoline values are much higher
than chemical values refineries will retain the propylene stream while in when gasoline values
are low they will separate and market this merchant product. There are two principal grades
of propylene: chemical grade (from crackers or refineries) and polymer grade (from crackers
only). There is a third source of propylene, from the dehydrogenation of propane gas, but it
accounts for only a small proportion of global propylene production currently. Propylene does
not have many direct applications in the consumer market but is used extensively as an
intermediate product in the chemical chain, for example in the production of fibres, textiles,
injection moulded plastics and paints among others.
Others
6%
Acrylic acid
4%
Cumene
4%
Oxo alcohol
Polypropylene
4%
68%
Acrylonitrile
7%
Propylene oxide
7%
Indoor/Outdoor
Carpets, Matting
Plastics, Signs,
Isopropyl Alcohol Acetone Methyl Plexiglass,
Methacrylate Paints,
Crude Tail-light Lenses,
Oil Propylene Lighting Panels
Solvents, Coatings,
Cosmetics, Health Care
Rain
Coats,
Inflatable
Oxo-Alcohols Plasticizers PVC Plastics Toys
Solvents Coatin
gs Carpets,
Sweater
s,
Draperi
Acrylonitrile Polyacrylonitrile es,
Dresses
Acrylic
Fiber
Modacrylic Lenses,
Acrylic
Fiber Light Fixtures,
Resins
Domestics,
Coatings
Coatings,
Synthetic
Furs
Phones, Auto
Cumene ABS Resins
Parts, Bathtubs
Coatings, Adhesives,
Acrylic Acid, Acrylates Super Absorbent Polymers,
Detergents
Miscellaneous
Long-term growth rate is expected to be around 1.5x GDP, higher than for basic ethylene
products
Globally, capacity growth is expected to be 3.6% annually through to 2015. The largest
rise is expected in North East Asia and the Middle East. In Europe and America we do
not expect any significant capacity expansions in near term (but potentially some de-
bottlenecking/capacity creep). We expect higher expansion in Polymer grade propylene
as compared to chemical grade propylene in the future.
Nameplate global operating rates reached below 80% in the last two years due to
economic crisis, however it is now expected to see some improvement but we believe
this improvement to remain muted due to significant capacity expansions in North East
Asia and Middle East. Effective operating rates (after outages are taken into
consideration) show propylene operating rates of the high 80s.
Figure 42: Global nameplate operating rates Figure 43: Regional nameplate operating rates
120,000 90% 110%
88%
100,000 86% 100%
80,000 84% 90%
82%
60,000 80% 80%
78%
40,000 76% 70%
20,000 74% 60%
72%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
0 70%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
N. E. Asia S. E. Asia
Global Capacity Operating rate N. America W. Europe
Figure 44: Major expansions (kt/pa) Figure 45: Top producers (kt/pa) 2010
750 6,000 7%
600 5,000 6%
4,000 5%
450 4%
3,000
300 3%
2,000 2%
150
1,000 1%
0 ---- 0%
Kayan
MRPL
Polymers
Borouge
Rushd
Sichuan
Sinopec
EGPC
Chemical
Exxon Mobil
LyondellBasell
Dow
SABIC
Industries
SINOPEC
CNPC
Formosa
Total
Reliance
Dutch/Shell
Ibn
Saudi
Bohai
Group
PC
Royal
Corp.
2011 2012 2013
Figure 46: Historical monthly pricing ($/tonne) Figure 47: Global % capacity additions
2,000
1,800 9%
1,600 8%
1,400 7%
1,200 6%
1,000
800 5%
600 4%
400 3%
200 2%
0 1%
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Jul-11
0%
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011E
2013E
2015E
U.S. S.E. Asia W. Europe
Source: CMAI Source: CMAI
Butadiene
Figure 48: Butadiene at a glance
Long-term growth rate 1.5x GDP
Growth rate relative to the sector Above average
Supply/Demand Tight with shortage of new capacity in C4’s
Margin prospects High due to tightness of C4’s, expected to remain high
Watch out for New capacities in Asia and de-bottlenecking
Source: Deutsche Bank
Butadiene, a colourless gas at room temperature (liquid a few degrees below freezing point),
is a by-product of the cracking process (that produces ethylene primarily). Approximately 5%
of the base chemicals produced in the cracking process are in the form of butadiene (a
molecule with four carbon atoms). The raw materials are again natural gas or naphtha. The
main use of butadiene is as an intermediate in the manufacture of various forms of rubber,
latex, plastics and several intermediate chemicals. The largest customers for butadiene
include Goodyear Tire & Rubber, Firestone Synthetic Rubber & Latex, DuPont Nylon, Dow
Chemical, Lanxess, Michelin and Ameripol Synpol. Butadiene usage has a very significant
exposure to the Global automotive industry and for this reason it’s produced and consumed in
all key regions.
methane
natural gas
ethane Synthetic Rubbers, eg SBR
ethylene
oil naphtha
Others
11%
Nitrile Rubber
S. B. Rubber
4%
28%
Adiponitrile
6%
S. B. Latex
12%
Source: CMAI and Chemical Week and Deutsche Bank Estimates * Synthetic rubbers
Gaskets,
Chloroprene
Seals, Hoses
Rubber
Crude
Oil C-4
Nitrile Rubber Shoe Soles,
Kitchen Mats,
Hoses,
Gaskets
Miscellaneous
Miscellaneous
Butylene
Oxide Foams, Insulation
Polyurethanes
Unsaturated Polyesters
Maleic
Anhydride
Alkyd Resins
Through the mid 1980s growth rates accelerated due to pull from ABS engineering
plastics (into electronic items such as computers). Post this, however, demand has
dropped back slightly although still above GDP and sector average growth rates.
Regionally demand continues to be led by Asia and particularly China (which is growing
double the regional level) as a result of its focus on the manufacture of finished goods
(e.g. autos, electronics, tires etc)
Demand in China outstrips supply with China structurally short C4’s and looking to
increase capacity in this product chain.
Currently, new butadiene capacity is being added below levels of demand. Therefore
operating rates are anticipated to tighten further out to 2015 from already healthy levels.
Regional differences in demand/supply will likely become evident in the coming years.
Going forward the most significant capacity additions are anticipated in Asia (ahead of
demand from end uses), though we expect demand to outstrip supply and operating
rates continue to tighten gradually.
With the structurally lower gas price in the US butadiene, a co-product mainly from
naphtha crackers, is getting tighter leading to our expectation for operating rates to
tighten. The only potential relief may come from relocation of tyre plants to other
regions.
The European market has gradually tightened in recent years as little new capacity has
been added. This is anticipated to continue in the coming years. It should be noted that
risks to demand from the relocation of tire production is of only limited influence in
Europe, as tire production has generally relocated from western to Central Europe where
it can still supplied by European industry.
BASF/Yangzi
Indian Oil
Fushun PC
Sichuan PC
Sinopec
Wuhan
0.0% ExxonMobil
Dow
FPCC
JSR
Sabina PC
TPC Group
Shell
Ineos
Braskem
LG Chem
2011 2012 2013
Benzene
Figure 56: Benzene at a glance
Long-term growth rate 1.25x GDP
Growth rate relative to the sector Average
Supply/Demand Likely to remain tight in the near term due to limited additions
Margin prospects Strong in 2010 and expected to remain healthy
Watch out for ... Middle Eastern expansions, de-bottlenecking, change in refinery outputs
Source: Deutsche Bank
Benzene can be derived from petroleum based sources or coal. Petroleum sources include
refinery streams, pyrolysis gasoline (a by-product of ethylene manufacture in cracking
naphtha, gas oil or LPG) and toluene. Coal-derived benzene is obtained from the light oil
resulting from coke-oven operations. Some of this light oil is processed by petroleum refiners
for benzene recovery.
Benzene can be produced via the toluene hydrodealkylation method (HDA) or using
disproportionation technologies. The relative cost effectiveness depends on the price gap
between benzene and toluene, as such HDA is an effective means of balancing the supply
and demand for benzene. When demand is weak relative to availability, dealkylation units can
be shut down.
Others
Alkylbenzene
5%
3%
Nitrobenzene
8%
Cyclohexane
12%
Ethylbenzene
53%
Cumene
19%
Source: CMAI
Polystyrene Insulation,
Resins Cups, Models
Styrene Instrument
Acrylonitrile Lenses,
Resins Houseware
Miscellaneous
Crude
Oil
Polycarbonate Resins
Acetone Protective
Epoxy Resins Coatings,
Cumene Bisphenol Adhesives
Benzene A
Miscellaneous
Phenol
Phenolic
Resins Plywood, Coatings, Housings
Miscellaneous
Cyclohexane
Miscellaneous
Isocyanates
Aniline
Rubber Chemicals
Pesticides
Dyes
Miscellaneous
Pesticides,
Chlorobenzenes Dyes
Miscellaneous
In 2008 and 2009 global demand for Benzene saw a sharp decline due to global
slowdown, however 2010 saw exponential increase in the Benzene demand and there
was a record increase in the global Benzene production. We expect global supply
demand conditions to remain tight in the near term and this will in turn result into higher
benzene prices.
Regionally, Northeast Asia is the biggest consumer of Benzene with around 40% of the
demand coming in from this region, followed by North America and West Europe which
account for 20% each.
The decision to build or operate benzene capacity is not driven purely by the economics
of benzene production. Predominantly it is driven by its co-production alongside mixed
xylenes and paraxylene (raw materials for polyester) with some smaller amount of ‘on-
purpose’ production to soak up available C7 plus streams (octane etc).
Ethylene Oxide
Figure 59: Ethylene oxide at a glance
Long-term growth rate 1.25x GDP
Supply/demand Steady recovery close to previous highs by 2015 helped by limited new capacity.
Watch out for… Very hazardous product to make, therefore restricts global trade
Source: Deutsche Bank estimates
Ethylene oxide is a colourless odourless gas used chiefly in the synthesis of ethylene glycol
(and subsequently polyester fibre and resin and also anti-freeze). It is manufactured through
the reacting of ethylene with air over a silver oxide catalyst. The manufacture of ethylene
oxide accounts for about 13% of ethylene consumption.
ethylene
ethylene oxide
water
Figure 61: End uses – 2011E Figure 62: Top producers (kt/pa) 2010
Others
2,000 8%
Glycol Ethers 4% 1,800 7%
Ethanol-amines 1,400
5%
1,200 5%
1,000 4%
Surface-active
agents
800 3%
11% 600
2%
400
200 1%
---- 0%
Ethylene Glycols
Dow
JUPC
Nan Ya
Reliance
SHARQ
YANPET
Shanghai
Ineos
Chemical
Honam
77%
PC
Shell
PC
Source: SRI and Deutsche Bank estimates. Note: Ethlene Glycols also includes di- and triethylene glycols. Source: CMAI
The market for ethylene oxide is relatively fragmented with the 20 largest producers only
accounting for just over 50% of the total market.
The majority of producers are integrated forward into ethylene glycol. Only some of the
larger producers (BASF, Shell, Dow, Reliance, Nan Ya) are integrated backwards into
ethylene production also.
Consumption of ethylene glycol was affected in 2008 and early 2009 more than other
end uses due to the world recession.
Over the next five years we anticipate global capacity to increase by an average of 2-3%
per annum. However, we anticipate this growth to be lumpy with little in North America
or Europe but large concentrations in the Middle East and Asia on the back of the
petrochemical expansions in these areas.
After touching its lowest point of capacity utilization in 2010, we forecast ethylene oxide
operating rates to improve gradually through 2015. This should be driven by limited
capacity additions and slightly higher demand (approximately 5% p.a.).
Figure 64: Global capacity additions % Figure 65: Regional capacity additions %
14% 25%
20%
12% 15%
10% 10%
8% 5%
6% 0%
-5%
4% -10%
2% -15%
0% -20%
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Ethylene Glycol
Figure 66: Ethylene glycol at a glance
Long-term growth rate 1.25x GDP
Growth rate relative to sector Average
Supply/demand Big capacities in 2010 still being absorbed but modest
improvement of operating rates expected in the future
Watch out for… Ultimately too much Mid-East/Asian capacity may suppress the
market. De-bottlenecking (particularly in the US) is also a risk to
supply
Source: Deutsche Bank estimates
Ethylene glycol (EG) is an intermediate product used in the production of a range of products
including polyester fibre, PET (polyester) resins and antifreeze. It is a clear, odorless, slightly
viscous liquid.
The first stage of EG production is to manufacture ethylene oxide (EO). Ethylene oxide is
produced by reacting ethylene with air over a silver oxide catalyst. The ethylene oxide is then
hydrated to generate ethylene glycol.
Ethylene glycol is the main consumer of ethylene oxide accounting for 65% of use
(approximately 77% including di- and triethylene glycols).
ethylene
ethylene oxide
water
Other
6%
Antifreeze
10%
Polyethylene
Terephthalate
(PET)
84%
MEG Prices and margins have begun to rise because it now appears that the capacity in
place and under construction may not be enough to satisfy demand beyond about mid-
2012.
Further capacity rationalization is possible in more mature markets given the low growth
prospects in these regions.
Figure 69: Global capacity additions % Figure 70: Regional capacity additions %
18% 50%
16% 40%
14% 30%
12% 20%
10% 10%
8% 0%
6% -10%
4% -20%
2%
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
0%
-2%
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Figure 71: Ethylene Glycol pricing trend (US$/mt) Figure 72: Recent Ethylene Glycol pricing (US$/mt)
1,600 1,600
1,400 1,400
1,200 1,200
1,000
1,000
800
600 800
400 600
200 400
0
200
Jan-2000
Jan-2001
Jan-2002
Jan-2003
Jan-2004
Jan-2005
Jan-2006
Jan-2007
Jan-2008
Jan-2009
Jan-2010
Jan-2011
0
Jan-2007 Jan-2008 Jan-2009 Jan-2010 Jan-2011
Methanol
Figure 73: Methanol at a glance
Long-term growth rate 1.5x GDP
Growth rate relative to the sector Above average
Supply/Demand Operating rates to improve after significant new capacities during
2007-11
Margin prospects Likely to normalize at current levels
Watch out for ... Increased Chinese production and fuel applications, possible
Chinese legislation and growing concerns over the use of methanol
in fuel
Source: Deutsche Bank
Methanol (CH3OH) is an alcohol that consists of only one carbon atom. It is mainly produced
by a process known as steam reforming, which uses natural gas as its main feedstock.
Methanol is one of the most important commodity chemicals as it is used as a raw material
in several intermediate chemicals and end uses such as MTBE (fuel additive), formaldehyde
and acetic acid. Because of its toxic properties, methanol is frequently used as a denaturant
additive for ethanol manufactured for industrial uses — this addition of methanol exempts
industrial ethanol from liquor excise taxation. Methanol is often called wood alcohol because
it was once produced chiefly as a byproduct of the destructive distillation of wood.
carbon monoxide
methanol
water
Others
20%
Pipeline
Dehydrating Agent
Formaldehyde
2%
34%
Solvent
3%
Methyl
Methacrylate
3%
Methylamines
3%
Chloromethanes
4% MTBE
Direct Fuel Uses Acetic 13%
8% Acid/Anhydride
10%
Geographically, the growth sector is China with annual average growth near 20 percent
while the rest of the world grows at a nominal 3 percent. We expect China methanol
consumption to grow from nearly 18 million metric tons in 2010 to nearly 44 million
metric tons in 2015. This should be driven by continued growth in formaldehyde
demand, huge growth in direct blending of methanol into the gasoline pool and newly
planned DME and MTO/MTP capacity. However, there is some growing concern over
the use of methanol as a fuel additive which remains a key risk to the demand growth
forecasts.
We expect supply to grow at around 6% per annum to 2015. Therefore, with global
methanol around this level we see operating rates remaining at current levels over the
medium-term. Current rates are averaging low 80s.
Figure 77: Methanol price (US$/mt) Figure 78: Global capacity expansion (%)
600 20%
500 18%
400 16%
14%
300 12%
200 10%
8%
100
6%
0 4%
2%
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
0%
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
US (Contract) Europe (Contract)
NE Asia (Spot) SE Asia (Spot)
Figure 79: Methanol operating rates Figure 80: Methanol industry cost curve
100%
80%
60%
40%
20%
0%
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Phenol
Figure 81: Phenol at a glance
Long-term growth rate 1.5x GDP
Growth rate relative to sector Above average
Supply/demand Improving from lows in 2009 due to limited new capacity
Watch out for… Volume pull (or not) from polycarbonate demand
Source: Deutsche Bank estimates
Phenol is an alcohol that has an aromatic (benzene ring) type structure. While phenol is a
white crystalline solid at room temperature, it is mostly consumed molten as a clear liquid.
Phenol was first isolated from coal tars in the 1800s. Currently the principal method (over
90%) of phenol production uses cumene as the feedstock.
Cumene is prepared by alkylating benzene with propylene. It then oxidises with air in an alkali
environment and the resultant product then splits into phenol and acetone (a useful by-
product used as a solvent in paints). An alternative method of synthesising phenol from
toluene which was historically more prevalent in Europe is now less used due to the weaker
cost economics. Most phenol produced is not consumed in-house, but sold to third parties.
benzene
cumene phenol
propylene
oxygen acetone
Other
20%
bisphenol A
38%
nylon/cyclohexanol
13%
phenolic resins
29%
Source: CMAI
Figure 84: Regional production growth (%) Figure 85: Top producers (kt/pa) 2009
40% 2,000 20%
30% 1,800
1,600 16%
20% 1,400
10% 1,200 12%
1,000
0%
800 8%
-10% 600
-20% 400 4%
200
1997
1999
2001
2003
2005
2007
2009
2011E
2013E
2015E
---- 0%
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI
Figure 86: North America Phenol Demand Figure 87: West Europe Phenol Demand
2.5
2.5
2.0
2.0
1.5 1.5
1.0 1.0
0.5 0.5
0.0
0.0
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Bisphenol A Nylon-KA Oil Phenolic Resins Others Bisphenol A Nylon-KA Oil Phenolic Resins Others
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI
Current operating rates are in the mid 80s with the industry likely to see limited new
capacity addition over the next few years (but some de-bottlenecking is inevitable). We
expect operating rates to modestly improve.
It should be noted that the economics of producing phenol remain significantly impacted
by the market for the by-product acetone of which 6 tonnes is produced for every 10
tonnes of phenol. Over the past few years demand for acetone has been impacted by
the development of a more cost–effective production method for its main product MMA
which does not require acetone.
Styrene
Figure 88: Styrene at a glance
Long-term growth rate GDP
Growth rate relative to sector Below average
Supply/demand Steady recovery through 2011 onwards due to very limited supply additions
Margin prospects Some margin improvement likely next five years
Watch out for… New capacities in Asia, but plant closures and further rationalization appear likely in
more mature markets
Source: Deutsche Bank estimates
Styrene is a colourless, water-insoluble liquid, which has a penetrating aromatic odour. There
are two processes by which it is made: ethylbenzene dehydrogenation and the propylene
oxide co-product method. The ethylbenzene process is the most common. Styrene is
predominantly used in the production of polystyrene, but also has uses in the production of
ABS rubber and styrene butadiene resins and emulsions.
styrene
ethyl benzene
hydrogen
ethyl benzene
oxygen
Source: SRI
Others
Styrene butadiene 12%
rubber
4%
Polystyrene
Unsaturated 38%
polyester resins
5%
Styrene butadiene
latex
5%
Acrylonitrile
butadiene rubber
Expandable
17%
Polystyrene
19%
Over the coming five years (2011-15) we anticipate less than 1% capacity growth p.a.
compared to demand growth estimated at 3% p.a. This would improve the operating
rates gradually to around 91% by 2015 compared to a global average operating rate of
81-82% in the last three years. However, this would still be lower than the preceding 20
years average of 93%.
In recent years, the styrenics rationalization impacted units that were not necessarily at
the tail end of the cost curve. For example, there are units in Japan that are probably less
cost competitive and less integrated than Mitsubishi Chemical’s Kashima unit, but it is
the one that is being shut down in 2011. Mitsubishi Chemical is moving out of base
chemicals, including styrenics. Dow is the biggest and most prominent example of this
trend, and it cut capacity for economic and strategic reasons to make the spin-off Styron
more appealing to a buyer. It worked, and Styron has been acquired. BASF took a slightly
different approach to styrenics and started selectively selling and/or shutting down
assets. The BASF Korea styrene plant was sold back to SK, since it was not cost
competitive in the current crude oil and naphtha price environment. BASF is separating
their styrenics business into a new entity named “Styrolution” to be merged with Ineos.
We expect more industry rationalization in the future.
Over the next five years (2011-15), we expect pricing and margins to improve slightly in
most regions driven by modestly improved operating rates.
Figure 93: Global supply/demand (kt/pa) Figure 94: Regional nameplate operating rate
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Global capacity Operating Rate,% North America West Europe Asia
Source: Deutsche Bank and CMAI estimates Source: Deutsche Bank and CMAI estimates
Figure 95: Major expansions (kt/pa) Figure 96: Top producers (kt/pa) 2010
600 3,000 9%
500 8%
400 2,500
7%
300 2,000 6%
200 5%
100 1,500
4%
----
1,000 3%
Styron
Styrolution
NS Styrene
ZRCC/Lyondell
Baling PC
Jilin Chemical
SP Chemicals
2%
Monomer
500
1%
---- 0%
JV
LyondellBasell
Ineos
SABIC
SINOPEC
CNPC
Abu Dhabi
BASF SE
Formosa
Total
Dutch/Shell
Group
Gov't
Royal
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI * Ineos acquired Innovene in December 2005
Figure 97: Historical pricing ($/tonne) Figure 98: Cash margins ($/tonne)
250
2,000
200
1,500 150
1,000 100
50
500
0
0 -50
Jan-1999
Jan-2000
Jan-2001
Jan-2002
Jan-2003
Jan-2004
Jan-2005
Jan-2006
Jan-2007
Jan-2008
Jan-2009
Jan-2010
Jan-2011
-100
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
North America Northeast Asia West Europe US Europe North East Asia
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI
Paraxylene (PX)
Figure 99: Paraxylene at a glance
Long-term growth rate >1.5x GDP
Growth rate relative to sector Above average
Supply/demand Strong current conditions with only limited capacity additions in the next few years
suggesting that tight operating rates should continue subject to demand
Margin prospects High at the moment and likely to remain quite strong
Watch out for… New supply additions from 2013 onwards and capacity creep/de-bottlenecking
Source: Deutsche Bank estimates
Paraxylene (PX) is a colourless liquid and is the most commercially important xylene. It is
almost entirely used as an intermediate into polyester (via PTA and DMT). Paraxylene is most
commonly separated from the mixed xylene stream that results from the refining of naphtha.
However, it can also be produced through toluene disproportionation which involves toluene
with a limited amount of C9 aromatics being combined with a hydrogen rich recycle gas,
preheated and passed through a catalyst bed. The liquid from this process is then
fractionated to recover the benzene product and the mixed xylenes.
Direct use of
meta -Xylene
Mixed Xylene
Coal Processing
Steam Cracking
Other Aromatic Mixed Xylenes Separation
ortho -Xylene
Sources recovery Isomerization
Benzene
Source: SRI
Figure 101: Paraxylene end uses – 2010 Figure 102: Top producers (kt/pa)
12%
% share of global capacity
10%
8%
6%
Dimethyl
Teraphthalic
Terephalate
Acid
4%
7%
93% 2%
0%
Mobil Corp
NPC- Iran
Industries
Chevron
Sinopec
Holdings
CNPC
BP
Gormosa
Petroleum
Reliance
Group
Nippon
Corp
Exxon
GS
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI
In the coming four years global capacity is anticipated to grow at around the level of
demand (assuming some de-bottlenecking and capacity creep additions). We expect the
current tight conditions to remain until 2012 and early 2013. We expect new potential
plants in the Middle East and Asia (where demand for the end product is growing
fastest) to accelerate in the medium-term.
Purified Terephthalic acid is a white, water-insoluble powder obtained from the oxidation of
Paraxylene with the solvent acetic acid. It is used primarily in the manufacture of polyester
(either resin called PET or fibre). PTA is also known as TPA (Terephthalic acid).
4%
PET Film Packaging
Source: SRI
PBT Others
Polyester Films 2% 3%
5%
PET Solid-State
Resins
30%
Polyester Fibers
60%
Others
Middle East 2%
2%
West Europe
6%
Indian
Subcontinent
9%
Southeast Asia Northeast Asia
10% 60%
North America
11%
Source: SRI
Regionally, Northeast Asia is the biggest producer with around 60% of the global
capacity and around half of the capacity concentrated in China. Despite being major
producers, China is a net importer of PTA due to its high domestic demand and we
expect this strong demand will remain a key driver of the PTA industry.
Currently, the supply demand conditions are very tight in the PTA market with plants
running at around 90% operating rates, however we expect this to decline modestly in
2012/13 due to material capacity additions.
Figure 108: Global supply/demand (kt/pa) Figure 109: PTA % capacity additions
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
Global Capacity Operating rate Global N. E. Asia N. America W. Europe
Source: Deutsche Bank and CMAI estimates Source: Deutsche Bank and CMAI estimates
Figure 110: Major expansions (kt/pa) Figure 111: Top producers (kt/pa) 2010
Yisheng
Yuandong
Jiaxing PC
Hanbang
PKN Orlen
Artenius
Chemical
1,000 2%
Zhejiang
Dalian
Hailun
PC
PC
PC
---- 0%
Yuandong
SINOPEC
Industries
Grupo Alfa
Eastern
Rongsheng
BP
Formosa
Chemicals
Chemical
Reliance
Zhejiang
Mitsub.
Group
Far
Mitsui
2011 2012 2013
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI
500
400
300
200
100
-100
-200
-300
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Acrylic Acid
Figure 113: Acrylic Acid at a glance
Long-term growth rate 1.5x GDP
Growth rate relative to the sector Above average
Supply/Demand Remains tight due to robust demand growth and limited capacity additions
Margin prospects Remaining high for the foreseeable future
Watch out for ... Debottlenecking, propylene availability
Source: Deutsche Bank
Acrylic acid, a colourless corrosive liquid with an acrid odour, comes in several different
grades, the most common of which are crude acrylic acid (CAA) and glacial acrylic acid
(GAA). The latter is a higher-purity grade than CAA. CAA is primarily consumed 'captively' and
is rarely sold commercially or transported long distances. GAA is used in the production of
acrylic polymers and various esters.
The vast majority of acrylic acid is produced via the oxidation of propylene (a major co-
product of the petrochemical cracking process) over a catalyst to create acrolein which is
then further oxidised to given acrylic acid.
Most acrylic acid produced is used as acrylate esters in the production of emulsions and
resins whose end markets include paints, textiles, adhesives and plastics. Polyacrylic acid,
another major product of acrylic acid, is used to manufacture superabsorbents (which give
baby nappies/diapers their absorbent properties), detergents, dispersants, flocculants and
thickeners. Flocculant have major uses in the water treatment chemical market.
propylene
Emulsions and resins
oxygen water
Figure 115: Acrylics demand by end-markets 2010 Figure 116: Acrylics demand by region 2010
Other
(water Superabso Europe
treatment rbents 26%
etc) 26%
33% Asia
45%
North
Coatings America
Adhesives 26% 29%
15%
Since the 2006-08 acrylics investment wave, there has not been any new capacity
addition. With recovering demand in most end-markets and exceptionally high outage
rates in 2009-10, the market has tightened significantly and effective operating rates
have increased to 91%. Although there is no planned capacity addition in 2011, likely
lower outage rates that those seen in 2009-10 and debottlenecking (e.g. both Arkema
and BASF have announced their intention to increase their existing acrylic acid capacity)
is likely to restrict further material tightening of the acrylics market (we forecast 91%
effective capacity utilisation in 2011E). Beyond 2011, there is only one material
expansion (250kt) planned by the Saudi Acrylic Monomer Company in 2012/13
(representing approx c5% of global capacity) but this should be easily absorbed by the
relatively fast growing demand. We therefore expect the Acrylics market to remain
strong (above mid-cycle level) until at least 2013 with effective operating rates above
92% (note that our effective operating rates reflect our own assessment of outages and
debottlenecking).
The top four companies (BASF, Dow, Arkema and Nippon Shokubai) account for
approximately 70% of global production. Dow’s position was reinforced in 2009 with the
Rohm & Haas acquisition. With this relatively high degree of consolidation, we would
expect the players to keep a disciplined approach to new capacity.
Propylene, the key raw material for acrylic acid and a naphta-cracker co-product is
currently in short-supply as most new crackers use cheaper ethane (natural gas) as
feedstock instead of naphta (oil). We estimate that once the propylene supply has been
secured, it takes at least 2-3 years to build an acrylic acid plant which gives us a relatively
good visibility until 2014.
Figure 118: Acrylic acid supply/demand outlook Figure 119: Top producers (kt/pa) 2010
6,000 95%
1,200 20%
5,000 90% 18%
1,000 16%
4,000
85% 14%
3,000 800
12%
80% 600 10%
2,000
8%
1,000 75% 400 6%
200 4%
0 70% 2%
---- 0%
2010E
2012E
1996
1998
2000
2002
2004
2006
2008
Dow
Industries
SINOPEC
LG Group
SunVic
Shanghai
BASF SE
Formosa
Shokubai
Arkema
Nippon
Group
Evonik
Huayi
Global capacity (kt) Effective operating rates
Source: CMAI, Arkema, Deutsche Bank Source: CMAI, Arkema, Deutsche Bank
3,000
2,500
2,000
1,500
1,000
500
----
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
North America Europe Asia ROW
Source: CMAI
Acetic Acid
Figure 121: Acetic Acid at a glance
Long-term growth rate 1x GDP
Growth rate relative to the sector Below average
Supply/Demand Increasing capacity may modestly impact the dynamics
Margin prospects Expected to remain stable
Watch out for ... Further Asian expansions, de-bottlenecking
Source: Deutsche Bank
Acetic acid is also known as ethanoic acid (effectively vinegar). It is a colourless hygroscopic
liquid, which readily absorbs water, and freezes below 16.7 C (62 °F) to a colourless
crystalline solid.. The most widely-used manufacturing process for acetic acid is called
methanol carbonylation (MC) which accounts for 80% of production. The MC process begins
with natural gas or methanol being oxidised to produce what is known as a synthesis gas
(syngas - a mixture of hydrogen and carbon monoxide). This syngas is then converted into
acetic acid using a catalyst in a process called methanol carbonylation (MC). However, there
are a number of variations of this technology most notably the AO Plus (used by Celanese
and BP). Alternative technologies include the direct oxidation of ethylene, ethane or methane.
Figure 122: Acetic Acid production Figure 123: End uses of acetic acid
Others
Naphtha or NGLs Direct vapour phase oxidation 15%
Ethylene
Vinyl acetate
monomer
33%
Liquide phase oxidation
Acetaldehyde
Solvent for TPA
17%
Acetic Acid
Fuel oil
Methanol Acetate esters Acetic anhydride
Methanol Carbonylation 17% 18%
Syngas
Fermentation
Carbohydrates
Demand for acetic acid increases broadly in line with GDP, and we currently expect
Chinese demand to remain a key driver for this product. We expect China to see a
demand growth of close to 7-8% per annum in near term with majority of growth
expected to come from VAM and acetic anhydride. US and West European demand is
expected to grow close to 2-3% per annum helped by a recovery in construction
markets in the US and robust demand from VAM producers in Western Europe.
Celanese is global leader in the global acetic acid market with one of the most advanced
production technology and very competitive production cost position.
A number of producers of acetic acid are forwards integrated into vinyl acetate monomer
(VAM). These include Celanese and Lyondell. However, given that acetic acid can be
transported such integration (while allowing savings) is not essential.
Figure 125: Top 10 producers of Acetic acid 2010 Figure 126: Capacity additions for Acetic acid (%)
2,500 25%
30%
2,000 20% 25%
1,500 15% 20%
15%
1,000 10%
10%
500 5% 5%
---- 0% 0%
SIPCHEM
LyondellBasell
SINOPEC
Sterling
Celanese
Jiangsu Sopo
Kingboard
CNPC
BP
Eastman
2006
2007
2008
2009
2010
2011E
2012E
2013E
Global Northeast Asia
Source: Tecnon OrbiChem Source: CMAi
Figure 127: Acetic acid demand by region 2011E Figure 128: Cost curve based on effective capacity 2011E
Others
9%
China
Western 30%
Europe
14%
United
States Rest of Asia
20% 27%
Acrylonitrile
Figure 129: Acrylonitrile at a glance
Long-term growth rate 1.25x GDP
Growth rate relative to the sector Average
Supply/Demand Remains healthy as limited new capacity likely to come on-stream whereas
demand is expected to remain robust
Margin prospects To remain at a high level for at the next 2-3 years assuming demand remains robust
Watch out for ... Replacement risk, de-bottlenecking/capacity creep, higher feedstock prices
Source: Deutsche Bank
Figure 130: End uses of Acrylonitrile 2011E Figure 131: Regional breakdown of Acrylonitrile 2011E
ROW
Others 9%
Nitrile
4%
Rubber
W. Europe
4%
15%
Acrylic
Adiponitrile
Fibers
6%
42% N. E. Asia
Acrylamide 51%
9%
N. America
ABS/SAN 25%
35%
Source: Deutsche Bank Source: Deutsche Bank
propylene
Ammonia Acrylonitrile
Source: SRI
Most industrial Acrylonitrile is produced through the Sohio process (BP/Ineos owned) which
represents more than half of global capacity. In this process, chemical-grade (often refinery-
grade) propylene, fertilizer-grade ammonia and air (sometimes oxygen enriched) are
combined in a fluidized-bed catalytic reactor at high temperature. Other processes include a
Propane to Acrylonitrile process (no commercial operations yet established) and a one-step
fluid-bed ammoxidation of Propane process. Hydrogen cyanide is a key by-product in
Acrylonitrile synthesis.
On a global basis the leading producer of Acrylonitrile is Ineos (formerly BP/Innovene) with
close to 22% of the global capacity followed by Asahi Kasei Corp with 12% of global
capacity. However, on a regional basis there are also a number of major players –Ineos and
Solutia in the US; Ineos, and DSM in Western Europe; and Asahi, CNPC and SINOPEC in
Asia.
Operating rates reached a record high in 2006 (close to 95%), after that there was a
steady decline due to higher competition from materials such as Polyester, followed by s
sharp demand depletion due to recession. Currently operating rates are running close to
80% and we expect some steady improvement due to very limited capacity additions
and increasing demand for ABS and some modest demand improvement for acrylic
fibre.
Regionally, more than 50% of the global capacity is concentrated in Asia, with most of
the plants situated in Japan and China. Globally, Ineos is the largest producer of
Acrylonitrile followed by Asahi Kasei and CNPC, these top three producer accounts for
more than 45% of the global capacity.
Figure 134: Global capacity additions (%) Figure 135: Global Capacity addition in key regions (%)
7%
6% 10%
5%
5%
4%
3% 0%
2%
1% -5%
0%
-10%
-1%
-2% -15%
-3%
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
-4%
2000
2002
2004
2006
2008
2010
2012E
2014E
North America West Europe Northeast Asia
Source: CMAI Source: CMAI
Figure 136: Supply/demand for Acrylonitrile Figure 137: Top 10 producers of Acrylonitrile (2010)
7,000 95%
6,000 1,400 25%
90%
5,000 1,200
85% 20%
4,000 1,000
80% 15%
3,000 800
2,000 75%
600 10%
1,000 70%
400
0 65% 5%
200
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
---- 0%
Capital II
Cytec
DSM
Kwang
Ineos
SINOPEC
Asahi
Kasei
CNPC
Formosa
Chemical
Mitsub.
Group
Tae
SK
Figure 138: Acrylonitrile major expansions Figure 139: Acrylonitrile pricing $/ton
300 2,800
250 2,400
200 2,000
150 1,600
1,200
100
800
50
400
0
0
SIPCHEM
CPDC
Tongsuh
Chemical
Chemical
Chemical
Asahi
Asahi
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Jul-11
Jan-12
Jul-12
PTT
PTT
Jilin
PC
Caprolactam
Figure 140: Caprolactam at a glance
Long-term growth rate 1.0-1.5x GDP
Growth rate relative to the sector Average
Supply/Demand Tight and likely to stay so through 2015 with limited new capacity
Margin prospects High and likely to remain so with limited new capacity
Watch out for ... Further Asian expansions and debottlenecking
Source: Deutsche Bank
Caprolactam is a toxic cyclic amide, produced as clear liquid or more commonly a white
crystalline form. Caprolactam is a raw material (monomer) for the nylon-6 production for fibre,
film and plastic applications.
Others
3%
Nylon 6 Fibers
61%
Source: SRI
Caprolactam can be made from either of three different raw materials: Cyclohexane, phenol,
or toluene. DSM has a very strong position in the caprolactam market with more than 20%
global share and over 40% of global production using DSM’s proprietary technology.
Caprolactam usually kept molten until used and is shipped in that form (at about 75C in
insulated vessels). It can also be flaked for small customers at a higher cost.
cyclohexane
cyclohexanone carboxylic acid
caprolactam
Figure 143: Capacity of caprolactam by raw materials Figure 144: Technology comparison
2010
Current technology Emerging technology
1900 Mitsubishi, Bayer, Polish, Snia
100%
1800 DSM HSO, Toray, Allied
80%
60% 1700 DSM HPO, BASF, HSNO Sumitomo
Integral costs ($/mt)*
40% 1600
DSM Altam
1200
Cyclohexane Phenol Cyclohexanol/Cyclohexanone
* Integral costs including capital charge
** XXX
Southeast Asia
3%
North America
21%
Northeast Asia
33% South America
1%
Source: CMAI
Caprolactam is a widely traded product, Western Europe, Central and Eastern Europe,
Japan and the United States send significant quantities to China, Taiwan and the
Republic of Korea. Net imports account for just under 50% of total Asian (ex Japan)
consumption.
The market for caprolactam is fairly concentrated with the top 10 players accounting for
nearly 70% of production.
Regionally, Asia remains the major demand driver for caprolactam. In Asia, China is the
biggest consumer and it continued to perform robustly even in the recent downturn.
Most of the capacity additions in the recent years were concentrated in this region with
only a few new plants coming on stream in Europe and Americas.
Caprolactam prices declined substantially in the downturn due to the sharp decline in
global demand. However this has rebounded strongly with the pickup in demand and
currently is running at high levels with tight supply/demand.
We expect the tight supply/demand balance to continue with limited capacity additions
in the next five years. The next major plant is expected in 2014 (200kT in China from
DSM) with debottlenecking in the meantime.
Figure 147: Global capacity additions (%) Figure 148: Global capacity by raw materials
7% 6,000
6%
5,000
5%
4% 4,000
3% 3,000
2%
1% 2,000
0% 1,000
-1%
0
-2%
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
-3%
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Cyclohexane Phenol Toluene Cyclohexanol/Cyclohexanone
Figure 149: Top 10 producers of Caprolactam Figure 150: Caprolactam pricing $/ton
SINOPEC
Lanxess
Ube Industries
CPDC
BASF SE
HanKook
Sumitomo
Jan-03
Jan-04
Jan-05
Jan-06
Jan-07
Jan-08
Jan-09
Jan-10
Jan-11
Jan-12
Synth.
Chem.
2011 Kuibyshevazot 50
2011 Lanxess 30
2012 Baling PC 90
2012 Zhejiang Hengyi 84
2012 CPDC 75
2013 Zhejiang Hengyi 116
2013 DNCC 100
2013 Dongji Chemical 75
2014 DNCC 100
Source: CMAI
Melamine
Figure 152: Melamine at a glance
Long-term growth rate 1.5x GDP
Growth rate relative to the sector Slightly higher
Supply/Demand Slight over-supply as the demand growth has remained subdued as compared to
capacity growth in the last five years
Margin prospects Short-tem improving, weakening medium term
Watch out for ... Recovery of construction market in developed economies
Source: Deutsche Bank
Melamine is a product used in impregnating resins and adhesive resins for the wood-
processing industry, boosting the scratch, moisture and heat resistance of wood based
products. Melamine is also used in many other products, such as car paints, durable plastic
tableware, euro bank notes and flame retardants. Trade names used for melamine products
include Formica and Arborite.
Paper/Textile Others
Treating 5%
Molding 4%
Compounds
8%
Surface Coatings
10%
Laminates
50%
Wood Adhesives
23%
Melamine is produced from urea, mainly by either two methods: catalyzed gas-phase
production or high pressure liquid-phase production. The gas phase process offers
significantly lower fixed costs at larger scale potential.
CO2
Source: DSM
Regionally, China is the largest end market for Melamine and it accounted for 39% of the
global consumption and 53% of the total capacity in 2010. China has seen a rapid growth in
its domestic demand and export in last decade and we expect its domestic demand to grow
at a rate of 10% in near term. After China, Europe is the second largest geographical market
for melamine followed by other Asia-Pacific countries. The Americas remains a relatively
small market for melamine and we don’t expect any major change in this in near term.
Figure 155: Geographical breakdown of Melamine Figure 156: Geographical breakdown of Melamine
market 2010 market 2015E
Others Others
14% 15%
North
America
North 5%
America
7% Asia
Asia
52%
56%
Europe
Europe 24%
27%
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Laminates Wood Adhesives Surface Molding Others
Coatings Compounds
North America Central and South America
Europe China
Other Asia Africa, Middle East and Oceania
Source: SRI
Within the melamine market OCI is the largest global producer (acquired DSM Melamine
assets in 2010) and it accounts for 14% of the global capacity. Other competitors have more
regional focuses.
Over capacity was major concern for this product in last couple of years, however now
we expect some capacity rationalization to take place in near term. We expect operating
rates to remain above 80-85% in the next five years helped by strong demand and
favorable supply demand dynamics. For 2011 we can see some capacity surplus due to
recent capacity addition in Qatar, Trinidad and China; however we expect this will be
broadly offset by the demand growth coming in from emerging Asia-Pacific economies.
The melamine industry has seen strong consolidation in the last few years with OCI
acquiring DSM Elastomers in 2010 and integration of AMI Agrolinz Melamine into
Borealis AG in 2009, these two entities now account for more than 20% of the global
capacity. This increasing consolidation will help customers to get suppliers which will
provide them with products and support services all over the world.
500
450
400
350
300
250
200
150
100
50
0
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
US W. Europe Japan
Source: SRI
1) Bulk/Gas-Phase Polymerisation
This is one of the most common (and modern) production methods and is used in the
manufacture of polyethylene and polypropylene. There is no solvent or dilutant in this
process, merely the monomer (e.g. ethylene) and a catalyst. As a result there are significant
environmental benefits from using this method. It is also less energy intensive per quantity of
polymer produced. Attempts are being made to make rubber-type polymers by such
methods, such as EPDM/SBR.
2) Solution Polymerisation
The monomer is dissolved in a solvent and the resultant polymer is also soluble. The polymer
can be used directly from this process, but solvent extraction can be difficult and expensive.
3) Slurry Polymerisation
In this process the polymer is produced as a slurry or paste from a solvent-based system.
Solvent removal can also be a problem with this method.
4) Suspension Polymerisation
This process is used when both the monomer and polymer are insoluble in the solvent but
the catalyst is soluble. Energy is required to prevent the original monomer and polymer
sticking together.
5) Emulsion Polymerisation
This high cost method is used in the manufacture of special latex polymers.
Although common usage tends to apply the generic term 'plastics' to everything, there are in
fact numerous types of plastics with a variety of characteristics suitable for a wide range of
applications. Plastics can be divided into two main categories - thermoplastics and
thermosets. Thermoplastics soften on heating and then harden again when cooled. They can
therefore often be re-moulded or extruded and, increasingly, even recycled. Thermosets
never soften once they have been moulded.
HDPE MDI
LDPE TDI
LLDPE Epoxy
PET resins Phenolic resins
polypropylene
polystyrene
polyvinyl chloride (PVC)
Source: Deutsche Bank
ABS PC
PS 4% 2%
5% PP
PET 25%
8%
LDPE
10%
LLDPE PVC
11% 18%
HDPE
17%
Source: SRI, Deutsche Bank
13 May 2011
Figure 163: Polymers: simplified flow diagram of the product pathways Involved in their production
PVC HDPE
polyethylenes LLDPE
ethylene
styrene polystyrene
ethylene glycol
M DI
toluene polyurethanes
TDI
Base Chem icals Arom atics
DM T
xylene paraxylene PET
PTA
propylene polypropylene
Deutsche Bank AG/London
Polyethylene (PE)
The majority of the ethylene produced globally is polymerized to form polyethylene (PE), the
most widely used plastic globally, with annual production of approx 90m tons. It is produced
in three different forms (HDPE, LLDPE and LDPE) each of which have different properties
giving it a wide range of applications. HDPE and LLDPE are often manufactured in the same
production facilities. Production can 'swing' from the manufacture of one to the other. LDPE
production facilities are dedicated to that product alone. The different ‘grades’ of each
polyethylene are produced using different combinations of pressure, temperature or
additives.
The biggest technological developments in this industry involve the use of catalyst in the
manufacturing process. Since the 1930s, chemists and engineers have used different types
of catalysts to link together olefin monomers to form polymers. Developed in the 1990s, new
metallocene catalysts enable the production of PE with much improved physical properties.
Currently, the Ziegler and metallocenes catalyst families are the most widely used catalysts
and they have proved very flexible at copolymerizing ethylene with other olefins.
120,000 90.0%
88.0%
100,000
86.0%
80,000 84.0%
82.0%
60,000
80.0%
40,000 78.0%
76.0%
20,000
74.0%
0 72.0%
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
Global Capacity Operating rate
Source: Deutsche Bank
Figure 165: Global PE product demand 2000 Figure 166: Global PE product demand 2011E
LLDPE LDPE
25% 26%
HDPE
HDPE
44%
46%
LDPE LLDPE
31% 28%
High density polyethylene (HDPE) is a rigid plastic made at low temperature and pressure. It
is the third largest commodity plastic material in the world after PVC and polypropylene (PP).
It is mainly used for rigid packaging items such as detergent or milk bottles, crates or car fuel
tanks. HDPE is commonly recycled. HDPE is generally produced by catalytic polymerization
of ethylene in either slurry (suspension), solution or gas phase reactors. A lot of research is
being carried out on the type of catalyst used in the production process as it plays a very vital
role in deciding the final properties of the product. Some key developments in this space
includes: DuPont’s iron and cobalt catalysts which produce very pure HDPE, Basell’s single,
multizone reactor which can produce bimodal and multimodal PEs using Ziegler-Natta or
single site catalysts.
Linear low density polyethylene (LLDPE) is a tough plastic also made at low pressure but
which has other monomers such as butane or octane added to it (a so-called co-polymer). It
has a higher tensile strength and higher impact resistance than LDPE. It is very flexible and
elongates under stress. It is not as easy to process as LDPE, has a lower gloss and a
narrower range for heat sealing. It is mainly used in the manufacture of films for plastic bags,
sheets, plastic wraps and heavy-duty applications, for example, agricultural film.
HDPE and LLDPE are often produced at the same plant in what is known as a “swing
facility”. Manufacturers can literally swing between the two forms of polyethylene that they
produce. For reasons of production economics, plants are generally dedicated to producing
one product or the other for long periods, however with the current technological advances
and the new catalyst families, this transition has become much easier as compared to the
historical production processes.
LDPE
LLDPE †
Source: Deutsche Bank. ‡ Manufactured at low pressure, but produces a product with very few side chains, due to the lack of co-monomer, † Manufactured at low
pressure using an alpha-olefin as a co-monomer. Side chains are periodically spaced
Figure 170: End uses of HDPE 2011E Figure 171: End uses of LLDPE 2011E
The global HDPE industry is consolidating and it has seen a strong growth in China and
Middle East resulting in considerable shift in the production capacity to these regions
whereas the number of European and US producers has declined. We expect these
emerging regions will account for more than 30% of the total production capacity by
2013. We believe that continued substitution of traditional materials will become a major
demand driver for this product in the long term.
For HDPE, nameplate capacity utilization is forecast to modestly improve over the next
five years from the current mid 80s levels. In 2012 we expect significant capacity
expansion in the Middle East region, which may temporarily impact the supply demand
dynamics. Effective operating rates may not improve over this five year period due to
very high outage rates through the past two years which are now expected to moderate
due to a better focus on maintenance and limited plant mothballing.
We forecast LLDPE capacity to show a similar trend to HDPE, with significant new
capacity in the Middle East and Asia. We expect LLDPE margins to remain relatively
robust near term.
Figure 174: HDPE global capacity additions (%) Figure 175: HDPE regional nameplate operating rate
14%
100%
12%
95%
10%
90%
8%
85%
6% 80%
4% 75%
2% 70%
0%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011E
2013E
2015E
Source: Deutsche Bank and CMAI estimates Source: Deutsche Bank and CMAI estimates
Figure 176: HDPE historical & forecast prices ($/tonne) Figure 177: HDPE top producers (kt/pa) 2011E
2,500 3,200 8.0%
2,800 7.0%
2,000
2,400 6.0%
1,500 2,000 5.0%
1,600 4.0%
1,000
1,200 3.0%
500 800 2.0%
400 1.0%
0 ---- 0.0%
Jul-03
Jul-04
Jul-05
Jul-06
Jul-07
Jul-08
Jul-09
Jul-10
Jul-11
Jul-12
Jan-03
Jan-04
Jan-05
Jan-06
Jan-07
Jan-08
Jan-09
Jan-10
Jan-11
Jan-12
Exxon Mobil
LyondellBasell
NPC-Iran
SABIC
Ineos
Dow
SINOPEC
Abu Dhabi
Formosa
Total
Group
Gov't
Corp.
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI
Figure 178: HDPE capacity additions by region (%) Figure 179: LLDPE capacity additions by region (%)
100% 100%
80% 80%
60% 60%
40% 40%
20% 20%
0% 0%
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Americas Europe Asia RoW
Americas Europe Asia RoW
Figure 180: LLDPE global capacity additions (%) Figure 181: LLDPE regional nameplate operating rate (%)
18%
120%
16%
110%
14% 100%
12% 90%
10% 80%
8% 70%
6% 60%
4% 50%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
2%
0%
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011E
2013E
2015E
Figure 182: LLDPE historical & forecast prices ($/tonne) Figure 183: LLDPE Top producers (kt/pa) 2011E
Jan-92
Jan-94
Jan-96
Jan-98
Jan-00
Jan-02
Jan-04
Jan-06
Jan-08
Jan-10
Jan-12
500 2.0%
---- 0.0%
Exxon
Nazionale
SABIC
SINOPEC
Dow
Japanese
Abu Dhabi
CNPC
Formosa
Sumitomo
Mobil
Group
Chem.
MEG
Ente
Gov't
LDPE was the first grade of polyethylene, produced in 1933 by ICI, made at high temperature
and pressure. It is a more flexible plastic than HDPE, is and its main uses are in carrier bags,
films and 'squeezable' applications such as toothpaste tubes.
Others
10%
Extrusion
Coating
10%
LDPE †
LLDPE
N.E. Asia
Others 27%
30%
N. America W. Europe
19% 24%
LDPE growth is limited due to high substitution pressure. We expect LDPE capacity is
expected to grow at an average rate of 3% per year through to 2015 but in 2011-13 the
new capacity additions rates appear lower. The net addition rate over the next five years
appears in-line with the demand growth of approximately 3% per year. Therefore some
modest tightening of operating rates in 2011 and 2012 is possible with rates then
declining from 2014 onwards. However, there is additional capacity risk from “low-cost”
suppliers de-bottlenecking in the near-term so we see the likelihood of a sustained step-
up in operating rates from the current levels as relatively low.
Environmental issues remain a major threat for LDPE demand in many regions. Many
countries such as India have banned usage of plastic bags and are looking for many such
other measures to cope up with the threat of the disposal problem.
Figure 189: Global supply/demand (kt/pa) Figure 190: Regional operating rate
30,000 94%
92% 100%
25,000 95%
90%
90%
20,000 88% 85%
86% 80%
15,000
84% 75%
10,000 82% 70%
80% 65%
5,000 60%
78%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
0 76%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010E
2012E
2014E
Global Capacity Operating rate N. America W. Europe N. E. Asia
Source: Deutsche Bank and CMAI estimates Source: Deutsche Bank and CMAI estimates
Figure 191: Major expansions (kt/pa) Figure 192: Top producers (kt/pa) 2011E
Nazionale Idr
LyondellBasell
Dow
SINOPEC
SABIC
Ineos
DuPont
Abu Dhabi
Westlake
Gov't
PC Urengoy
Corp.
Ente
2011 2012 2013 2014
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI
Figure 193: Capacity additions by region Figure 194:Global capacity additions (%)
100%
5%
80% 5%
4%
60% 4%
3%
40% 3%
20% 2%
2%
0% 1%
1%
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
0%
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011E
2013E
2015E
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI estimates
Polypropylene
Figure 195: Polypropylene at a glance
Long-term growth rate 1.25-1.5x GDP
Growth rate relative to sector Above average
Supply/demand Recovery from trough conditions in 2010 – unlikely to reach previous cycle peaks
Margin prospects High outage rates in 2010 meant that effective operating rates better than
nameplate which helped margins. Tighter nameplate supply/demand from 2011
onwards may not therefore results in materially higher margins
Watch out for… New competitors in Middle East, Asia, de-bottlenecking and lower outage
rates/plant problems
Source: Deutsche Bank estimates
Currently, gas phase production is the process of choice – it offers significant cost
advantages over solution and slurry polymerisation methods (see manufacture of polymers).
Currently significant research is being carried out into the introduction of metallocene
catalysts to improve the properties of the product. Commercial quantities of product from
this process are currently available from a number of operators.
propylene polypropylene
Others
8%
Pipe & Extrusion
3%
Injection Molding
Fiber 35%
14%
Raffia
17%
Figure 199: Polypropylene demand by region 2011E Figure 200: Polypropylene capacity by region 2011E
Others
N.E. Asia Others N.E. Asia
34%
36% 36% 34%
N. America
W. Europe N. America W. Europe
14%
16% 15% 15%
Global PP demand declined very significantly in the last downturn as most of the major
end markets of PP such as autos and housing were very badly impacted, however
demand is now reaching pre-crisis levels.
We expect raw material pricing to remain a major concern for the PP producers in the
near term as higher gasoline prices will continue to result in some relatively tight supply
of propylene.
Figure 201: Polypropylene capacity additions (%) Figure 202: Top producers (kt/pa) 2010
18%
16% 7,000 12%
14% 6,000 10%
12% 5,000 8%
10% 4,000
6%
8% 3,000
2,000 4%
6%
1,000 2%
4%
2% ---- 0%
Exxon Mobil
LyondellBasell
SINOPEC
Industries
SABIC
Ineos
CNPC
Abu Dhabi
Formosa
Total
Reliance
0%
Group
Gov't
Corp.
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
2011E
2013E
Figure 203: Global supply/demand (kt/pa) Figure 204: Regional nameplate operating rate
N. America W. Europe
Global Capacity Operating rate N. E. Asia Middle East
Source: Deutsche Bank and CMAI estimates Source: Deutsche Bank and CMAI estimates
Figure 205: Historical and Forecast Prices ($/tonne) Figure 206: Historical and Forecast Margins ($/tonne)
3,000 400
2,500 250
100
2,000
-50
1,500 -200
1,000 -350
-500
500
-650
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Jul-11
Jan-12
Jul-12
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Jul-11
Jan-12
Jul-12
Source: Deutsche Bank and CMAI Source: Deutsche Bank and CMAI estimates
Other
17%
Bottles
2% Pipe and Fittings
40%
Wire and Cable
8%
Profiles and
Tubes
17%
Source: Deutsche Bank and CMAI
PVC is the third most widely used plastic globally after PP and PE. It has diverse properties
and has significant cost advantages over other plastics. Applications include pipes, windows,
cables, packaging and flooring. It is manufactured by the polymerization of vinyl chloride
monomer (VCM) in a slurry based process. Hence the cost and supply of VCM is crucial to
the industry. PVC can also, but less commonly, be produced from ethylene dichloride (EDC).
The industry has been criticized in the past few years due to environmental concerns over
PVC and the chlorine industry in general. PVC, when incinerated, releases trace quantities of
toxic dioxins, which some believe may have human fertility implications. Historically, PVS was
not recycled because of the higher cost associated, however now with the increasing debate
over safety and environmental issues many manufacturers have started vinyl recycling
programs, recycling both the manufacturing waste and the consumed PVC materials.
ethylene
vinyl chloride
polyvinyl chloride
m onom er
chlorine
Others
29%
N. E. Asia
42%
N. America
14%
Europe
15%
Figure 212: Global PVC capacity additions Figure 213: Global capacity additions by region (%)
100%
12%
10% 80%
8% 60%
6% 40%
4% 20%
2%
0%
0%
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
We see more new PVC capacity coming on stream in 2011-2013 (+5-6% CAGR), mostly
in China (the region will account for over 40% of the global capacity in the period 2011-
2013). Whilst some global capacity rationalization is underway, it should be more than
offset by new capacity and the current over supply situation is expected to remain.
We expect that Chinese PVC capacities are currently running at around 60% utilization
rate with the players running their capacity mostly for the domestic market. In addition,
with non-integrated PVC producers (into coal mines) becoming increasingly non-
economical and new environmental regulations coming in force in 2012, we expect
some capacity rationalization in China. We believe these trends should provide some
protection to European margins (although the protection will be limited as the limited
exports of Chinese PVC are offset by greater exports of finished products which include
PVC).
Figure 214: Global supply/demand (kt/pa) Figure 215: Regional nameplate operating rate
60,000 100%
100%
50,000 80% 95%
90%
40,000
60% 85%
30,000 80%
40% 75%
20,000 70%
10,000 20% 65%
60%
0 0%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
Global Capacity Operating Rate N. America W. Europe Middle East Asia
Figure 216: Major expansions (kt/pa) Figure 217: Top producers (kt/pa) 2010
4,000 9%
600
3,500 8%
500 3,000 7%
400 2,500 6%
5%
300 2,000
4%
200 1,500 3%
100 1,000 2%
500 1%
----
---- 0%
Ibn Hayyan
Hanwa
Tianyuan
Guangzhou
Jingniu
Tianchen
Zhongtai
Chemical
Chemical
Xinjiang
Chem
Beiyuan
Xinjiang
Hebei
Qinghai
Yihua
Solvay
SINOPEC
Ineos
Shin-Etsu
LG Group
Georgia
Formosa
Occidental
Arkema
Yibin
Westlake
Tosoh
Group
Gulf
2011 2012 2013
Figure 218: PVC production cost comparison Figure 219: Regional PVC cash costs in $/Metric Ton
1200 1,400
1000 1,200
1,000
800
800
600 600
400 400
200 200
0
0
Jan-00
Jan-02
Jan-04
Jan-06
Jan-08
Jan-10
Jan-12
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Q1 11E
Q3 11E
NEA- Ethylene based PVC China Carbide-based PVC United States NE Asia W. Europe
Figure 220: Historical and Forecast Prices ($/tonne) Figure 221: Historical and Forecast Margins ($/tonne)
2,400 750
2,000 600
450
1,600
300
1,200
150
`
800 0
400 -150
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Jul-11
Jan-12
Jul-12
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Jul-11
Jan-12
Jul-12
Polystyrene (PS)
Figure 222: Polystyrene at a glance
Long-term growth rate GDP
Growth rate relative to sector Below average
Supply/demand Steady recovery from 2012 onwards helped by limited capacity additions but
supply/demand balances to remain weak
Margin prospects Remaining relatively weak due to low operating rates
Watch out for… High feedstock costs, most of the margin captured upstream, look for more
restructuring and capacity closures going forward
Source: Deutsche Bank estimates
ethane
benzene
Others
32% Packaging - single
use
40%
Electronics /
Appliances
28%
Though the coming three years (2011-2013) we anticipate only marginal capacity
increases as the PS market is facing very tough competition from other polymers such
as PP, PVC and ABS.
Another very important reason for declining PS demand is volatile benzene prices which
have materially increased in the past few years. These increasing raw material costs
have forced some end users to look for other polymers to substitute PS.
We expect operating rates to see gradual improvement in the coming years as there are
very limited new capacities which are expected to come on-stream in the coming three
years. However the demand is expected to remain subdued as the major end markets of
PS are still struggling to come out of the bottoms.
Over capacity remains a major concern for the PS market. We expect some
improvement in this area in the coming areas as the market is rationalizing old capacities
and very few new capacities are expected to come on-stream.
Globally the PS market is seeing some consolidation with BASF, Nova, INEOS and Dow
all currently involved in consolidation of their businesses to some extent. We expect this
to further continue and result in higher capacity shutdowns.
Figure 226: Global supply/demand (kt/pa) Figure 227: Regional nameplate operating rate
100%
12,000 75% 90%
10,000 70% 80%
8,000 70%
65%
6,000 60%
60%
4,000 50%
2,000 55%
40%
0 50%
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
North America Western Europe
Global Capacity Operating rate Asia exc. Japan
Figure 228: Major expansions (kt/pa) Figure 229: Top producers (kt/pa) 2010
Pars PC
Total PC
Chemical
Chemical
Chemical
Laidun
200
Rentai
Rentai
Rentai
Saudi
---- 0%
Nazionale
Ineos
Chi Mei
Dow
SINOPEC
Capital
Abu Dhabi
BASF SE
Formosa
Total
Bain
Group
Ente
Gov't
2011 2012 2013
Figure 230: Historical and Forecast Prices ($/tonne) Figure 231: Historical and Forecast Margins ($/tonne)
3,000 500
2,500 400
2,000 300
1,500 200
1,000 100
500 0
-100
0
-200
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Jul-11
Jan-12
Jul-12
Jan-03
Jul-03
Jan-04
Jul-04
Jan-05
Jul-05
Jan-06
Jul-06
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jul-09
Jan-10
Jul-10
Jan-11
Jul-11
Jan-12
Jul-12
Figure 232: Global capacity additions (%) Figure 233: Regional capacity additions (%)
100%
16%
14% 80%
12%
60%
10%
8% 40%
6%
4% 20%
2%
0% 0%
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
-2%
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Engineering resins and high performance plastics are generally distinguished from other
plastics such as polyester or polystyrene by their improved properties which generally come
at a higher cost. They tend to exhibit superior mechanical and thermal properties in a wide
range of conditions compared to more general plastics. The terms engineering plastics
usually refers to thermoplastic (can be re-melted) rather than thermoset materials.
Engineering plastics tend to be higher volume products than the more niche application high
performance plastics.
Engineering Resins
Nylon 6,66 Polyacetal (POM)
(high spec, high volume)
Polycarbonate PBT
Thermoplastics
(lower spec, high volume) Polypropylene PMMA
Polyethylene PVC ABS
Polystyrene
Note: Products shown are examples only, this is not a comprehensive list
Source: Celamese and DSM
The main end markets for engineering resins are electronics and electrical, autos, industrials,
discs (compact disks, DVDs – only polycarbonate) and extrusion applications.
Figure 236: Geographical breakdown of engineering Figure 237: End market breakdown on engineering
plastics plastics market
Packaging
RoW
&
6% Electrical
Extrusion
Europe 8% &
Optical &
Rest of 25% electronics
Glazing
Asia 27%
16%
21%
Consumer
North &
China America Industrial
Auto
23% 25% 26%
23%
Source: DSM, Deutsche Bank estimates Source: DSM, Deutsche Bank estimates
Engineering plastics is in fact a term to describe a wide range of mainly thermoset resins
with significantly different market sizes ranging from the large size of polycarbonate and
nylon to the very small markets for some of the new innovative composite markets using
materials such as carbon fibre nanotubes and long fibre resin (too small to show on the chart
below). Due to this large product range there is also considerable breadth in raw materials –
based on resins including polyester, polyethylene, polyamide, polycarbonate etc.
As a result of the wide range of plastics and end products involved a significant number of
companies participate in the engineering plastics market. Some participants focus on only
one area, others have developed a portfolio encompassing a range of products (generally the
focus being the end market). Key players in the market as a whole include SABIC (formerly
GE Plastics), Bayer and DuPont in the higher volume products. In the lower volume, more
niche products of Ticona (Celanese), Mitsubishi, Dow and DSM.
Figure 238: Main participants in selected engineering resin and high performance plastics markets
Nylon 6 Nylon 6,6 HT PA Polycarbonate HPPA
(high temp. polyamide) (High Perf. Polyamides)
Polyurethanes (PU)
Figure 239: Polyurethanes at a glance
Long-term growth rate 1-2x GDP
Growth rate relative to the sector Above Average
Supply/Demand MDI supply/demand balance improving, TDI low operating rates as new capacity
comes on-stream
Margin prospects MDI should maintain good margins, overcapacity and feedstock volatility likely to
pressure TDI margins
Watch out for ... New capacity additions and for TDI plant closures for companies high on the
cost curve
Source: Deutsche Bank
Polyurethanes are used in a variety of different applications and end markets for their
cushioning and insulatory properties. Produced by the reaction of an isocyanate with a polyol
they are capable of being formulated into a broad range of physical forms. Due to its more
expensive cost (compared to other elastomers) polyurethanes tend to be used in more
demanding applications. There are two main types of polyurethanes: rigid (based on MDI,
methylene diphenyldiisocyanate) and flexible (based on TDI, toluene diisocyanate).
MDI and TDI are not shipped long distances, with prices determined based on regional
supply/demand. So a company can have a profitable plant in one region and an unprofitable
plant in another.
polyol
(long chain alcohol)
DNT = Dinitroluene
TDA = Toluene Diamine
Methyl di-isocyanate (MDI) is preferred for rigid foams, special flexible plastics (for example,
shoe soles) and moulded flexible foams for vehicles and furniture. Lesser applications include
paints and adhesives. Importantly, its rigidity and insulating properties make MDI ideal for use
in construction, refrigeration and automotive markets. Not only does the material protect,
prove easy to process and dampen noise; it also affords significant energy savings through
heat insulation. MDI has a varied set of applications and it is increasingly used to substitute
other products especially in the construction, packaging and refrigeration markets.
To produce MDI, aniline, usually derived from nitrobenzene, is reacted with formaldehyde, a
derivative of methanol. MDI is reacted with a polyol to manufacture polyurethanes.
formaldehyde
Rigid polyurethane
Figure 243: End uses of MDI 2010 Figure 244: Company capacity shares 2010
Fibres,
Insulation, Other
Elastomers & 14% Bayer
Others 23%
Packaging 8%
12% Dow
13%
Refrigeration BASF SE
13% 20%
Yantai
Construction Wanhua
50%
13%
Injection Huntsman
moulding Group
17% 17%
Source: Deutsche Bank estimates Source: CMAI
The MDI market is a consolidated market where the four major players account for 73% of
global capacities. Bayer and BASF are the global market leaders with 23% and 20% market
share, followed by Dow, Huntsman and Wanhua.
MDI like many other commodity chemicals reached a cyclical trough in 2009 and
operating rates should continue to rise in line with global demand. However, large
capacity additions over the next 4-5 years will likely keep effective operating rates in the
mid to low 80s.
Over the next four years (2011-2015) we forecast global capacity to expand by 20%
(CAGR of 4.6%) but most of the new capacity is planned for 2014 (BASF in China) and
2016 (Bayer in China). The majority of all planned expansions are expected in Asia/Pacific
where MDI demand is growing faster.
Despite significant increases in both propylene and benzene raw material costs, pricing
power in the industry has allowed much of this to be passed through to customers.
SABIC is talking about building a large MDI and/or TDI plant in Saudi but no firm plans as
yet so likely not before 2015.
Figure 246: MDI capacity additions Figure 247: MDI effective capacity utilisation
20% 95%
90%
15% 85%
80%
10% 75%
70%
5%
65%
60%
0%
55%
-5% 50%
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2011E
2012E
2013E
2014E
2015E
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
Figure 248: Global capacity (2011E) Figure 249: Global planned MDI additions
East Latin America Company Plant Region Size (k mt) As % total Start up
Europe 1% cap year
4%
Wanhua Ningbo, Asia 300 5% 2011
N America Zhejiang
23%
Wanhua Yantai, Asia 120 2% 2011
Asia Inc. Shandong
Japan
41% Borsodchem Kazincbarcika Eastern 110 2% 2012
Europe
Blue Star Tianjin Asia 100 2% 2012
Bayer Caojing, Asia 150 2% 2013
Shanghai
BASF Chongqing Asia 400 6% 2014
West Europe
31% Bayer Brunsbuttel Europe 260 4% 2014
Bayer Caojing, Asia 500 7% 2015-16
Shanghai
Source: CMAI Source: Deutsche Bank, CMAI, Bayer
Toluene di-isocyanate (TDI) is a flexible type of polyurethane. Less versatile than its rigid
sister MDI, its growth is far more dependent on the health of the global economy. Main end
markets include furniture and automotive where it is largely used as cushioning. TDI is a
derivative of benzene. Benzene is converted into toluene, which is further converted into a
diamine that is reacted to produce TDI. As with MDI, TDI is reacted with a polyol to
manufacture polyurethanes.
flexible
polyurethane
polyol
propylene propylene oxide
(long chain alcohol)
Figure 252: End uses of TDI 2011E Figure 253: Company market shares 2010
Elastomers Other
4% 4%
BASF
Coatings Others 24%
4% 28%
China
Chemical
3%
Dow Bayer
4% 19%
Flexible foam Yantai
88% Wanhua Gansu Ying.
4% Mitsui
7% Chemicals
11%
TDI has as slower growth than MDI since its end markets (furniture and auto cushioning)
do not have the same drive from the Asian market. Estimated market growth rate is
around 4-5% pa.
Large capacity additions are coming on-stream over the next 5 years, much of which is
low cost capacity which will push out the cost curve. We estimate that 2011-2015,
capacity additions in Asia, Germany and Hungary will result in a 30% (CAGR 6.7%)
increase in global capacity by 2015. Demand will not grow fast enough to absorb this
and so effective operating rates are likely to fall from the current mid to high 80s levels.
We view it as unlikely that smaller producers will put on capacity when big producers
have large plants coming on-stream. We expect (and reflect in our supply/demand
model) that smaller producers higher on the cost curve will delay or cancel planned
capacity. We do not expect operating rates to fall too sharply as a result and expect
them to be around 80% from 2013-15. Consolidation is likely to continue as larger
producers that are lower on the cost curve take share from higher cost producers.
SABIC is talking about building a large MDI and/or TDI plant in Saudi but no firm plans as
yet so likely not before 2015.
Figure 255: TDI capacity expansions Figure 256: TDI effective capacity utilisation rates
30% 100%
25% 95%
90%
20% 85%
15% 80%
75%
10% 70%
5% 65%
60%
0%
55%
-5% 50%
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Source: CMAI, Deutsche Bank, CMAI, Bayer Source: Deutsche Bank, CMAI, Bayer
Figure 257: Global capacity (2011E) Figure 258: Planned TDI additions
Methyl methacrylate (MMA) is the basic building block for acrylic sheeting and acrylic resins.
Developed in the early 1900s by Dr Otto Rohm and other German chemists, it is sold either
in solid form or as a resin pMMA (polymethylmethacrylate). Construction/re-modelling
activity, automotive applications and OEM account for ~80% of world MMA consumption.
PMMA is sold under the trade names of Plexiglas, Perspex, Acrylite, Acrylplast, and Lucite
and is commonly called acrylic glass or simply acrylic. MMA is generally produced via
acetone cyanohydrin (ACH). For the end-use markets the product is usually polymerised and
compounded to produce pMMA (the plastic).
Over the years, acrylic polymers have become popular due to their toughness, chemical
resistance and good weathering properties. They continue to be used as a substitute for
more traditional materials such as glass and metals.
Surface Coating
acetic acid acetone cyanohydrin MMA 24%
Resins
Extrusion &
HCN methyl alcohol Moulding 17%
Figure 261: 2010 Major producer capacities kt Figure 262: End uses of MMA
Others
14%
Lucite Intl
Impact Modifiers/
16% Processing Aids
5% Acrylic Sheet
33%
Others
36%
Dow
13%
Surface Coatings
21%
Mitsub.
Cyro
Rayon Molding
Industries
10% Compounds
4% Rohm 27%
LG MMA Sumitomo
9%
5% Chem.
7%
Source: Deutsche Bank, CMAI Source: Deutsche Bank estimates
The top five producers account for 55% of world capacity. Both Lucite International and
Dow have the largest shares with 16% and 13% of the market respectively. Increasingly
capacity additions in MMA have centered in Asia, where demand is growing fastest.
Figure 264: MMA capacity additions Figure 265: Consumption of MMA by region
12% Other
2%
10% Europe
17%
8%
6%
4%
Americas
2% 25% Asia
56%
0%
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
Figure 268: End uses of PET resin Figure 269: Polyester bottle resin market share
Mossi &
Ghisolfi Jiangsu
Carbonated 8% Sanfang.
soft drinks Non-Food
7% Artenius
19% containers
29% 4%
DAK
Americas
4%
Eastman
Other 4%
drinks Invista
Others
Food 3%
24% 70%
containers
28%
0 50%
2000
2002
2004
2006
2008
2010
2012E
2014E
Figure 275: Historical quarterly margins ($/tonne) Figure 276: Recent & forecast margins ($/tonne)
400.00 400.00
300.00 300.00
200.00 200.00
100.00 100.00
0.00 0.00
-100.00 -100.00
-200.00 -200.00
Jan-1999
Jan-2000
Jan-2001
Jan-2002
Jan-2003
Jan-2004
Jan-2005
Jan-2006
Jan-2007
Jan-2008
Jan-2009
Jan-2010
Jan-2011
Jan-2012
Jan-2008
Jan-2009
Jan-2010
Jan-2011
Jan-2012
Jul-2008
Jul-2009
Jul-2010
Jul-2011
Jul-2012
North America Northeast Asia West Europe North America Northeast Asia West Europe
Source: CMAI Source: CMAI
Nylon/Polyamide
Figure 277: Nylon/polyamide at a glance
Long-term growth rate 1.5x GDP for plastic applications
Growth rate relative to the sector Above for plastic applications
Supply/Demand Currently tight
Margin prospects Should remain relatively high but new supply risk in Nylon 6
Watch out for ... New capacity in Nylon 6 (China), higher growth in non-textile, niche applications
such as auto, oil & gas, electronics etc
Source: Deutsche Bank. Nylon used in auto-engineering plastic application grows in excess of 2 x GDP
Nylon 6 and nylon 6,6 are the most important of all nylon fibers, accounting for
approximately 91% of total production. Both nylon 6 and nylon 6,6 are used for similar
applications. Nylon 6 has a lower melt temperature but better resistance to light degradation,
dyeability, elastic recovery, fatigue resistance and thermal stability. As a result of these
properties nylon 6 tends to be used more in textiles (clothing) while nylon 6,6 is used in
more industrial applications including engineering plastics. Engineering plastics account for
the consumption of about 30% of all nylon.
Other nylon fibers include nylon 46, 610, 612, 11, 12 and the aramids offer high
performances and are used primarily in specialty and non-textile, niche applications such as
automotive tubing and connectors, off-shore flexible pipes, sport equipments, industrial
tubes and wire & cable. They are therefore consumed in much smaller quantities.
Figure 278: World’s nylon consumption by type Figure 279: Specialty polyamide outperform standard
Other
Nylons
9%
Nylon 6
47%
Nylon 6,6
44%
Nylon 6,6 is produced from adipic acid and nylon 6 from caprolactam.
caprolactam nylon 6
Source: Deutsche Bank (1) a mixture of cyclohexanone, the ketone or K component, and cyclohexanol, the alcohol or A component, (2) also known as hexanedinitrile, (3) Hexamethylenediamine
Figure 282: End uses of nylon 6 Figure 283: End uses of nylon 6,6
Engineering Textile
Resins & Filament
Other Yarn
35% 22%
Figure 284: Geographical consumption of Nylon resins Figure 285: End uses of polyamide for engineering
2010 plastics (by capacity)
Central and
South Other
5% Electronic &
Africa & America
Electrical
Middle East 4%
5% 22%
Europe
36% Auto
42%
Asia
23%
Consum er &
North Ind. Goods
America 36%
27%
Source: SRI Source: Rhodia
Figure 286: Nylon 6 market shares Figure 287: Nylon 6 top 10 players (‘000 metric tonnes)
BASF SE 3,000
11% 2,500
Li Peng
7% 2,000
DSM 1,500
6% 1,000
Formosa 500
Group ----
Xinhui Meida…
4%
Honeywell
Formosa Group
Zig Sheng
Kuibyshevazot
DOMO Group
Others
DSM
Li Peng
SINOPEC
BASF SE
Honeywell
Others 4%
65% DOMO
Group
3%
Figure 288: Nylon 66 mkt share Figure 289: Top 10 (thousand metric tonnes)
600
Koch 500
Others Industries
26% 400
23% 300
200
100
Radici ----
Zhong Ping…
Group
Rhodia
Nylstar
Radici Group
Shenma Group
DuPont
Koch Industries
Others
SK Capital II
BASF SE
4%
15%
BASF SE
5%
Rhodia
12% SK Capital
II
15%
Source: Deutsche Bank estimates Source: Arkema
Other
Evonik
20%
24%
Ube Arkema
15% 100%
EMS
22%
Arkema
19%
Despite their slightly different physical properties nylon 6 and 6,6 tend to be used
interchangeably in most end-use applications. In the carpeting industry, nylon 6,6 may be
preferred because of its molecular structure, which leads to greater product durability.
The nylon resin market is becoming more consolidated and companies are beginning to
compete globally rather than on a regional basis. Backwards integration into caprolactam
occurs in many of the larger participants. In Western Europe all producers of nylon 6,6
are integrated back into adipic acid. The nylon 6 market remains more fragmented than
the nylon 66 market.
The raw material for nylon 6 (caprolactam) and nylon 6,6 (adipic acid) tend to be priced
on a cost plus basis with the predominant price setting region being Asia. As such
production costs are very sensitive to 1) the oil price and 2) tightness of individual raw
material feedstocks.
There is a significant amount of Nylon 6 supply coming on-stream in China from 2010-12,
which will keep operating rates low. We therefore expect rates to show little
improvement from the current 80% level (effective). For Nylon 6,6 there is little
additional supply coming on-stream, which will likely result in rising operating rates (from
the current levels of 90% effective).
Supply of other nylon resins is also increasing (e.g. Arkema is trebling its PA 11 and
PA12 capacity in China with an expected start up in H2 2012) however we note this is to
meet the sharply growing demand from Asian customers, in particular the automotive
and energy markets.
Figure 292: Anticipated capacity additions in nylon 6,6 Figure 293: Anticipated capacity additions in nylon 6
10% 12%
8% 10%
6%
4% 8%
2% 6%
0%
-2% 4%
-4% 2%
-6%
0%
-8%
-10% -2%
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
Polycarbonate (PC)
Figure 294: Polycarbonate at a glance
Long-term growth rate 1.5-2x GDP
Growth rate relative to sector Above average
Supply/demand Modest recovery in operating rates but outage rates remain high and support better
underlying supply/demand trends
Margin prospects Some modest tightening expected in the coming years
Watch out for… Auto glazing growth, trends in CD/DVDs and substitution trends in packaging, de-
bottlenecking/capacity creep
Source: Deutsche Bank estimates
Polycarbonate is the second largest volume engineering resin produced (after nylon). With
high levels of impact and ductility, fire resistance and engineering properties over a wide
range of temperatures, clear polycarbonate resin goes into a number of end-users particularly
optical media (CD, DVD) and electronics, but also automotive, consumer goods, bottles &
packaging, medical & healthcare, glazing. Polycarbonate is produced from bisphenol A and
carbonic acid. There are two different production processes: Interfacial polycondensation (a
reaction between phosgene and bisphenol A and melt trans-esterification (a reaction
between bisphenol A and diphenylcarbonate).
Acetone
Biphenol A polycarbonates
phenol
High barriers to entry into the polycarbonate resin business exist because of the requirement
for initial large investment, access to technological licensing, possible start-up difficulties and
establishment of efficient and effective marketing of PC resins. This is an oligopolistic market
where SABIC and Bayer are dominant with around 25% share each.
Figure 296: End uses of polycarbonate Figure 297: Polycarbonate market shares
Other
18% Others SABIC
Electrical/ 31% Plastics
Electronic 26%
27%
Transportat
ion Bayer Poly
14% Shanghai
4%
Optical Formosa Bayer
Media Idemitsu Teijin 25%
Glazing
and Sheet 21% 4% Polycarb Teijin
20% 5% 5%
Source: Deutsche Bank, SRI Source: Deutsche Bank, CMAI
Figure 301: Global capacity by region (2010) Figure 302: Global planned PC capacity additions
Ultra high molecular weight polyethylene (UHMWPE) is also known as high modulus
polyethylene (HMPE) or high performance polyethylene (HPPE). It has extremely long chains,
with molecular weight which result in a very tough material, with the highest impact strength
of any thermoplastic presently made. It is highly resistant to corrosive chemicals, with
exception of oxidizing acids. It has extremely low moisture absorption, very low coefficient of
friction, is self lubricating and is highly resistant to abrasion (10 times more resistant to
abrasion than Carbon Steel). UHMWPE finds use in high modulus fibres for example, Spectra
(Honeywell) or Dyneema (DSM) for bulletproof vests. Due to its low friction and wear
resistance it is used in industrial impact wear, and sliding applications in both normal and
corrosive environment, such as Dyneema for towing, mooring and anchoring cables, fishing
lines and nets, protective gloves and medical applications. Other UHMWPE includes GUR
from Ticona (Celanese).
Composite materials (or composites for short) are engineered materials made from two or
more constituent materials that remain separate and distinct on a macroscopic level while
forming a single component. The most common thermoplastics used are polyester, vinyl
ester, epoxy, phenolic, polyimide, and polyamide. The reinforcement materials are often
fibres but also commonly ground minerals.
Nanotubes (NTs) are a composite which include very small carbon fibres combined
with the thermoplastics (usually PS) to add strength as well as unique electrical and
efficient heat conducting properties to the material
Solvents
Figure 304: Solvents at a glance
Long-term growth rate 1-1.25x GDP
Growth rate relative to the sector Below average
Supply/Demand Relatively balanced
Margin prospects Flat
Watch out for ... New capacity in Asia, poor competitive behavior, environmental issues
Source: Deutsche Bank
Chemically a solvent is the liquid used to dissolve or soften a solid substance to form a
solution. Industry examples of the use of solvents include industrial cleaning where the
solvent dissolves the grease and keeps it in the water solution and paints where the solvent
dissolves or softens the solid resins (pigments, additives) to allow them to be deposited on a
treated surface in a uniform film.
Liquid solvents may be either aqueous (water) or organic (petroleum) based. There are three
major groups of organic solvents: the oxygenated, chlorinated and hydrocarbon classes.
Oxygenated solvents include products such as alcohols, glycol ethers, esters and
ketones. These are used in a variety of industries such as lacquer solvents, paint
removers, anti-freeze and in food processing and preservation. This is the largest class of
solvents and they are generally considered to more environmentally acceptable than the
two remaining classes. The main players in this market are Eastman, Shell, BASF, Dow
Chemical, Celanese and BP.
The principal chlorinated solvents are methylene chloride (used in chemical processing,
pharmaceuticals and surface treatment including paint stripping and urethane foam
blowing), perchloroethylene (used for dry cleaning and metal cleaning), and
trichloroethylene (used in specialty adhesives, dry cleaning, metal cleaning, pesticides,
pharmaceuticals, as a degreaser for hide and fur and as an intermediate in the production
of ethylene fluorides). Chlorinated solvent manufacturers include Solvay and Dow.
Hydrocarbon solvents are derived from higher olefin fractions, for example, xylene and
toluene. They also often include mineral spirits. A large proportion of hydrocarbon
solvents are used in the paint industry. They are also often mixed with surfactants to
produce cleaning agents. Major producers of this solvent include Shell, Exxon, Ashland
and Degussa.
Other
15%
Printing inks
3%
Metals
4%
Adhesives
4% Paints & Coatings
55%
Industrial
Cleaning
9%
Pharma and
agriculture
10%
After a decline in demand during 2008 and 2009 due to recession, we now forecast
global demand for solvents to increase 3-4% pa through 2015. This growth should be
supported by demand from electronics, medical products, and automotives.
Oxygenated and other solvents (most of which are environmentally- benign "green"
solvents) are expected to show market share gains while demand for
chlorofluorocarbons and chlorinated solvents is anticipated to continue its downward
trend as a result of environmental regulations.
We expect the Asia/Pacific region to hold the strongest growth prospects through 2015
with most of the actual production of these solvent-based products happening in the
Asia/Pacific region due to lower labor and transportation costs. We expect China to
continue to see strong demand for solvents driven by demand in paints and coatings,
chemicals, rubbers, adhesives, cosmetics, pharmacy and others.
Surfactants
Figure 307: Surfactants at a glance
Long-term growth rate GDP
Growth rate relative to the sector Average
Margin prospects Low relative to the sector (on average) but some areas have very high (sustainable)
margins
Watch out for ... Consolidation, further rationalization globally
Source: Deutsche Bank
Surfactants or 'surface active agents' allow oil molecules to mix with or ‘dissolve’ in water.
Surfactants are primarily used as detergents. They can, however, also be used in personal
care products to enhance properties such as emollience, solvency, and solubility, as well as
in healthcare, chemical and agrochemical products as a solvent.
Surfactants can be synthesized from two broad types of raw material: oleochemicals (natural
oils) or petrochemicals. Oleochemicals include coconut oil, palm kernel oil and tallow,
amongst others. The petrochemical raw material is primarily linear alkylbenzene (LAB)
which is synthesised from benzene and ethylene oxide. The substances produced from these
two groups of raw materials can be combined or used individually to produce a range of
surfactants.
Surfactants are categorised not just by raw materials, but also by the level of complexity and
refinement of their chemical properties. Through further processing, more complex
surfactants may be produced which offer greater value to their customers. These added
value surfactants are referred to as specialties and may have properties such as skin
kindness, high foaming and durability.
Depending on their production, surfactants possess different chemical properties, which are
more applicable to certain end users:
Anionics are the largest class of surfactants. The water-loving part of the molecule is
negatively charged. They are often used in detergents, toiletries, washing powders and
industrial applications as well as the personal care market. This accounts for
approximately 37% of the total production.
Nonionics are uncharged molecules but still soluble in water. Petrochemicals are the
main raw material. Nonionics are used mainly in detergents and industrial applications.
This accounts for approximately 46% of the total production.
Cationics are positively charged. They are milder than both anionics and nonionics and
hence are used in baby products and shampoos. These surfactants are in general more
expensive than anionics, because of the high pressure hydrogenation reaction carried
out during their synthesis. This accounts for approximately 12% of the total production.
Amphoterics have an active chemical entity attached to both sides of the molecule.
They are used in specialised applications such as conditioners. This accounts for
approximately 5% of the total production.
Coconut,
benzene paraffins linear olefins Palm Kernal Oils
and Tallow
glycerine
ALCOHOLS
linear alkyl benzene synthetic fatty
ethylene oxide fatty acid
(LAB) alcohols alcohols
am ines
cationic
anionic non-ionic amphoteric
surfactants surfactants surfactants
surfactants
Europe is the largest consumer (by volume) of surfactants accounting for 35% of the
global market. North America and Asia remain large markets, consuming 31% and 26%
respectively. We expect global consumption for surfactants to grow at 2-3% per annum
through to 2015.
We expect regional growth rates in surfactants consumption to vary with China, Middle
East and Africa the highest (expected to grow by 6-8% per annum). The growth rates in
other regions should vary from low (in the case of Western Europe) to medium (in the
case of Latin America). The poor growth in Western Europe is due to a stagnant
economy, low population growth, and reduced surfactant concentration in formulations.
Profit margins for surfactant producers have been squeezed in recent years. There has
been pressure from higher raw material costs (i.e., crude oil, natural gas, and natural oils)
since 2005 and few companies have been able to fully recover these higher costs.
The industry has continued to consolidate in recent years. One trend has been that the
major vertically integrated companies such as P&G and Croda have invested in or
acquired oleochemical-based raw materials. The other trend has been the rapid
disappearance of small producers.
Fine chemicals
Figure 310: Fine chemicals at a glance
Long-term growth rate Largely around GDP although many niches offer better or worse rates
Growth rate relative to the sector Historically high but now below average due to commoditization
Supply/Demand Niche markets, but excess capacity in some areas
Margin prospects Poor short-term, selected niches maintaining high levels
Watch out for ... Further consolidation, biotech
Source: Deutsche Bank
A fine chemical is, in theory, a small volume, high value chemical which sells to an exact
chemical specification. Production often involves a number of complicated steps. Perhaps
the best example of a fine chemical is the active ingredient in a pharmaceutical, which is the
chemical that gives the pharmaceutical its medicinal effect. Indeed, in recent years the term
'fine chemical' has been increasingly used to refer to only pharmaceutical and
agrochemical intermediates.
We view fine chemicals in the wider (more traditional) sense of the definition and as such see
pharmaceutical and agrochemical end-markets (life-science) accounting for 40% and 25%
respectively. Outside the life-science industry, roughly 7% of fine chemical sales arise in
dyestuff end-markets and 5% in the markets for flavors and fragrances. The remaining
20% or so of fine chemical sales are destined for a multitude of industrial and consumer end-
markets.
Traditionally, fine chemicals have been regarded as stable growth, added value chemical
products. However, as customers have become more focused on price, increased
competition in many fine chemical markets from lower cost Asian producers has meant that
this need not necessarily hold true. For example, dyestuffs represent a sizeable component
of fine chemical markets globally. However, competition from Asian producers has led to the
commoditization of dyestuff markets and, with it, a sharp deterioration in dyestuff industry
profitability. Flavors and fragrances remains one of the few “fine chemicals” where some
degree of pricing power remains.
Other
18%
Dyes
5%
Flavours & Pharmaceuticals
Fragrances 45%
7%
Agrochemicals
25%
Life science molecules are intermediates and sometimes end compounds used in the
formulations of agrochemicals or drugs sold by the pharmaceutical, agrochemical and biotech
markets. Those chemical companies who operate in this industry are involved in the out-
sourced manufacture of product, not in the R&D discovery or marketing of the products.
The chemical-based products supplied to the Pharma and agrochemical industry generally
are based on small molecules, produced through a range of technologies such as
hydrogenation, condensation, estification, etherification, chlorination, oxidation, halogenation,
and chirality.
Historically the traditional participants within the life-science molecule industry were the
Pharma/agrochemical/biotech companies. Through out-sourcing and in some cases the
separating of chemical assets from larger Pharma groups the manufacture of (some parts of)
these products have moved to chemical companies – contract manufacturers. However, a
significant part of this industry still remains in-house at the customers – some of the largest
competitors to the chemical companies in this industry are its own customers.
However, in more recent years there has been a reversal of the trend to out-source
production. Drivers of the subsequent drive back to in-sourcing:
A focus on manufacturing costs by pharmaceutical companies (in many cases post large
mergers/acquisitions) has led to a greater evaluation of capacity utilization of in-house
production asset and their cost structures. Pharmaceutical companies manufacturing at
lower capacity utilization have been seen not only to produce some of their new
compounds in-house but to also in-source production back from contract manufacturers
in order to improve their cost structures.
When a product is out-sourced the Pharma company gives control of the supply of its
product to the contract manufacturer. If the contract manufacturer encounters issues
(either from FDA regulation compliance as seen by many in the late 1990s, or more
general manufacturing problems) it can significantly impact the sales and cashflow of the
Pharma company. The risk from these issues can be partially countered by using at least
two contract manufacturers and also by focusing on those with strong records in
manufacturing and FDA compliance, however some Pharma companies have preferred
to be in complete control of manufacturing in order to manage this risk
For active compounds and biotech products significant returns can be made in
manufacturing (if plant capacity utilization is sufficient). Outsourcing of product can in
these cases be seen as passing on a healthy return to a contract manufacturer that could
be captured internally by the Pharma/biotech company
For Pharma and biotech intermediates the FDA and the European agencies regulate the
manufacturing process and end product quality of exclusively produced compounds. This
regulatory control involves the approval of manufacturing facilities, processes and end
products and involves inspections of plants on a regular basis. The regulatory agencies
participation is more significant further towards the end-product (i.e. the advanced
intermediate/active ingredient). The regulation for biotech manufacturing is the most
substantial in this industry (because most biotech products have to be injected, given they
are proteins if they were taken orally they would be digested rather like steak). It should be
noted where applicable these regulatory controls are of vital importance with the FDA having
authority to shut production, seize product and fine a company for digressions.
Those building blocks at the early stages of production tend to be chemicals which can be
used in a number of end uses and end products (and in many cases these products are so far
away from the end product there is little regulation). These products can be sold to a large
number of customers. Only the latter stages of production are products manufactured on an
exclusive basis for specific customers. It is these products which have a degree of
differentiation and therefore the greater value added. The production of these molecules
tends to be referred to as ‘exclusive synthesis’.
Value Added
Perform ance/
Oil Interm ediates Advanced Finished/’Active
Base Chem icals Form ulated
Gas (building block) Interm ediates M olecule’
Products
The critical success factors for companies producing chemical/small molecule life-science
molecules are:
Access to a wide range of technologies. This not only provides the skills for contract
manufacturers to produce the products but also allows scope for possible improvements
in the costs of manufacture by using different technologies to reduce the number of
steps of production.
Process development capability. This again can help to reduce costs of production and
helps maintain margins for the contract manufacturer in the face of yearly price
discussions.
Close interaction, development and project management with customers from initial
stages of drug discovery.
Further towards the finished product and as products become more exclusive the barriers to
entry increase with a greater requirement for technology and a more onerous regulation
environment particularly for pharma products from the FDA and European agencies. For
active ingredients/finished products exposure to raw material costs are modest and margins
can be towards the top end of the specialty chemical peer group.
Historically life-science molecules have been manufactured within multi-purpose plants and
generally on a batch production basis, although for larger products focused manufacturing
has been built and continuous (or perfusion) manufacturing developed. As a result of batch
production methods capacity data for the industry is not readily available. While sales data
from publicly listed companies provides some idea of size of positions in this business, the
definition of products included in life-science often differ (ranging from active ingredients,
through exclusive synthesis down to the most basic of chemical building blocks).
Production of a biotech product is based on a cell line which goes through a fermentation
process to yield the desired cells, which are then purified/sterilized and then packaged into
the individual dosage containers.
Figure 317: Biotech manufacturing process Figure 318: Breakdown of technologies used in biotech
manufacturing market
Fill/finish
17%
12 months 4-7 w eeks 2 -4 w eeks 1-2 m onths
Transgenic
cell line creation
fill and m am m als
and process fermentation purification
finish
development 6%
Source: Company data and Deutsche Bank Source: Company data and Deutsche Bank
Large molecules
Within the manufacturing process the cell line used is dependant on the end product desired.
The two main technologies are
Antibodies: An antibody is a soluble protein used by the immune system to identify and
neutralize foreign objects like bacteria and viruses. Each antibody recognizes a specific
antigen (a substance that stimulates an immune response unique to its target) and
specifically bind to that substance to neutralise or purify that substance
Fusion antibody: An antibody is linked with another substance (a chemical process after
the biomanufacturing). A fusion antibody rather than binding to a antigen to neutralise it,
delivers another substance to neutralise or kill it
Anti-body fragment: Within an antibody only a small part (a fragment) actually binds
onto the targeted antigen the remainder is just ‘scaffolding’. It is a cheaper and more
straightforward to manufacture a fragment than a full antibody – it can be made through
microbial manufacturing rather than requiring mammalian process. However, for chronic
diseases where drugs are required for long periods of time the side-effect profile is
generally perceived to be better if a product is based on a mammal cell line. Therefore
antibody fragments tends to be used for drugs with only short periods of application.
Monoclonal antbodies: Antibodies that are identical because they were produced by
one type of immune cell, all clones of a single parent cell. Given (almost) any substance,
it is possible to create monoclonal antibodies that specifically bind to that substance;
they can then serve to detect or purify that substance. The use of monoclonal antibodies
for example in cancer treatment involves monoclonal antibodies that bind only to cancer
cell-specific antigens and induce an immunological response against the target cancer
cell.
Proteins are essentially polymers made up of a specific sequence of amino acids. The
term can be used to describe basic proteins such as insulin as well as much more
complex antibodies. Proteins and peptides are polypeptide molecules: peptides being
short chains of amino acids, proteins long chains of amino-acids
Within biotech, barriers to entry are higher than elsewhere in life-science molecules, with a
stricter and more wide ranging regulatory environment than for chemical life-science
molecules - regulatory approval and compliance maintenance is required for not just for the
plant but for each individual product manufactured within each individual vessel. This
provides a strong barriers to supplier substitution vessel as it can take up to nine months to
achieve regulation approval for a vessel.
Other barriers to entry include the substantial costs of investment required to build large
scale (£200-500m) with a 2-3 year lag before the plant can be filled, and the experience
required to scaling up production when larger quantities of product are required.
The critical success factors for companies producing large biotech molecules are:
Regulatory approval (FDA) of facilities. These are more onerous than those of small
molecules. A strong FDA record is invaluable in these operations.
Close interaction, development and project management with customers from initial
stages of drug discovery. Ability to negotiate longer term contracts (and potentially
contributions to capacity builds) from customers in order to reduce the risk of large plant
builds
procurem ent /
i i
Construction
Start up
0 1 2 3 4
Source: Lonza
Flavours
The major end markets is the flavouring market, an industry worth Euro 8.6bn globally,
include beverages and food such as bakery products, confectionery, savoury snacks and
meat. There are only four basic flavours that the nerve endings in the taste buds on the
tongue can detect: sweet, sour, salty and bitter. The popular conception of flavour, however,
involves the combination of these four basic stimuli with simultaneous odour sensations. In
flavours we continue to note opportunities for stronger overall growth driven by increasing
volumes of pre-prepared foods, where flavours are required to offset the loss of food ‘taste’
during the industrialisation process. Some of the growing trends in flavours include
sweetness modulation (customers looking for reduced sugar content), sodium modulation
(customers looking for low sodium consumption) and natural solutions (driven by new EU
regulations)
Fragrances
The global fragrance market is a Euro 8bn industry and is divided into three key segments:
Personal care, one of the largest markets, used in cosmetic and toiletry products.
The household market, where fragrances are used in products such as detergents and air
fresheners.
Figure 322: Flavours & Fragrances market by player Figure 323: Flavours & Fragrances market by region
(2011E) (2011E)
Frutarom
Others Others
7% 13%
Hasegawa 3%
3% Givaudan US
24% China 31%
Mane Fils
9%
4%
Sensient Japan
5%
10%
Takasago Firmenich
8% 17%
Symrise IFF
13% 16% W. Europe
37%
Source: Deutsche Bank, Company Data Source: Deutsche Bank, Symrise, SRI consulting, IAL Consultants
Figure 324: End use markets for Flavours (2010) Figure 325: End use markets for Fragrances (2010)
Other
Dairy 7% Fine
7% Fragrance
& Beauty
Beverage Care Functional
36% 29% Fragrances
Sweet 41%
19%
Savory Ingredients
31% 30%
Source: IAL Consultants and IFF Source: IAL Consultants and IFF
Figure 326: Breakdown of flavours and fragrances in the Figure 327: Breakdown of geographical exposures in the
top players (2010) top players (2010)
Givaudan Givaudan
Firmenich
Symrise
Symrise
IFF
IFF
Takasago Takasago
0% 20% 40% 60% 80% 100% 120% 0% 20% 40% 60% 80% 100%
Industry has seen significant consolidation: The flavours and food ingredients market has
seen significant consolidation at the top end: IFF purchasing BBA (US) in 2000 and Givaudan
acquiring FIS (from Nestlé) in 2002, the acquisition of Harmaan & Reiemer from Bayer by
EQT Northern Private Equity Funds in 2002 and its merger with DRAGOCO (private German,
majority shareholder Horst-Otto Gerberding) to form Symrise (which in itself could become a
takeover target) and Givaudan acquisition of Quest (ICI’s flavours and fragrances) in 2006,
Firmenich acquisition of Dansico Flavours business in 2007 and Symrise’s acquisition of Chr.
Hansen, Manheimer Fragrances and Intercontinental fragrances in 2008 and Futura Labs in
2010. At the beginning of 2011, DuPont announced its intention to buy Danisco. There have
also been many smaller technology or niche flavour and fragrance producers who have been
bought to add the range of the larger companies. Top seven producers now accounts for
87% of the market with the rest being held by relatively small producers
Industry players see the F&F market growing on average 2-3% pa over long term.
Over the past 5 years the top tier participants have seen average local currency growth of
5.0% pa (although the range varies significantly from 0.5% to 10.6%). While clearly 2008/9
have been difficult years growth for F&F players has been resilient when compared to other
speciality chemical companies. F&F market recovered in 2010 (underlying sales growth of
10.6%) driven by some customer re-stocking to more normal inventory levels, a recovery in
consumer demand and ongoing strong emerging markets growth. On a long-term basis the
top tier F&F players guide for an industry growth rate of 2-3%.
Figure 328: Sales growth of the top tier flavour and fragrance companies
YoY growth 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011E
Top tier F&F average 5.0% 2.7% 3.7% 2.9% 5.8% 4.3% 0.5% 3.6% 10.6% 5.6%
Givaudan 6.1% 4.2% 2.2% 2.5% 3.5% 2.8% 1.0% 1.4% 8.9% 5.2%
IFF 1.0% -2.0% 4.0% 0.0% 5.0% 5.0% 2.0% 0.0% 13.0% NA
Firmenich 9.5% 6.6% 7.1% 8.7% 8.3% **18.4% -4.3% 12.1% NA NA
Symrise NA NA Û1.5% Û0.2% 7.5% 6.2% 3.5% 0.5% 11.1% 5.0%
Source: Company data, Deutsche Bank, ÛReflecting the restructuring of the newly merged businesses, ** including acquisition of Danisco Flavours. With no pro-forma local currency sales growth available we have excluded
this from the average growth calculation
Demand for food remains consistent over cycles. Over the past 50 years spending on
food in the US has proved relatively consistent showing around 1.5-2.0% growth. While there
have been times of lower growth in many cases these correlate with times of deflation and a
lowering of the value of the product rather than necessarily a drop in the volume. A further a-
cyclical argument can be presented for flavours given that during economic downturns there
tends to be a trend to reduce dining out (which uses only little flavour, accounting for 5% of
the market) in favour of prepared foods (including frozen) eaten at home (which contain a
much greater proportion of added flavours). The flavour market is however subject to
destocking. While customers only have a limited scope for destocking (due to the
requirement for food freshness), reductions of their holdings of flavours (which can have a
longer life span) has been seen to create a degree of cyclicality. This was what exactly
happened during the 2008/09 downturn when sales for the top-tier players grew lower than
the historic industry average. However, this destocking is seen as only temporary in nature
given the limited time frame that food inventory can be stored. This was also corroborated by
the strong rebound we saw in the 2010 when the sales by top tier players grew by 10.6%.
7.0%
6.0%
5.0%
4.0%
3.0%
2.0%
1.0%
0.0%
-1.0%
-2.0%
-3.0%
Jun-47
Jun-49
Jun-51
Jun-53
Jun-55
Jun-57
Jun-59
Jun-61
Jun-63
Jun-65
Jun-67
Jun-69
Jun-71
Jun-73
Jun-75
Jun-77
Jun-79
Jun-81
Jun-83
Jun-85
Jun-87
Jun-89
Jun-91
Jun-93
Jun-95
Jun-97
Jun-99
Jun-01
Jun-03
Jun-05
Jun-07
Jun-09
Home & Personal care (HPC) is largely resilient to recession: The personal care and
cosmetic industry has a well known resilience to recession best highlighted by the “lipstick
effect” (as first highlighted by Estee Lauder). During times of economic uncertainty, women
still spend on affordable luxuries as a substitute for more expensive items like clothing and
jewellery. The theory was first identified in the Great Depression, when industrial production
in the US halved, but sales of lipsticks rose 25% between 1929 and 1933. This was also seen
in the 1990 and 2001 recessions in the US, the number of people working in the cosmetics
industry increased as demand for make-up rose in the US (Estee Lauder lipstick sales +11%
in 2001) although this effect has not been as strong in all economic turndowns and does not
appear in all categories of HPC (e.g. not perfumes or air care). However, again H&PC industry
has been impacted by destocking as in late 2008/early 2009 although the impact of
destocking was generally less pronounced than for the flavour and fragrance players.
Growth tends to be similar to customers: Revenues in F&F (ex M&A and FX) show a
correlation to customer sales. This relationship is most pronounced in the consolidated
consumer goods industry, while the correlation is weaker to the food & drink manufacturing
reflecting the relatively fragmented nature of the customer industry (which we represent here
with just the top 7 of the participants which we estimate to make up less than 20% of the
industry). Given the lumpy nature of the F&F business (e.g. orders 1-6 times a year for
product) compared to the customer (more steady consistent sales over a period) the F&F
companies see greater volatility in sales than their customers. This was again the case during
the last recession and subsequent bounce back where the average sales growth/decline in
F&F businesses was higher than its customers largely due to the more pronounced impact of
restocking/destocking.
Figure 330: F&F local currency sales growth relative to average of customer organic
sales growth
16.0%
14.0%
12.0%
10.0%
8.0%
6.0%
4.0%
2.0%
0.0%
-2.0%
-4.0%
Q1 06
Q2 06
Q3 06
Q4 06
Q1 07
Q2 07
Q3 07
Q4 07
Q1 08
Q2 08
Q3 08
Q4 08
Q1 09
Q2 09
Q3 09
Q4 09
Q1 10
Q2 10
Q3 10
Q4 10
Average customer growth F&F
Low correlation to GDP & consumer indexes: There appears only limited correlation of
F&F growth to consumer spending or GDP. It should be noted that while the end use
demand for F&F is related to consumer spending, the non-discretionary element of F&F end
markets implies that F&F sales growth does not correlate significantly with consumer spend
indices.
Figure 331: F&F sales relative to US and European Figure 332: F&F sales relative to US & European GDP
consumer index
15% 6% 15%
10% 4% 10%
2% 5%
5%
0%
0%
0% -2%
-5%
-5% -4%
-10%
Q1 02
Q3 02
Q1 03
Q3 03
Q1 04
Q3 04
Q1 05
Q3 05
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Q1 02
Q3 02
Q1 03
Q3 03
Q1 04
Q3 04
Q1 05
Q3 05
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Approx 15% of sales of industry are into the economically sensitive luxury products:
The economically sensitive F&F business is generally perceived to be fine fragrances and
luxury personal care which account for approximately 6-18% of sales of the top tier
companies. Historically these fine fragrance sales historically have shown significant variation
(+/- 20%). While only IFF report fine fragrance data on a consistent basis, this data shows
that 2008/09 trough has certainly lasted longer (with previous downturns lasting only 4-6
months) although the rebound was equally strong with IFF reporting four consecutive quarter
of double digit growth through 2010.
Figure 333: Fine Fragrance weakness since Q4 07 lasted Figure 334: Fine Fragrance weakness centered on North
till Q4 09 but the rebound was been equally strong America and Europe
40%
80%
30% 60%
20% 40%
10% 20%
0%
0% -20%
-10% -40%
-20%
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Givaudan 9%
IFF 19%
Firmenich * 13%
Symrise 7%
Industry 12%
Source: Company data and Deutsche Bank,* DB est
Lumpiness: Sales in the flavours and fragrance markets can show significant ‘lumpiness’
over 12 month period. This is a result of the impact product launches, which require a
significant amount of ‘shelf filling’ product at one time, with only a smaller ‘top-up’ amount in
subsequent months. Movements in market shares are best to be judged over a period of at
least 12 months in order to avoid temporary impacts such as these. On a rolling 12 month
basis IFF has lead the sector with a growth of 13%, followed by Symrise at 11% and
Givaudan at 8.8%. Higher growth for IFF was mainly due to its higher exposure to Fine
Fragrances which was the worst hit during the 2008/09 downturn.
Figure 336: Seasonality in the F&F industry: Sales of IFF Figure 337: Rolling 12-month underlying (ex FX, M&A)
and Givaudan on a quarterly basis rebased to Q1 2003 sales growth
14.0%
175 12.0%
10.0%
150 8.0%
6.0%
125 4.0%
2.0%
100 0.0%
-2.0%
75 -4.0%
Q1 03
Q3 03
Q1 04
Q3 04
Q1 05
Q3 05
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Q1 11
Q1 04
Q3 04
Q1 05
Q3 05
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Q1 11
Top tier F&F companies should continue to take market share from the small to
medium size peer group for the foreseeable future. As customers look to focus their own
costs we believe the use of core lists and a restricted number of F&F houses used will
accentuate this trend. Barriers to entry in F&F are wide-ranging: the high innovation rate, R&D
critical mass, inclusion on top customer core lists, regional dominance and global presence,
access to raw materials, increased regulatory environment, full traceability of product and to
a lesser extent integration with customer ERP systems.
Over the past five years the top five companies have increased their market share from
68% to 79%. Through the past five years top tier F&F companies have taken market share
both on an organic basis and also by acquisition (Quest by Givaudan, Danisco Flavors by
Firmenich, Chr. Hansen, Manheimer Fragrances and Intercontinental fragrances by Symrise).
In 2010 top tier companies grew by 10.6% compared to market growth, we estimate of 8%.
With all constituents of the top tier F&F companies growing ahead of market in the period
these market shares gains appear to have largely been at the cost of the medium and small
F&F participants.
Figure 338: 12 month rolling local currency flavour Figure 339: 12 month rolling local currency fragrance
growth by company growth by company
20%
15%
15%
10%
10%
5%
5%
0%
-5% 0%
-10% -5%
Q1 04
Q3 04
Q1 05
Q3 05
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Q1 11
Q1 04
Q3 04
Q1 05
Q3 05
Q1 06
Q3 06
Q1 07
Q3 07
Q1 08
Q3 08
Q1 09
Q3 09
Q1 10
Q3 10
Q1 11
Drivers of ability to achieve market share gains above the top tier peers include the
proportionate exposure to
The faster growing emerging markets: With an improvement from the current low
penetration levels of processed meals and scented products, growth in the F&F was the
fastest in the emerging market countries in the last five years. Growth rates in Emerging
Asia, Central and Eastern Europe, and Latin America averaged between 4-8% pa in the
period– in some cases two to three times the growth seen in more mature markets for
the top tier players. The top tier flavour and fragrance companies have approximately
43% of their sales in emerging markets. However, the type of emerging market
exposure differs between companies. Givaudan has a greater proportion of its sales into
Asia and Latin America than its peers, proportionately below in Middle East and Central
and Eastern Europe. IFF’s exposures have a greater leverage towards Latin America (and
lesser into Eastern Europe and Middle East and Africa), Symrise has a significant
exposure to Asia, Central and Eastern Europe and Africa and the Middle East, but a much
lower proportion from Latin America. Through 2010 exposure to Latin America and
emerging Asia has been important to supporting growth. Over the next five years we
expect emerging markets to outgrow the developed markets in both flavour and
fragrance segments mainly driven by the higher growth in disposable income vs. the
developed markets.
Flavours
Developed markets 2.5% 38% 47%
Emerging Markets 6.0% 62% 53%
Source: IAL consultants, IFF
R&D: Top tier F&F players spend approximately 8% of their sales on R&D. Amongst the
top four players Givaudan is the market leader in the absolute R&D spend followed by
Firmenich, IFF and Symrise. We believe returns on R&D should be sustainable despite
the shortening of product life-cycles. Over the past few years the fine fragrance and
personal care industry has seen the proliferation of product line extensions. While these
have aided volumes in the market the life span of these products have in many cases
significantly reduced creating concerns of declining returns on R&D (while many
products proliferations can have related fragrances – eg perfume, perfumed body
moisturiser and shampoos – each fragrance has to be separately developed). However
F&F participants believe such changes have not had an impact due to a greater focus on
the efficient allocation of R&D. An example of this comes from IFF which has in recent
years achieved consistent returns in fine fragrances despite this being a category with
the largest reduction in product life-span in the past five years.
Figure 342: R&D spending by top tier F&F players (2010)
R&D to sales R&D spend ($m) R&D as % of sales
Figure 343: Fast growing market segments (2010-2013E) Figure 344: Portfoilo segmentation of F&F players
15.0%
Average F&F market growth
12.0%
9.0%
6.0%
3.0%
0.0%
Sun care
Skin care
Functional
food/drink
grooming
Slimming
products
Organic
Men's
food
Sources: Datamonitor, MarketsandMarkets, just-food, Global Industry Analysts, Packaged Facts Sources: Datamonitor, MarketsandMarkets, just-food, Global Industry Analysts, Packaged Facts
Increasing penetration of core lists: The ability to service a customer and enter into the
new product brief process increasingly requires the F&F company to be included in the
customers ‘core list’. However, details of the core lists of clients remain sparse. These
core-lists are reviewed by the F&F customers every 3-4 years on an average. Since 2008
Symrise has been winning new core list positions at an average rate of 2 new lists per
year. IFF has provided no details of change in core listings during this period although it
continues to state it is on the core list of the “majority” of its “strategic customers”.
Givaudan stated in May 2009 that it had gained a position on Colgate Palmolive’s core
list, while highlighting more core list wins at key accounts through H1 10.
Raw materials show a relatively limited sensitivity to oil prices. For the flavours and
fragrances houses the largest costs incurred are for the purchase of raw materials which
account for approximately 40% of sales. It is estimated that those raw materials which are
sensitive to the oil price account for approximately 30-56% of total raw material costs (the
lower proportion of costs being for those companies with a greater focus on flavour which
uses much more nature based ingredient or a lesser chemical molecule operation).
While the names of these raw materials in many cases tend to be well known there is little
transparency in their pricing with many bought direct from farmers, co-operatives or traders.
These naturals can see significant price changes from time to time (depending on harvests,
weather etc.). However with well over 10,000 potential natural based raw materials prices
changes in some often tend to be offset by others.
Figure 346: Natural flavour and fragrance extracts of greatest commercial importance
by category
Concretes / Absolutes Resinoids Oleoresins Extracts
Price changes in raw materials are being generally offset. Over the past years the F&F
companies have taken significant steps to minimize the impact of changes in raw material
prices. The evidence for this can be seen in the gross profit margin which bears little
correlation to the movement in oil or the movement in some of the larger raw materials such
as vanilla. Methods used to combat rises in raw material costs in older products include price
rises (increasingly more accepted in recent years and in general offsetting 50% of impact),
changes in formulation (only with agreement with customers), increased efficiency of
sourcing and changes in portfolio mixes and backward linkages in some key natural raw
materials (e.g. Symrise is backwardly integrated in menthol). It should be remembered that
raw material price changes do not impact new product profitability (approx 25-30% of
portfolios YoY) as current raw material prices are taken into account during their development
in initial price settings.
Figure 347: Gross margins of the F&F companies relative to the oil price
45% 120
100
40%
80
35%
60
30%
40
25%
20
20% 0
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
Margin should remain stable: We believe that F&F EBITDA margins should be at least
sustainable longer term as the cost of the flavour and fragrance is only 2-6% of the total
costing to a customer (<0.5% beverages up to 5-6% for fine fragrance); packaging and
marketing being much more important. Secondly, pricing is a lesser part of the innovation
process (purchasing managers only entering negotiations typically after a year). Additionally,
the integral nature of the flavour or fragrance to the success of the customer product results
in low pricing pressure.
Sales comparisons
F&F Sales $m 4071 2623 2759 2085 1313 787 515 637 481
Proportion to group sales into F&F (%) 100% 100% 100% 88%# 87% 59% 100% 100% 100%
Breakdown of flavour sales 53% 46% 43% 51% 60% 53% 87% 49% 51%
Beverages (%) 19% 11%# na 18% na 5% 34% na na
Savoury (%) 19% 17%# na 17% na 11% 7% na na
Confectionery/bakery (%) 8% 8%# na 13% na 3% 12% na na
Dairy (%) 7% 2%# na 0% na 11% 23% na na
Other (%) 0% 7%# na 3% na 24% 11% na na
Breakdown of fragrance sales 47% 54% 57% 37%# 27% 6% 13% 51% 49%
Fine fragrances (%) 9% 19% na 7%# na na na na na
Home and Personal Care (%) 31% 23% na 17%# na na na na na
Aroma Chemicals (%) na na na 8%# na na na na na
Other 6% 12% na 5%# na na na na na
Profitability comparisons
EBIT in F&F $m 629 418 na 324 58 122 50 na 37
EBIT margin 15.5% 16.0% na 15.5% 4.7% 15.5% 9.8% na 7.8%
EBITDA in F&F $m 925 498 na 439 NA 147 89 na 49
EBITDA margin 22.7% 19.0% na 21.1% NA 18.7% 17.3% na 10.2%
R&D $m 323 219 na 143 89 31 43 na NA
Source: Deutsche Bank, Company Data, Reuters, Bloomberg,*June ending 2010 data, †September ending 2010 data, ‡March ending 2010 Data,, •Includes Latin America, #DB estimates
Figure 349: Ranking of sub-sector profitability in the Flavours and Fragrances industry
Fine Fragrances Personal Care Confectionary/Bakery Savoury Fragrance Ingredients
Beverages Dairy Household
Source: Deutsche Bank Symrise states its cosmetic ingredients has profitability between Fine Fragrances and Personal Care
Figure 350: Ranking of sub-sector growth in the Flavours and Fragrances industry
Beverages Personal Care Fragrance Ingredients Fine Fragrances Confectionary/Bakery
Savoury Household Dairy
Source: Deutsche Bank Symrise states its cosmetic ingredients has growth at same level as beverages and savoury
Dyes, pigments and masterbatches are compounds used to impart colour, especially onto
textile materials but also onto leather, paper, and plastics. Dyes are soluble in water as
opposed to pigments which are insoluble. Pigments are used in masterbatches which are
then used to colour plastics
All dyestuffs are organic, that is derived from hydrocarbons rather than mineral based. There
are many different chemical varieties of dyes, and they are classified in terms of the way the
chemical is applied or held in the material. It is possible to classify dyes according to their
application:
Acid Dyes: These are insoluble in acid baths, and are used for dyeing protein fibers such
as wool, silk, nylon, leather and paper. Most of the synthetic food colors also belong to
this group.
Azoic Dyes: These 'ice colour' dyes are made using ice to keep the chemicals at low
temperatures. These are brilliant, long-lasting dyes used primarily on cotton. They are the
one most versatile of all the classes and therefore widely used.
Basic Dyes: These are soluble in acid, but insoluble once the solution is made basic
(alkali added). They are usually used for duplicator inks, carbon paper and typewriter
ribbons. In solvents other than water they form writing and printing inks.
Direct Dyes: These are used to dye cotton directly and also union goods (mixed cotton,
wool and silk). They are also used as pH indicators and as biological stains.
Disperse Dyes: Used to dye synthetics (cellulose acetate, plastics and polyesters) which
are difficult to dye. They are mainly used to dye polyester but can also be used to
nylone, cellulose triacetate and acrylic fibers.
Reactive Dyes: The newest dyes to be created, these are used for dyeing cellulosic
fibres and some nylons. They react to form a chemical link between the dye of the fibre
and consequently produce dyes of outstanding wash-resistance. Some of these dyes
can be used at room temperatures and these are one of the best choice for dyeing
cotton and other cellulose fibers at home.
Sulphur Dyes: A large group of dyes which produce dull shades on cotton (in some
cases used in more value added applications). Sulfur black 1 is one of the largest selling
dyes by volume.
The demand for textile dyes is linked to the demand for the end product mainly clothing.
Textile fibres have a long-term steady growth rate of 2-3%. However, this growth varies
depending on the type of fibre: polyester grows at approximately 3-4% pa. Dyes can be used
on a variety of substrates and growth depends on current market penetration and end use
growth. The demand for leather dyes depends on the supply of hides. The demand for paper
is based on the paper market but also the on-going fashion for brighter increasingly coloured
paper.
RoW
Europe 4%
9%
Americas
25%
Asia
62%
In the last decade global dye industry has seen a major structural change with production
shifting form US, West Europe and Japan to other Asian countries, particularly in China
which now comprises more than 40% of the global dye production.
In the last ten years this industry has been badly impacted by over supply, resulting into
significant pricing pressure. To combat this low cost competition significant restructuring
has taken place in the industry over the past few years, we don’t expect any material
improvement in this condition in near term as higher competition from small and
medium players remains a major threat for this industry.
Despite all these problem areas this industry also has certain small pockets of high
growth such as specialty dyes which has robust demand levels and we see material
growth opportunities in these new areas.
Pigments
The faster growing market of colourants is that of pigments. Pigments can categorised as
organic or inorganic colour pigments. Organic can provide certain advantages over inorganic
pigments. They generally possess greater brightness and tinctorial strength and can serve as
replacements for inorganic pigments.
Figure 353: Breakdown of inorganic pigments market Figure 354: Regional breakdown of Inorganic Pigments
market
Bismuth Iron Blues Cadmiums Others
Vanadate 1% 1% India 10%
2% 4%
Ultramarines Central and China
5% South 34%
Iron Oxides
Chromium 42% America
Oxide 7%
8%
Chromates North
9% America
Complex 22%
Inorganic Europe
31% 23%
Source: Deutsche Bank estimates, SRI Source: Deutsche Bank estimates, SRI
Figure 355: Breakdown of organic pigments market Figure 356: Regional breakdown of Organic Pigments
(2009) market (2009)
Others
High-
16% China
Performance/
Other 28%
27% India
7%
Azo
53%
Japan
12%
Phthalo- United
cyanine Europe States
20% 16% 21%
Source: Deutsche Bank estimates, SRI Source: Deutsche Bank estimates, SRI
In 2009 the global market for organic and inorganic pigments amounted to $5.2bn, this
segment was one of the most adversely impacted segment in the last recession,
However most end markets have returned to pre-crisis levels and we now expect a
steady improvement going forward.
Printing inks is one of the key end market for the pigment industry and this end market is
expected to continue to see a long-term slow decline due to increasing substitution from
the electronic media.
Regionally, US and Europe were the worst impacted by global slow down where Asia
was comparatively resilient and provided a support to this industry - going forward we
expect emerging economies to remain the significant demand driver.
In inorganic pigments synthetic iron oxide holds the largest share with approx 73% of
the total volumes and China is the biggest player with more than 40% market share.
Masterbatches
Masterbatches are the dyes contained in plastic pellets which are used to colour plastics.
These plastics are mostly used in packaging and building but also in electronic and auto
applications. Clariant is market leader in this industry with approximately 20% of the global
market share.
The customer base for manufacturers is very fragmented, ranging from the large auto and
consumer companies to hundreds of thousands of small compounders and plastic product
manufacturers. Due to the specialty nature of the product, the requirement of individual
specifications per customer and per product, and the necessity of quick delivery times to
customers, a close manufacturing location to the customer is essential. Masterbatch
productions tend to require only a low level of capital.
Figure 357: End markets for Masterbatches (2009) Figure 358: Breakdown of coloured Masterbatch market
(2009)
Other
10% Black
15%
Durable goods
4%
Electronic
5% Packaging
42%
Auto
7%
White
26% Colour
59%
Building
32%
Figure 359: Geographical breakdown of masterbatch Figure 360: Market share in masterbatches (2009)
market (2009)
Clariant
RoW 22%
Europe
25%
30%
PolyOne
10%
Asia Other
15% 68%
US
30%
Some of the key players include A. Schulman Inc, Americhem, Ampacet Corporation,
Cabot Corporation, Clariant, Colortech Inc, Dainichiseika Color & Chemicals, Dow
Corning, etc.
Plastic additives are chemicals which are added to a range of plastics in order to alter the
characteristics of the plastics either for the final product (e.g. UV stabilisers which protect the
product from sun degradation) or during its manufacture (e.g. processing aids). The plastic
additives market is worth approximately $17bn.
Within plastic additives there are eight main classifications of product, which in turn
frequently contain a number of individual chemicals. We exclude colourants for plastics -
masterbatches – which are discussed in the previous section on colourants, and commodity
plastic additives such as polymerisation catalysts.
Antioxidants
Antistatic agents
Chemical blowing agents
Flame retardants
Heat stabilizers
Impact modifiers and processing aids
Lubricants
Ultraviolet light stabilizers
The plastic additives market is still rather fragmented with the top 5 producers having 33% of
the market. Although there are many participants, two to four companies tend to dominate
each functional type within each major world region (~90% market share). Post a large
degree of M&A and consolidation, several major producers now produce a broad range of
functional additives. Volumes of individual additive products are often quite small. As such
product is generally produced in one or two plants and exported globally.
Figure 362: World consumption of additives by polymer Figure 363: Plastic additives world market shares by
class 2009 value 2009
Other BASF
12% 10% Chemtura
PVC 9%
Thermosets 40% Dow
15% 4%
Arkema
4%
Albemarle
2%
Other Kaneka
Polyolefins/ 67% Songwon 2%
PS 2%
33%
Plastics additives are sold to base resin producers, custom compounders and plastic
fabricators. The base resin producers that purchase additives directly from additive producers
do their own compounding and sell finished products largely to plastics fabricators, although
a few do their own fabrication and sell directly to end users. Because there are relatively few
base resin producers (compared with the number of fabricators), they tend to be large
corporations with considerable compounding skills. Indeed, these companies may produce
some of their own additives for captive consumption.
Source: SRI
As a result of customer demand for a single supplier, additives are increasingly supplied to
compounders and fabricators in the form of “one-pack” granulated dry blends that can
contain heat stabilizers, antioxidants and lubricants as well as colorants (masterbatches).
Akcros Chemicals X X X X
Akzo Nobel X X X X
Albemarle X X X
Arkema X X X X
Baerlocher X X X X
Lanxess X X X X X
BASF X X X X X X
Clariant X X X X X X
Chemtura X X X X X X X X
Cytec Industries X X X
Degussa X X
Ferro Corporation X X X X X
Kaneka Texas Corp X
Lonza X X
Dow X X X X
Source: SRI
Enough flexibility and resources to find and develop replacement products for types of
plastics additives that lose their markets because of government regulations, voluntary
commitments from the industry, changes in demand or new technical trends favoring
different products, as well as sufficient R&D investment to increase the chances of
finding such new solutions.
Health and environmental issues continue to dominate certain sectors of the plastics
additives industry, particularly flame retardants, blowing agents and heat stabilizers. As a
result there is a continuing shift away from brominated and chlorinated flame retardants,
and growth in non-halogenated products. Heat stabilizers containing lead will continue to
be under scrutiny from non-government organizations (e.g. Green Peace) and will
gradually be replaced by products such as calcium/zinc or calcium/organics.
Raw material pressures are continuing and discipline in some areas of Plastic Additives is not
always the same. The strongest pricing trends tend to be in the most consolidated parts of
the Plastic Additives chain.
K
A
1%
13%
E
30%
B (all types)
D 33%
2%
C
21%
Source: Deutsche Bank, DSM, Adisseo
B3 tissue respiration, carbohydrate and lipid cereal 25% pig and poultry 75%
metabolism
B5 energy metabolism, antibody synthesis cosmetics, multivitamins 48% feed ingredient 52%
B6 metabolism of protein, carbohydrates, lipids food ingredient 75% feed ingredient 25%
B7 maintenance of healthy skin, hair and nerves cosmetic products 16% cattle industry 84%
B9 synthesis of nucleic acid breads, flour cornmeal, rice 41% pig and poultry 59%
B12 bone marrow cells, nervous system, normal food fortification, multivitamins 40% pig and poultry 60%
blood function
C absorption of iron, wound healing, maintenance processed food and beverages, 98% 2%
of capillaries vitamin supplements
D regulate levels of calcium and phosphate ions food, milk 18% pigs and poultry 82%
E biological antioxidant- protect tissue from food, cosmetic and supplement 53% feed additives 47%
damaging reactions industries
K liver, blood coagulation blood coagulation, infant formula 2% poultry diets 98%
Animal feed
Human health
57%
43%
During processing to restore vital nutrients to levels comparable with original levels
Figure 370: Breakdown of vitamins for animal feed Figure 371: Breakdown of vitamin for human market
market
Vit. E
10% Vit A
Vit E Vit A 10% Vit B12
31% 32%
5%
Vit B1
Vit C 4%
50% Vit B2
3%
Vit D
6% Nicotinate
Vit C 3%
Others Vit B6
Vit B
6% 12% 3%
25%
Source: DSM, Deutsche Bank estimates Source: DSM, Deutsche Bank estimates
Supply dynamics
Commercially all vitamins are manufactured by chemical synthesis or fermentation (with the
exception of natural vitamin E which is extracted from vegetable oil) or a combination of the
two. The potential to cut costs is limited although we expect there to be constant refining of
processes leading to small incremental reduction in costs. This has been highlighted by the
fact that there have been very few technological ‘breakthroughs’ in the past few years.
-Retailers
Dietary supplement -Food services
manufacturers -Drugstores Consumer
-Health shops
Personal care
manufacturers
Aquacultures
Bespoke Premix Bespoke Feed
Ruminants
Pets
Other
The market for vitamins is dominated by 2 industry leaders DSM and BASF
Chinese producers presence varies by vitamin, however they account for approximately 50%
of the global volume of vitamins produced, although no single Chinese producer has more
than 10% market share. Each Chinese province was instructed to have adequate feed and
vitamin facilities in the 1970s and 80s as focus was put on increasing agricultural output.
Surplus capacity is sold onto the global market, in general by means of traders. Vitamin C, B1,
B2 and E are restricted products in China which means that they can only be produced in
domestically by companies which are majority Chinese owned.
Figure 373: Relative market position in carotenoids Figure 374: Relative market positions in vitamins
Carotenoids
Vitamins
China
Chinese Other BASF DSM BASF Other DSM Chinese
China
producers producers
Vitamin B1 3
Vitamin B2 3
Panthothenic Acid 3
Vitamin B3 3
Folic acid 3
Vitamin B12 3
Vitamin C 4.0
Vitamin D2 3
Vitamin D3 3
Vitamin E 6
Biotin 3.5
Source: Deutsche Bank estimates and company information
The two natural penicillins obtained from the ‘original’ penicillin are penicillin G (PEN G) and
the more acid-resistant penicillin V (PEN V). They are active only against Gram-positive
bacteria and not against Gram-negative species, including many serious pathogens like those
which cause tuberculosis. However, the use of pencillins has been expanded by modifying
pencillins chemically to remove the side chain (which determines the antibiotic properties of
the penicillin) and then adding an alternative side chain that confer new properties. These
processes create the more modern semi-synthetic penicillins (SSPs) such as Ampicillin,
Carbenicillin and Oxacillin. Semi synthetic cephalosporins (SSCs) can also be manufactured.
The intermediates for these semi-synthetic products are 6-APA (penicillins), 7 ADCA
(cephalosporins) and other side chains such as PHPG (ParaHydroxy Phenyl Glycine) and PG
(pheylglycine).
G lu c o s e T o lu e n e / M A N
R A W M A T E R IA L S
P e n G /V BALD / G LA
6 -A P A 7 -A D C A PG / PHPG
IN T E R M E D IA T E S
S S P ’s S S C ’s B U L K A C T IV IT IE S
D o s a g e F o rm F O R M U L A T IO N
P a tie n ts M A R K E T E E R /D IS T R IB U T IO N /R E T A IL E R
Source: DSM
Others
Sulfonamides 6%
4%
Tetracyclins Cephalosporins
5% 27%
Aminoglycosides
6%
Quinolones
13%
Macrolides Beta-lactams
13% 26%
DSM is the leading player in global betalactams and cephalosporins market with number
2 position in Penicillin and 6-APA and market leading position in 7-ACDA, SSP and SSC
market.
We expect further consolidation penicillin market with DSM already having announced
the formation of a JV with Sinochem. Sinochem will have a 50% equity interest in DSM
Anti-Infectives and this JV will include all the global activities of DSM Anti-Infectives. This
should allow DSM to achieve a stronger position structurally in anti-infectives with
access to Sinochem's strong distribution in the Chinese market.
W Europe
Africa 5%
8%
Far East
Australasia 29%
8%
SE Asia
8%
S Am erica
9% UK
13%
M iddle East
N Am erica
10%
10%
Source: DSM
Figure 381: E120bn Household Care market Figure 382: E350bn Personal Care market
Oral Care
Surface Care 11%
14%
Source: Euromonitor, Deutsche Bank estimates Source: Euromonitor, Deutsche Bank estimates
Other L'Oréal
39% 10%
Unilever
10% U nilever
Other 7%
50%
Colgate
4%
Reckitt Benckiser
9% Avon
3%
Beiersdorf
Lion 3%
1% Henkel
Estée Lauder
Sara Lee 6% 3%
J& J
2% Kao Corp SC Johnson Kao Shiseido 3%
2% Colgate 6% 2% 3%
Clorox 4%
2%
Source: Euromonitor, Deutsche Bank estimates Source: Euromonitor, Deutsche Bank estimates
detergent, cleaners and more. Due to the “necessity” nature of HPC products, increasing
trend towards grooming (to keep an ageing population looking young, and male grooming),
increasing healthcare spending, and increasing sophistication and demand for
environmentally friendly homecare products make these end markets attractive for chemical
companies. In addition to this, the small cost of these chemical ingredients in the overall cost
of the end consumer product, along with the continued product innovation give these
chemical companies decent pricing power.
Croda High Skin care, sun care, hair care, baby care, colour cosmetics, male Inorganic UV absorbers, lanolins, emollients, polymers,
grooming, bath and shower and antiperspirant markets proteins, surfactants and skin care actives
Laundry, household, industrial and institutional cleaning Proteins and their derivatives, softeners, surfactants,
applications, as well as for wipes, tissues, nappies and hygiene solvents, emulsifiers, solubilisers, hydrotropes, tissue
articles lotions, botanical extracts, fatty acids and glycerine
BASF Medium Hair/Body, Oral Care, Home Care, Skin Care, -Industrial and Additives for 2 in 1 shampoos, detergents for baby
Institutional Cleaning shampoos, additives for liquid soaps, lipid layer enhancer
& moisturizers, cold processable pearlshine concentrates,
sensitive skin laundry detergents, Sensitive skin fabric
softeners, additives for easy ironing/less wrinkle claims,
special low foaming surfactants for multifunctional
automatic dish detergent, additives improving gloss and
performance of cleaners Face care products like light
touch products by gel-cream structure, mild systems for
sensitive skin, color cosmetics e.g. face and eye make-up,
lip sticks, Sun care products, Emollients that improve
solubility of UV filters, sprayable sun care concepts,
Foaming / Defoaming Surfactants, multifunctional
polymers for hard surface cleaners, laundry detergents
AkzoNobel Low Hair care, skin care and sun care, soups, disinfectants, plastics, Surface-active agents which are used to mix or separate
soaps, detergents, cosmetics two different materials
Givaudan High Fragrances for air care, laundry care, home care products and fine Fragrances for shampoos, soaps, deodorants, body
fragrances lotions, candles, air fresheners, laundry detergent and
fabric softeners, perfumes and colognes
Symrise High Personal care, household, dental care, and pharmaceuticals Fragrances for personal care, household, dental care, and
pharmaceuticals
Clariant Low Laundry detergents and household cleaning products Cleaning agents, stain removers, laundry detergents,
dishwasher detergents, liquid all-purpose cleaners, liquid
metal /ceramic cleaners, sanitary cleaners
Rhodia Low Beauty, Hair & Skin Care, Home & Fabric Care, Industrial & Ingredients for personal care and home care products
Institutional Cleaning
DSM Low Skin care, sun care, hair care Ingredients for personal care products
Source: Deutsche Bank
Western Europe
28% Asia Pacific
25%
Australasia
1%
Eastern Europe
7%
North America
19%
Latin America
Middle East and 15%
Africa
5%
Long run growth of household care market to be in line with global GDP
The household care market during normal times has historically grown at around GDP and we
forecast the market to grow at this rate in the future moving to 1.5X GDP as emerging market
growth drivers pick up.
Emerging markets are the central growth story for Home and Personal Care
For both Personal and Home Care we anticipate growth being driven by Asia, Eastern
Europe, LATAM and the Middle East. These markets should continue to be the primary
growth drivers in these markets as urbanization, shifts into the middle classes, consumption
patterns and the wealth of emerging countries increase. Furthermore as these consumers
continue to trade up to premium products, margins are likely to increase.
Figure 389: GDP per capita highlights emerging markets growth prospects…
World $10,706
High income: OECD $37,026 Middle East & North Africa (all income levels) $9,885
North America $45,597 Middle East & North Africa (developing only) $7,035
United Kingdom $36,496 East Asia & Pacific (all income levels) $8,960
Germany $36,449 East Asia & Pacific (developing only) $6,073
Euro area $34,127 China $6,838
France $33,655 India $3,275
Spain $32,545 South Asia $2,955
Latin America & Caribbean (all income levels) $10,835 Sub-Saharan Africa (all income levels) $2,118
Latin America & Caribbean (developing only) $10,590 Sub-Saharan Africa (developing only) $2,094
Source: The World Bank, (PPP current international $)
Figure 390: Private consumption in China should be Figure 391: …spending by global middle class to grow
above current US levels by 2020….. exponentially (millions of 1995 PPP $)
Water Treatment
Water treatment technologies and products are used to purify, supply, recycle and dispose of
water. Treatment chemicals are used all along the chain from water sourcing to waste
disposal. The nature of pollutants is well-known (minerals, metals, organics and bacteria) and
the technologies (chemical, physicochemical, mass transfer and fermentation) currently used
in water treatment are mature.
The water management chemicals market is split into two major categories:
Specialty chemicals, such as ion exchange resins and organic coagulants and flocculants,
and formulated products, including biocides and corrosion and scale inhibitors.
Commodity chemicals such as alum (aluminum sulfate), chlorine, ferric sulfate, ferric
chloride and polyaluminum chloride.
Figure 392: World consumption of water management Figure 393: Global water supply & demand [bn m3]
chemicals by region (2010)
Global water management industry growth is dependent on (1) regulatory drivers, (2)
industrial development requiring high-quality process water, and (3) drinking water
improvement projects in part motivated by drinking water scarcity. Items 2 and 3 are
most important in developing nations, particularly in China.
The United States uses specialty water treatment chemicals more intensively than
Europe and Japan—particularly coagulants and flocculants. In Western Europe and
Japan, engineering and technical solutions are preferred when they can be used as a
substitute for specialty chemicals. When chemicals are used, the less expensive
commodity chemicals such as alum (aluminum sulfate), ferric sulfate, ferric chloride and
polyaluminum chloride are typically used in preference to organic polymers due to cost
although with efficacy of organic polymers continuing to rise – the trend of substitution
is continuing.
Paper Chemicals
Figure 394: Paper chemicals at a glance
Long-term growth rate Sub GDP
Growth rate relative to the sector Below average
Supply/Demand Not that relevant as capacities can be easily expanded and time to build a new
plant is very short (6-12m)
Margin prospects Remaining low with few attractive niches
Watch out for ... Further consolidation, new privately owned capacity additions in Asia
Source: Deutsche Bank
The paper chemical producers make wide range of products which are used by Paper
manufactures to influence paper properties like improved printability, coloration, special
coatings and strength for all kinds of papers and board. Key end markets for chemical
companies in this segment include paper & printing, packaging & board and specialties.
The paper chemical market can be divided broadly into “specialty” and “commodity”
chemicals. World consumption of specialty paper chemicals is estimated at approximately
$15 billion; while consumption of commodity chemicals for pulp and paper production is
around an additional $8 billion.
Specialty paper chemicals can be classified into three groups according to their function and
point of use in the paper production process:
Pulp and fiber treatment chemicals such as bleaching, pulping and deinking chemicals
Processing aids, which are used to improve the efficiency of paper production including
defoamers, pitch-control agents, biocides/slimicides, and retention and drainage aids
Functional chemicals, which are used to impart various properties to the finished
paper, ranging from improved strength and optical properties to enhanced printability
(dry- and wet-strength resins, sizing agents, coating binders and specialties, as well as
dyes, pigments and fluorescent whitening agents).
Commodity chemicals would include chlorine and oxygen, hydrogen peroxide, sodium salts
and sulfuric acid (used mainly in pulp production).
Figure 395: World consumption of specialty paper Figure 396: Global Pulp & Paper Chemicals market by
chemicals by region applications
There can also be classified based on the technologies that the products offer through the
production chain for paper:
Source: BASF
Pulp and Paper chemicals market is largely dependent on the paper industry and hence
reflects the trends in the industry. The global paper industry has been witnessing a lot of
pressure due to increasing substitution in digit media and in plastic packaging.
The recent recession (late 2008 and 2009) had a material impact on the pulp and paper
chemicals industry. The demand of different paper grades decreased significantly in
2009, especially in the traditional markets of North America and Europe. In these
markets, paper demand dropped by about 10-25% approximately, depending on the
grade. Though the markets have now recovered, growth is likely to be modest in Europe,
North America and Japan, while China, South East Asia, East Europe and Latin America
are projected to gain strength
Over the next five years, the world consumption of specialty paper chemicals is
expected to increase at an average annual rate of 2-3% per year (volume basis). The
growth is expected to be slower in the markets of North America, Western Europe and
Japan (all between 1-2% p.a. through 2015) while China should continue to grow at a
fast rate (c. 6% p.a. through 2015). Other emerging markets of Eastern Europe and Asia
are also expected to grow steadily at 3% p.a. during this period.
China’s annual growth rate in paper production and consumption of paper chemicals is
the highest in the world, with a 7% per year gain in paper production since the year
2000. However, China’s consumption of specialty paper chemicals reflects production
dominated by lower-value grades of paper and paperboard, which require less specialty
paper chemicals. The major paper chemicals used in China are hydrogen peroxide,
modified starches, polyacrylamides (PAM) and synthetic sizes. In China, more than 200
companies are involved in paper chemicals production.
To reduce costs and achieve environmental and regulatory compliance objectives, the
use of virgin fibers (especially chemical pulps) and alum is expected to decrease, while
recycled paper fibers, fillers and pigments, and specialty paper chemicals will extend
their share in the raw material mix of the paper and board industry.
While the paper and paper chemical industries have been historically under pressure
from green groups, this has subsided in recent years. There have been no considerable
environmental and/or chemical issues since the late 1990s, when the industry stopped
using elemental chlorine-based bleaching and switched to the dioxide-based bleaching
used now. Consequently, there are no real legislative pressures on the paper industry.
Leather Chemicals
Leather Chemicals markets includes chemicals that are used for tanning, re-tanning, and
finishing of leather products across various stages of the leather manufacturing process.
Leather chemicals demand is directly linked to the developments in the leather goods and
leather processing industry. Beamhouse chemicals, binders, chrome tanning salts, colorants
for wet end and finishing, fatliquor, finishing auxiliaries, patent leather chemicals,
preservatives and retanning chemicals are products manufactured by major players for the
leather markets. Key applications include leathers shoes, automotive, furniture and garments.
Americas
22%
Asia-Pac
46%
EMEA
32%
Source: Lanxess
Global leather chemicals demand was estimated at Euro 2.5bn in 2010. The future
growth is expected to be driven by demand from end-use markets (particularly leather
footwear, automotive and apparel markets), decreasing hide quality and shift to higher
environmental standards leading demand for innovative leather chemicals and steadily
growing meat consumption.
Low growth prospects in the European markets mean that further consolidation in this
area is inevitable.
Leather markets grow slowly but steadily in line with meat consumption. The availability
of raw materials, rather than the end-product sales, is the key determinant of growth
patterns and trends in the leather chemicals market. Global meat consumption is
expected to increase from approximately 67 mt in 2010 to 74 mt in 2018.
We forecast the Asia-Pacific market for leather chemicals to grow much faster over the
next five years due to high availability of raw materials and lower cost of operations.
Thiochemicals
Figure 399: Thiochemicals at a glance
Long-term growth rate 2x GDP
Growth rate relative to the sector Above average
Supply/Demand Currently high and likely to remain high despite large further investments
Margin prospects Should remain high
Watch out for ... Aggressive competition for market share, raw material, strong capacity additions
Source: Deutsche Bank
Thiochemcials are mainly sulphur derivatives with hydrogen often called thiols (thiochemicals)
or mercaptans. The main application for these sulphur derivatives is in methionine (an amino
acid used as an ingredient in mainly poultry but also piglet and ruminant feed) and to a lesser
extent in the polymer, pharma, natural gas odouriser, solvent and petrochemical market. The
main players in the sector are Arkema, Chevron Phillips Chemical, certain local producers for
some products and integrated methionine producers such as Evonik and Adisseo.
Figure 400: Global thiochemicals demand by end market Figure 401: Global thiochemicals demand by region
Methionine is an essential amino acid, which is a basic building block for protein formulation.
It is widely used as a feed additive for poultry and swine in order to promote the growth in an
animal, shorten the feeding cycle and raise the quantity of lean meat.
Figure 402: Global methionine demand drivers Figure 403: Broiler feeds average inclusion rates for
methionine (kg/tonne of feed)
The methionine industry is highly consolidated with 4 players controlling 97% of the market.
Barriers to entry are high due to technical and nutrition expertise requirements, strict
regulations and high capital requirements. Access to key intermediates and raw materials
(such as methylmercaptan and hydrogen sulphide) is also crucial for methionine production.
Figure 404: Methionine total capacities (DL-powder Figure 405: Methionine price chart (European quotes)
equ.)
We expect methionine demand to increase by 6% p.a. globally and 10% in China for
2009-12. This growth should be driven mainly by growth in developing countries as a
result of higher inclusion rates of methionine per kilogram of meat, such that local
production yields can meet rising regional demand.
Capacity utilization is near full capacity (97% in 2010). The new capacity plans over 2011-
15E (see Figure 23) should be just enough to satisfy demand and the market should
remain tight ensuring industry margins should remain high. Adisseo, the world’s second
largest methionine producer, has been achieving stable EBITDA margins of 35%.
Textile Chemicals
Figure 406: Textile Chemicals at a glance
Long-term growth rate Sub-GDP
Growth rate relative to the sector Below average
Supply/Demand Oversupply to continue given low barriers to entry
Margin prospects Remain at a very low level
Watch out for ... Rising labour costs in China, competitive behavior, migration of customer base
Source: Deutsche Bank
The global textile chemicals market had a value in 2010 of about $10bn. Textile chemical
products range from highly specialized chemicals (biocides, flame retardants, water
repellents and warp sizes, for example) to relatively simple commodity chemicals or mixtures
thereof (such as emulsified oils and greases, starch, sulphonated oils, waxes and some
surfactants). Over 60 chemical product classes are used in yarn formation, fabric pre-
treatment and finishing, textile laminating and coating, and other miscellaneous applications.
Textile chemicals represent only a small part of the total yarn/fabric/textile production cost.
Source: SRI
The industry is fragmented which has led to competition. Many companies are privately
owned (often run for cash). The industry is heavily located in Asia (due to the low-cost labour)
and we expect the steady migration of customers to low-cost regions to continue.
Figure 408: Labour costs for Textile Fibre production Figure 409: World production of textile fibres
($/hr)
Other
Americas 7%
6%
India
8%
Asia
79%
Many products exist (over 6,500) and the same function may be served by many products.
These are relatively easy to copy and many interrelated functions are filled by the use of
interdependent groups of products.
The principal reason for the increase in Chinese apparel exports to the United States,
Western Europe and other Asian countries, is the low cost of labour in China. Although
India and Indonesia have low labour costs as well, China is leading in international textile
exports because of its well-integrated network in production and marketing in overseas
markets. However, Chinese labour costs have been increasing rapidly and this may yet
encourage other regions to compete more.
As a result of the relocation of fibre and textile production to Asia and the associated
aggressive price competition, most chemical companies have scaled back or shut-down
their textile chemical operations in developed markets.
Construction Chemicals
Figure 411: Construction Chemicals at a glance
Long-term growth rate 1.25x GDP
Growth rate relative to the sector Average
Margin prospects Low currently but should some improvement (driven by recovery in Western
construction markets)
Watch out for ... Raw materials, new capacities in Asia
Source: Deutsche Bank
Construction chemicals are chemical compounds that are added as such or in formulations to
or on construction materials at the construction site in order to improve workability, enhance
performance, add functionality or protect the construction material or the finished structure
made out of it. They undergo chemical reactions (e.g., cross-linking) or physical changes (e.g.,
solidification from melt) during their application. Construction chemicals are used as
formulated products, so they are handled as powders, pastes or solutions at the site.
Protective coatings – All coatings applied to construction materials will have a certain
protective effect due to the formation of a barrier between the environment and the
underlying structure.
Adhesives and sealants – Adhesives and sealants are important components in building
construction, allowing the bonding of dissimilar materials like glass to metal or insulation
foam to concrete. The amount of labour needed is reduced compared with more
traditional fastening systems like nails, screws, nuts and bolts.
Concrete admixtures – ingredients added to the concrete matrix during mixing as solids
or liquids to improve various properties. These tend to be higher growth than average.
Asphalt additives – Asphalt is a mixture of aggregate with bitumen and some additive.
The bitumen forms a film around the aggregate beads and glues them together.
Additives are used to enhance the aggregate/bitumen interaction and the workability of
the raw asphalt.
Figure 412: Consumption of construction chemicals by Figure 413: Consumption of construction chemicals by
type region
Asphalt
additives Rest of the
4% China
World
27%
Protective 26%
coatings
Concrete 43%
admixtures
26%
Japan
12%
Western
Adhesives Europe
and North 22%
sealants America
27% 13%
Source: SRI Source: SRI
The raw materials needed for the production of construction chemicals are manufactured by
the large chemical producers. Polymers are the most important group of raw materials and
are found in virtually every construction chemical formulation, ranging from adhesives to
waterproofing treatments. Growth in construction chemicals is driven by demand for
materials with improved functionality and sustainability, allowing for differentiated building
materials and reduced total construction cost (material and labour).
Synthetic resins are intermediate products used to impart a particular characteristic to the
final product, for example heat-resistance, molecule binding or adhesive qualities. They are
used in a large number of products including inks, paints, coatings and electronic
components.
Synthetic resins are produced via the polycondensation (to make a thermosetting resin) or
polymerisation (for a thermoplastic resin) of different types of monomers. Thermosetting
produces infusible or insoluble products, which are most commonly used in non-moulded
applications such as industrial paints and varnishes, coatings, casting compounds, laminates
and adhesives.
The choice of monomer raw material depends on the end usage, but is wide ranging.
Monomers include melamine, methanol, urea, polyester and phenol to name but a few. For
example,
Epoxy resins have good adhesion properties, strength, little shrinkage and good heat
resistance. They find particular applications in adhesives for aeroplanes, cars, spacecraft,
and so on. Their electrical properties also mean they are used as an adhesive for semi-
conductor chips.
Amino resins (urea or melamine based) have an extreme surface hardness and
resistance to discoloration and fire. Melamine resin is commonly used for kitchen and
table surfaces.
Phenolic resins have good stability in heat and a resistance to chemical corrosion and
moisture penetration. This resin tends to be used for electrical components, brake linings
and rubber resins.
Other Types of Resin Include:
Urethane resins (which include isocyanates and polyisocyanates largely used in paints).
Polyester resin (coatings, plastic products, and others).
Alkyds (used for electrical insulation, electronic components, paints, and others).
Architectural
coatings
7%
M elam ine resins
for surfaces
4%
Phenolic resins
11%
Resins for
Foundary resins
structural
1%
com posites
Resins for insulationand 45%
friction m aterials 1%
The final composition of the resin involves adding fillers, additives, and pigments depending
on the end product application. In some cases fibres can be added in order to provide
reinforcement.
There are many resin producers globally. Most producers concentrate on resins using one or
two raw materials only: the type of resin produced is usually dependent on the chemistry of
the company or a similar end-use application. For example, paint companies such as Akzo
Nobel tend to be involved in the production of resins used in paints.
DSM Rohm & Haas Evonik GE also jv with Bayer and Toshiba
Lonza Evonik Lyondell Dow Corning
Arkema DSM Bayer Wacker
AOC Ineos Shin-Etsu
Ashland CYRO Cytec and Evonik Evonik
Cook Composites & Polymers Spartech
Eastman
Phenolic resins Epoxy resins Amino Resins urea formaldehyde, melamine Alkyd resins
formaldehyde
Borden 4 Dow BASF DSM
2 3
Dynea Huntsman TOTAL Eastman
Georgia Pacific Resolution Performance Products Borden Borden
Cytec Arkema
Georgia Pacific Dyno
Neste 1
Solutia
Chimica Pomponesco
(1) In Europe through a 96% participation in Krems Chemie; (2) Former assets of Neste and Dyno which were merged in 2000; (3) In 2003 Huntsman bought Vantico the former Performance Polymers business of Ciba;
(4) IncludingBakelite
Source: Company data
Resin demand is being driven by replacing metals and construction materials with light
with more light weight substitutes and development of legislation in the US and China
following European eco-friendly legislation.
In specialty resin markets, profit levels depend more on the properties than the costs of
production. Technical support and innovation remain important drivers of future growth
in this business.
There has been a structural move to waterborne resins, powder and UV curing resins
and away from traditional solvent based (high VOC)
Paints (coatings)
Figure 417: Paints at a glance
Long-term growth rate GDP
Growth rate relative to the sector Average
Supply/Demand Selectively improving
Margin prospects Stable
Watch out for ... Further consolidation
Source: Deutsche Bank
Paint, also known as coatings, is usually a formulation of a finely divided pigment (for opacity
and colour) dispersed in a liquid composed of a resin or binder and a volatile solvent (e.g.
organic solvent or water).
Radiation
curables Other
Powder 2% 2%
5%
High Solids
8%
Conventional
Waterborne
Solventbornes
Industrial
42%
9%
Waterborne
Emulsions for
architectural
32%
Paints have a wide range of uses from interior decoration to marine and aerospace
applications. The different sub-sectors of the paints industry vary considerably in their
structure and key players. Packaging coatings, automotive OEM (original equipment
manufacturers), aerospace and marine coatings, for example, are truly global markets
dominated by a handful of participants. Other markets such as those for industrial, coil and
automotive re-finish have, to date, tended to be regional in emphasis and, as such, more
fragmented, although even here consolidation is increasingly seeing the creation of global
suppliers.
By volume the largest coatings market is that of decorative or architectural paints (typically
for use in the home). These consumer-oriented businesses account for roughly 50% of global
coatings demand. Decorative coatings are used in both the professional and do-it-yourself
(DIY) markets. Although regional in nature, consolidation within this part of the industry is
gradually seeing the emergence of global producers, building globally recognised brands (for
example AkzoNobel’s Dulux).
On a regional basis the largest market for coatings is the US, this is a factor not just of its
population but also its consumption per capita which is towards the top end of the range for
most countries. This market is largely a result of the large decorative/architectural market.
China, Japan, Germany, Brazil and Korea are also significant.
Figure 420: World production of paint and coatings Figure 421: Per capital breakdown of paint consumption
of selected countries
Kg/capita
Oceania Singapore 18.0
1% North
America US 18.3
19%
Canada 15.2
Asia Germany 19.7
Central and
39%
South
Sweden 17.0
America
6% Italy 18.5
United Kingdom 14.9
Raw material costs for coatings typically account for about 50-55% of sales revenue.
Significant within this are the costs of titanium dioxide at 20% of sales (see later section),
resins (15%), solvents (5%) and packaging for the container (5%).
Automotive OEM – Paints and services for OEM buses, trucks and specialized
commercial vehicle builders
Automotive refinish – Paints and services for collision repairers and commercial vehicle
refinishes
Architectural – Interior and exterior wall paints and trim paints (lacquers) for consumers
and professionals
Aircraft – External and internal coatings for commercial, general aviation and military
markets for both OEM application and maintenance and repair
Decorative paints
42%
Powder coatings
7%
Auto refinish
7%
Protective coatings
8%
General industrial
8% Automotive OEM
10%
Source: Deutsche Bank, Akzo Nobel, SRI
12%
10%
8%
6%
4%
2%
0%
AkzoNobel PPG Sherwin DuPont BASF Nippon Paint Valspar Kansai Paint Jotun Masco
Williams
Source: Akzo Nobel, Deutsche Bank
Consumer coatings are geared to disposable income, maintenance spend, DIY and
housing transactions more than construction.
Other end uses can also offer higher growth, e.g. aerospace 4-5%, as well as new
technologies, e.g. powder coatings 4%. Water borne coatings are seeing faster growth
than solvent based paints.
Post a period of heavy pricing competition in the US in the 1990s (in order to be the
primarily supplier to the main DIY retailers) manufacturers have become more disciplined
attempting to differentiate on quality.
Due to the seasonality of the business and lag in passing on cost inflation, raw material
inflation has the potential to place particular pressure on margins in the short term.
This coatings market has seen considerable consolidation over the past 10-15 years (see
below). This has been to take advantage of the very large economies of scale in this area
from not just production but also marketing and distribution. The market remains
fragmented, however – 60% of Asia is serviced by small to medium sized producers
(20% and 35% in US and Europe respectively).
Sector characterized by consolidation
Akzo Nobel bought Courtaulds paint (and fibre) operations in 1998. DuPont purchased the
Herberts Group from Hoechst (Germany) in 1999. With the acquisition, DuPont became a
major supplier of powder coatings and waterborne base coats for automotive OEM. In 1999,
Sigma merged with Kalon as a result of the ATOFINA-Total merger. In 1999, Valspar acquired
Dexter’s container coatings business and expanded its operations in Europe and its share of
the worldwide container coatings market to over 30%. In 2000, AkzoNobel acquired the
coatings business (mainly aerospace coatings in the United States) of Dexter (sales of $47m
in 1999). In 2002, Ferro sold its powder coatings business to Rohm and Haas (European
business) and to AkzoNobel (North American business). Rohm & Haas paid $60m for a
business with about $75m in annual sales. Akzo paid $73m for a business with about $80m
in annual sales. In 2003, Bain Management (financial interests) acquired SigmaKalon for Euro
1bn. In 2004, Sherwin-Williams acquired Duron Inc., which mainly produces and markets
architectural coatings. Annual Duron sales were $350m, focused on serving the professional
and do-it-yourself (DIY) markets in the eastern United States and they operate 230 company
owned stores. In 2004, Comercial Mexicana de Pinturas (COMEX) acquired Professional Paint
in the United States, which had sales of about $500m per year. Professional Paint, formed in
2000, is the parent company of seven medium-sized paint manufacturers and marketers of
architectural coatings in the Western United States and Canada. Most recently there have
been two large acquisitions with PPG acquiring SigmaKalon at the start of 2008 to expand its
European decorative coatings presence. At the same time AkzoNobel completed the
acquisition of ICI, again expanding its presence in decorative coatings and also increasing its
emerging market exposure.
Adhesives
Figure 425: Adhesives at a glance
Long-term growth rate GDP+2%
Growth rate relative to the sector Slightly above Average
Supply/Demand Not applicable
Margin prospects Reasonable long-term
Watch out for ... Further consolidation globally
Source: Deutsche Bank
An adhesive is a material used to bond two solids together. There are hundreds of adhesive
preparations on the market, supplemented by hundreds of available formulations targeted at
varied end uses. The three largest end-user markets are packaging, construction and
furniture/woodworking, which form over 65% of total revenues.
There are three types of adhesives. Animal adhesives are a mature market and mostly
focused in developing countries. The global chemical businesses tend to focus on the much
larger, faster growing and more specialty markets of starch and synthetic adhesives.
Animal Glues (protein glues). These are the oldest type of adhesive and are made from
animal bone. These are used for example in the woodworking industry and in the
manufacture of drinking cups and ice-cream containers.
Starch Adhesives. These adhesives are made from cornstarch, tapioca flour, wheat
flour and potato starch. Starch adhesives can be applied cold and do not have the
undesirable characteristic odour of some animal glues. Disadvantages include less
strength and lower water resistance. Starch adhesives are less costly than synthetic-
resin adhesives. Starch adhesives can be used for veneers, plywood, postage stamps,
and can be further modified into glues for glass and metals.
Synthetic Adhesives. These are used where water resistance is required and/or other
special conditions must be met. Synthetic adhesives can either be: rubbery thermosets
(mainly used as sealants, that is fastening materials together to exclude weather or
gases); thermoplastics (most hot-melt, non-solvent glues including polyamides, rubber-
based, polystyrenes, acrylates, vinyls adhesives); or a combination of both (to obtain
better properties than those achievable with single components, for example good
adhesion and high-temperature resistance). Raw materials for these products are wide
ranging, but include ethylene, formaldehyde and urethanes.
Adhesives may also be categorised by their end markets which all have different growth
rates and profit drivers.
North America
24%
Asia/Pacific
31%
Africa/Middle
East Western Europe
4% 28%
Latin America
5%
Eastern Europe
8%
Source: Henkel
4
$bn
0
Henkel ICI* H.B. Fuller Huntsman Bostik Dow 3M
Findley
Source: *2006 figure, acquired by Akzo Nobel, Company data and Deutsche Bank estimates
With the continued growth in the use of plastic parts in transport vehicles and
construction, engineering adhesives are forecast to see strong growth. Other significant
growth opportunities include increased use in electronics and in medical situations and
clean energy technologies (solar panels & wind turbines).
Emerging markets will be a prime source of growth for adhesive manufacturers. The
shoe sole market, particularly in Asia remains an area of potential.
Industrial adhesives are forecast to prove more dependent on economic activity for
growth. The growth of solvent free adhesives for food applications, OEM, motor
vehicles and laminating are expected to see stronger growth rates.
Source: Henkel
Demand for consumer adhesives should be more stable and less vulnerable to
fluctuations in economies. Growth in this area is based on marketing, branding and new
innovations such as improved applications (increased ease of use) and formulations (less
solvents, more 'child friendliness').
This industry has seen a large amount of restructuring over the past seven years, with
the top ten companies purchasing many small adhesive producers. As with the markets
for coatings, size offers considerable economies of scale. Market fragmentation also
offers good scope for growth through acquisition. Further consolidation is likely.
Inorganic chemicals
The chlor-alkali industry – chlorine and caustic soda
The chlor-alkali industry, which produces caustic soda, chlorine and soda ash, is one of the
largest chemical industries by value. The applications of its products are so diverse that the
majority of all consumer products will have some stage of their production dependent on
them.
Caustic soda (NaOH) and chlorine (Cl2) are mainly produced as co products by the electrolysis
of brine (salt solution or NaCl). They are produced in a ratio of 1 unit chlorine to 1.1 of caustic
soda. However, both can be produced by alternative methods. Chlor-alkali is an energy
intensive industry with electricity typically accounting for 40-50% of variable production
costs.
Figure 431: Manufacture of chlor-alkali products Figure 432: Electrolysis - The production of caustic soda
and chlorine
Cath ode (ne gati ve ) An o de (p osi ti ve)
attr acts Na+ attr acts Cl -
chlorine (Cl2)
causti c
chl or i ne
soda a nd
hy dr o ge n
brine solution Electrolysis
br ine
caustic soda (NaOH)
As the production and thus pricing of both chlorine and caustic soda is much linked, both are
often referred to as one unit called an electrochemical unit (ECU) – ECU price, ECU margin
etc. Producers also use the ECU as a cost/productivity yardstick to monitor efficiency and
costs. As the ratio for the production of the two products is fixed, the pricing of each
commodity can be volatile when demand for one product is out of balance with the other.
Caustic soda is an important component in the petroleum, alumina and pulp and paper
industries. It is also used in a wide range of chemical processes. Chlorine has a wide variety
of applications, with its largest being the production of PVC and organic chemicals. Earlier It
was also used in the pulp and paper industries as a bleaching agent, but this type of
bleaching has largely disappeared in North America and Western Europe because of
environmental concerns. Some large users of caustic soda, such as paper mills, may install
facilities that allow use of either caustic or soda ash; the choice will depend on the cost per
unit of Na2O. The potential for switching is estimated at 200-300kt per year in the United
States. Strictly from the standpoint of economics, soda ash becomes a feasible substitute for
caustic soda when the delivered price of caustic soda (50% basis) is more than 1.5 times the
delivered price of soda ash.
The chlorine industry has been under considerable pressure from an environmental
perspective - chlorine and its derivatives are considered by some as harmful. Most of these
negative effects have already been felt and there are now substitute products for many
applications of chlorine and chlorine derivatives. However, production of these alternatives is
not yet cost effective.
Miscellaneous
Siding, Flooring,
PVC Shower Curtains,
Resins Pipe
Ethylene Dichloride, & Other
Chlorinated Ethanes
Dry Cleaning,
Solvent Metal Cleaning,
Chlorinated Dyes, Degreasing
Pesticides
Benzene
Chlor-Alkali
Plant
Coatings,
Epichlorohydrin Epoxy Adhesives, Printed
Resins Circuit Boards
Water
Treatment Other Chemicals
Soaps, Detergents,
Caustic Cleaners
Soda
Water Treatment
Oil
Refining
Miscellaneous
Miscellaneous
Figure 434: End uses of chlorine (2010) Figure 435: End uses of caustic soda (2010)
Organics
Others Others
Vinyls 17%
32% 24%
35%
Inorganics
2%
Pulp &
Pulp & Paper
Water
Paper 15%
Treatment
2% 5%
Figure 436: Geographical breakdown of demand for Figure 437: Geographical breakdown of demand for
chlorine (2010) caustic (2010)
C. Europe &
Africa & Mid- S. America
CIS
East 3% Africa & Mid-
4%
4% East
C.
S. America 4%
Europe/CIS
4% 6%
W. Europe
Asia Asia
16% W. Europe
53% 52%
15%
N. America
20% N. America
19%
There are three main production techniques for caustic-chlorine, all of which use brine as the
raw material. Over the last few years there has been a trend away from the older mercury
cell production towards more environmentally friendly production processes.
Mercury Cell. This is the oldest method of production and until the mid-1980s was the
dominant method because of the high quality of the product produced. In a mercury cell,
chlorine is collected at the anode (the positively-charged end of the cell) and mercury is
used as the cathode (the negatively-charged end of the cell) which is at the bottom of an
inclined reactor tank. The mercury amalgam (a sodium mercury compound, Na-Hg) is
then transferred to another vessel and water is added. The reaction which takes place
produces caustic soda, hydrogen gas and the mercury is regained. The extent to which
mercury is recovered from water is very important environmentally, as even a partial
mercury discharge in the water table is unacceptable. As a result of this, the technology
shift has already taken place in Japan, where all capacity has been converted from
mercury or diaphragm cell technology to membrane cells. However, the change of
process technology in Western Europe has been slow as clean-up costs of closing down
such a cell are significant and generally poor investment cycle. Of the three methods
outlined, this method consumes the greatest amount of electricity (3.2-3.6 megawatt-
hours per metric ton ECU), and production costs are approximately 30% higher than for
membrane cell technology.
Diaphragm Cell. In the diaphragm cell, chlorine, hydrogen and sodium hydroxide are
produced simultaneously. This type of cell contains a diaphragm, usually made of
asbestos fibres, which helps to keep the caustic soda and chlorine separate once
produced. A major advantage of the diaphragm cell is that it can use fairly impure brine.
However, this produces caustic soda which contains a high concentration of brine, and a
great deal of electricity is consumed in concentrating the end product (approximately 3.4-
3.8 megawatt-hours per metric ton). Diaphragm cells continue to be used where
inexpensive brine is available or where cogeneration of power and steam provides
inexpensive steam. However, the technology has been clearly surpassed by membrane,
hence, very little new diaphragm capacity has been added in the last fifteen years.
Membrane Cell. The membrane cell also contains a barrier to keep the caustic soda and
chlorine separate, but it is more effective, since it selectively allows the movement of
sodium ions (Na+) from the anode chamber to the cathode chamber. Membrane cells
use more concentrated brine and produce a more concentrated product. The product is
also purer, since brine is added to the electrolysis cell on the anode side, that is, no brine
enters the cathode chamber, so the product has very little salt impurity. It is also the
most energy efficient method with total energy required is 2.15-2.57 megawatt-hours
per metric ton ECU. As energy costs tend to escalate, the motivation to switch away
from diaphragm cells increases.
Most new plants will be based on membrane cells, because of production economics and
environmental considerations. Today almost all of the Japanese capacity is based on
membrane cells.
Chlor-alkali capacity additions reached a high point in 2008-2010. New capacities and
lower demand in 2008-2009 due to the world economic recession caused operating
rates to decline to 75% in 2009 for chlorine. Now with improving demand scenario,
operating rates in chlorine production are anticipated to improve gradually from 77% in
2010 to 84% by 2015 also driven by restricted capacity additions. Through 2011-2015
only 8.2m tonnes of new capacity have been announced (mainly coming in China) due to
the already high capacity situation in the Chlor-alkali markets.
Currently, majority of the new world capacity of Chlor-alkali is coming up in China. This is
expected to be 2/3 of the total new capacity on average. These capacity expansions have
been driven by their strategy of becoming self-sufficient in PVC and also to leverage its
domestic resources of coal, limestone and salt to produce chlor-alkali. North East Asia is
now and will continue to be the largest producing and consuming region for Chlor-alkali.
In 2008, the US ECU price and margin seems to have peaked, declining from then due to
excess capacity and lower than normal operating rates as the economy recovers from
the recession. On our current estimates the market is forecast to trough in 2013,
beginning to rise again from 2014. In Europe, ECU margins dropped considerably. We
anticipate cash costs to increase and remain higher than historical in Europe through
2015. Margins should improve gradually through 2015 as excess chlor-alkali and vinyls
capacities are absorbed however the margin peak should come only around 2015.
Figure 440: Supply/demand and capacity in chlorine Figure 441: Supply/demand and capacity in caustic soda
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Nameplate Capacity (000 mt) Operating Rate,% Nameplate Capacity (000 mt) Operating Rate,%
2005
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
-150
ECU asset sharing value (West Europe) U.S. Europe Northeast Asia
Figure 444: Top 10 producers Chlorine Figure 445: Top 10 producers caustic soda
9% 9%
8% 8%
7% 7%
6% 6%
5% 5%
4% 4%
3% 3%
2% 2%
1% 1%
0% 0%
Solvay
Dow
Bayer
AkzoNobel
TOSOH
Olin
PPG
Occidental
Ineos
Formosa
Dow
Solvay
Bayer
AkzoNobel
TOSOH
Olin
PPG
Occidental
Ineos
Formosa
Figure 446: Global capacity additions, chlorine(%) Figure 447: Global capacity additions, caustic soda (%)
7% 8%
6% 7%
5% 6%
5%
4%
4%
3%
3%
2%
2%
1% 1%
0% 0%
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2006
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
Source: CMAI
Soda ash
Figure 448: Soda ash at a glance
Long-term growth rate Sub-GDP
Growth rate relative to the sector Below average
Supply/Demand Very modest capacity additions but with only low growth prospects
supply/demand balances are unlikely to show a material increase
Watch out for ... Consolidation and emerging markets shift
Source: Deutsche Bank
Soda Ash (sodium carbonate) is used in the manufacture of glass, pulp and paper,
detergents, and chemicals such as sodium silicates and sodium phosphates. It is also used
as an alkaline agent in many chemical industries. Domestically it is used as a water softener
during laundry.
Others
Pulp & paper
9%
2%
Flue gas
desulfurization Chemicals
4% 28%
Others Glass
5%
Soaps &
detergents
10%
Since caustic soda can be substituted for soda ash in certain uses (particularly in pulp and
paper, water treatment, and certain chemical sectors), the pricing of the two are linked. It
should be noted that soda ash is more influenced by caustic soda than vice-versa because
caustic soda production is often a by-product of the production of chlorine (which is required
for PVC).
Figure 450: Caustic soda/soda ash relationship Figure 451: Caustic soda/soda ash prices (US$/tonne)
800 380
700
Salt + Water Trona Limestone + Salt
600 330
electrolysis refining
500
400 280
Chlorine Caustic Soda Soda Ash 300
200 230
100
VCM
0 180
Jul-2005
Jul-2006
Jul-2007
Jul-2008
Jul-2009
Jul-2010
Jan-2005
Jan-2006
Jan-2007
Jan-2008
Jan-2009
Jan-2010
Jan-2011
PVC Chemicals Detergents, Pulp & Paper Glass, Metals & Mining
The natural process involves mining trona ore and then refining it to produce soda ash
(sodium carbonate Na2CO3). Trona can be mined by conventional mining techniques
(similar to those used in coal mining) and by solution mining (a technique developed by
FMC). Solution mining is where trona is collected in solution. The trona is obtained from
the solution and then can be treated in the same way as a traditionally mined ore.
Two processes are used to convert trona to soda ash. One produces dense soda ash,
the other light soda ash. Each have different properties, and as a result are used in
different applications. Dense ash is the preferred type for glass manufacture and light
ash is favoured in dry detergent compounds and applications which involve dissolving
the ash. Environmental issues are raised in the production of soda ash via this process.
The synthetic process is also known as the Solvay process. This is the combination of
limestone (CaCO3) and salt (NaCl) to produce soda ash with the production of additional
by-products. The principal byproduct of the Solvay process is calcium chloride (CaCl2) in
aqueous solution.
This process is expensive due to high-energy requirements, higher operating costs and
problems associated with waste disposal. Environmentally, the biggest problem is the
effluent containing highly visible pollutants. These pollutants eventually settle to the
bottom of the solution, so the milky-white effluent is stored in large reservoirs and the
overflow is sent to nearby surface waters. A number of these problems have been
somewhat relieved by process modifications developed in Japan.
Figure 452: Manufacture of soda ash from natural Figure 453: Manufacture of Soda Ash by the synthetic
sodium carbonate Solvay process
Rec ycled am monia
am m oni a (NH 3 )
amm onium chloride
Brine
(sodium chloride NaCl) soda ash
sodium bicarbonate
carbon dioxide CO 2
Recycled CO2
On the whole, the natural process is cheaper than the synthetic, since it does not have a
high-energy requirement or environmental problems. However, the natural process requires a
source of the ore to be nearby (or faces high costs for transportation of the ore), which
generally means that plants implementing the natural process are found in remote areas, thus
incurring high distribution costs.
In the production of soda ash, US producers have a substantial cost advantage over their
West European competitors due to the presence of large trona ore deposits in the US (mined
from deposits near Green River, Wyoming by traditional and solution mining). Such deposits
do not exist in Western Europe, thus originally forcing European producers to use the
synthetic process. The North American producers are often referred to collectively by the
name of their trade organisation, ANSAC, the Association of North American Soda Ash
Companies.
Over the last ten years the industry has seen (much needed) consolidation and
rationalisation. FMC acquired Texas Gulf (from Total) in 2000. In 2002 Rhodia sold its
assets to Bain Capital (venture capital). In 2005 India’s GHCL acquired a majority stake in
SC Bega Upsom (Romania), and Solvay closed 162kt capacity in Austria, and a 204kt
plant closed in Russia. In 2007, Nirma Group acquired US-based soda producer, SVM. In
2008, Tata Chemicals acquired General Chemical Industrial Products making it the
second largest soda ash producer.
Pricing in Europe is predominantly made through annual contracts (Jan 1st) whereas in
the US it is shorter-term.
Though 2010 capacity utilization increased to a high level of 90% (from high 90s in 2008
and around 80% in 2009). This is a result of steady demand and more restricted supply
in Europe and the US. Chinese companies have expanded synthetic capacity rapidly in
recent years accounting for over 35% of the global capacity in 2010.
We project world soda ash consumption to grow at around 3-4% p.a. for the next five
years. However, growth rates will vary from highs of 5% for Asia and 2% for Central and
South America to a flattish development in North America and Europe.
25.0 100%
90%
20.0 80%
70%
15.0 60%
50%
10.0 40%
30%
5.0 20%
10%
0.0 0%
Asia
Australia/Oceania
Commonwealth
South America
North America
of Independent
Middle East
Central and
States
Titanium dioxide (TiO2) is produced from mined naturally occurring compounds and is the
standard white pigment used principally in paints, paper and plastics. It is the most important
pigment in the world, accounting for approximately 70% of total volume. It enhances
brightness and opacity in products such as paints and coatings, plastics, paper, inks, fibres,
food and cosmetics. As well as having dielectric properties, titanium dioxide also possesses
high ultraviolet absorption and high chemical stability. This allows it to be used in specialty
applications, such as electro-ceramics and glass.
Coatings
Plastics 57%
23%
Source: Kronos
Figure 458: Major world producers of titanium dioxide Figure 459: Worlds most important deposits of basic
feedstocks raw materials use to manufacture TiO2
Rio Tinto
Other 20%
23%
Du Pont
2%
RECYCLED
RECYCLED
Figure 461: Market share of titanium dioxide production Figure 462: Consumption of titanium dioxide by region
2009
Middle East
Central & & Africa
Other DuPont Eastern
23% 6%
37% Europe
6%
Latin
America
Cristal 8% Asia-Pacific
(Saudi) 40%
14%
North
Tronox Kronos America
7% Huntsman 10% 18% Western
9% Europe
22%
Source: Kronos Source: TZMI
Figure 463: TiO2 Global Supply/demand model Figure 464: North America TiO2 prices ($/lb)
$0.70
1990
1992
1994
1996
1999
2001
2003
2006
2008
2010
Figure 465: TiO2 capacity additions Figure 466: TiO2 demand still trails GDP
10%
8%
6%
4%
2%
0%
(2%)
(4%)
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012E
2014E
Source: Deutsche Bank Source: TZMI Database, Consensus Economics
Supply is likely to continue to remain tight over the next few years but we expect that
capacity is likely to grow at 2-3% per annum over the next few years. From 2015
onwards we are likely to see new raw material and TiO2 capacity coming on-stream with
capacity growth potentially rising to over 10%pa for at least two years
The drive toward consolidation is forcing the titanium dioxide industry to adopt a more
global focus, but also to deal with larger customers that wield greater power. The
coatings companies that provide architectural coatings, in turn, are pressured by the “big
boxes” (e.g., Home Depot, Loews, and other large warehouse-type retailers) to minimize
prices.
Hydrogen peroxide
Figure 468: Hydrogen peroxide at a glance
Long-term growth rate GDP
Growth rate relative to the sector Below average
Supply/Demand Oversupply due to capacity in Russia & Ukraine and sluggish paper market
Margin prospects Low
Watch out for ... New applications for propylene oxide production, new capacity additions in Asia
Source: Deutsche Bank
Hydrogen peroxide (H2O2) is a colorless, syrupy liquid that is a strong oxidizing agent and, in
water solution, a weak acid. It is the most commonly used peroxide compound. Its largest
market is in the production of paper pulp. It is also used as a reactive agent (reagent) for
chemical synthesis, the detoxification and purification of water and effluent, an antiseptic and
in the manufacture of cosmetics and pharmaceuticals.
The advantages of using hydrogen peroxide for bleaching pulp are two-fold:
Improved environmental implications are a very important factor. Due to this, hydrogen
peroxide, which decomposes into water and oxygen, is replacing other oxidising
compounds, such as chlorine, in pulp bleaching and other applications.
Figure 469: End uses of hydrogen peroxide Figure 470: Hydrogen peroxide market
Environme Specialty
ntal/ Mining Solvay
grades and
16%
applications other
4% 7%
Other
Textiles 41%
10% Degussa
14%
Pulp &
Paper mills
48% Arkema
Chemicals 9%
and Mitsubishi FMC
Laundry 3% Kemira Eka 6%
products 5% 6%
31%
Source: SRI Source: SRI
Hydrogen peroxide is usually produced using alkylanthraquinone and the addition of hydrogen
gas and air in two separate additions. Theoretically, only hydrogen is required as a feedstock.
Within the production process, air is used as the oxygen source and alklylanthraquinone is
regenerated.
New technology is being developed to allow the direct production of hydrogen peroxide over
a catalyst, that is, avoiding the requirement of alkylanthraquinone. In this case, oxygen, and
not air, must be added for the production of a pure product.
Hy dr ogen Ox ygen
Recy cled
alkylanthraquinone
We expect demand for hydrogen peroxide to grow in line with GDP at best – we expect
supply additions to broadly match this level of demand growth so see limited prospects
for a material tightening of operating rates in the medium-term.
Main regional growth driver is Asia (especially China) where bleach substitution is on-
going. The substitution of bleach in the US and Europe is complete. We forecast growth
in Europe and the US to be in-line with pulp and paper industry (sub GDP).
The hydrogen peroxide market is currently quite tight in Europe as European customers
(particularly in paper) have benefitted from stronger exports to Asia.
In Europe and Asia we expect future growth for hydrogen peroxide to come from a new
production method for propylene oxide (PO) a raw material for polyurethane. Solvay is
currently building a 330kt plant as a JV with Dow Chemicals in Thailand for this purpose
due to come on-stream in Q3 2011.
1000
800
600
400
200
0
Europe China North Central & Japan Africa & CIS India Other
America South Middle Asia
America East
2008 2013E
Source: SRI
Agribusiness
Agrochemicals
Figure 473: Agrochemicals at a glance
Long-term growth rate 2-3%
Growth rate relative to the sector Below the chemical sector on average but above for innovative products
Supply/Demand Not applicable
Margin prospects High and stable
Watch out for ... Possible subsidy reform in the US & EU, Tighter regulations on agrochemical
usage (eg EU), Biofuels, On-going penetration of GM crops
Source: Deutsche Bank
Agrochemicals are used to protect plants from weeds, pests and diseases in order to
maximise farm yields. Agrochemicals are also called ‘crop protection’ products. They
effectively maximise a plant’s ability to absorb vital nutrients by limiting competitive pressure
and keeping it healthy.
Seed Treatment (with insecticides and/or fungicides) for the protection of seeds at
planting.
Fungicides
26%
Herbicides
42%
Insecticides
27%
In 2010, the global agrochemical market was valued at $40bn. Agrochemicals are used on a
global scale but the highest usage rates are in Far East (particularly China), Latin America,
North America and West Europe. Agrochemicals are used across a wide range of crops, with
fruit and vegetables, cereals, soybean, rice, maize and cotton the most important.
Figure 475: Agrochemical market by region (2011E) Figure 476: Agrochemical market by crop (2011E)
Figure 477: Global agrochemical market shares (2011E) Figure 478: Farmer production costs (2011E)*
Source: Deutsche Bank, Cropnosis Source: USDA * wheat production. Note: Power & Machinery include repairs
The global agrochemical market is dominated by six major players: Bayer, Syngenta, BASF,
Dow, Monsanto and DuPont. These companies account for over 80% of the market.
Figure 479: The Market -Who does what and where (2010 Sales $m)
2010 ---------- By agrochemical product --------- --------------------- By region ---------------------
Company Total Herbicides Insecticide Fungicides Others Bio-tech Europe N. Am LatAm Asia ROW
Syngenta 8,878 3,295 1,475 2,662 1,446 Yes 2,649 (1) 2383 2300 1546 0
(1)
Bayer 7,286 2,579 1,817 2,083 808 Yes 2,693 1,268 1,971 1,354 na
BASF 5,350 1,870 1,173 2,307 0 Yes 2,033 1,337 1,391(1) 588 na
Dow Agrosciences 4,072 2,357 491 805 419) Yes na na na na na
Monsanto 2,891 2,029 na na na Yes na na na na na
DuPont 2,453 1,090 818 545 0 Yes na na na na na
(2) (2) (2) (2)
Sumitomo Chemical 2411 798 919 533 162 na na na na na
Makhteshim-Agan 2,362 1,191 631 470 71 966 404 540 na 453(3)
Nufarm 1991 1489 (2) 149(2) 103(2) 250(2) 436 508 313 733 na
FMC 1,242 559 596 87 0 159 (1) 252 629 202 na
Source: Deutsche Bank, Cropnosis, (1) Includes Middle East and Africa, (2) DB estimates, (3) Includes ROW and Israel, July ending 2010 data for Nufarm, March ending 2010 data for Sumitomo Chemicals, Data for Bayer only
includes their Crop protection division
Price -1.0% -0.9% -1.5% -0.5% -1.5% -1.5% -2.7% -4.4% -1.7% -1.0% 5.4% 3.5% --5.0%
Volumes change 2.8% -1.1% -1.5% -1.1% -3.5% -2.9% 8.0% -1.4% 1.2% 7.7% 9.0% -3.0% 8.0%
Total 1.8% -2.0% -3.0% -1.6% -5.0% -4.4% 5.3% -5.8% -0.6% 6.7% 14.4% 0.5% 3.0%
Source: Deutsche Bank, Cropnosis
0.5 10
0.4 8
0.3 6
0.2 4
0.1 2
0.0 0
1960 1970 1980 1990 2000 2010E 2020E
Arable land (hectares/person) LHS
World population (billion) RHS
Source: Yara (IFA, Worldmarkets.com) Source: Yara. *Note: without consideration of any further growth in bio energy
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010E
2011E
90
2005
2006
2007
2008
2009
2010
2011E
2012E
Gross cash income (USD m)
Government payments (USD m)
Source: USDA Source: EU Directorate General Agriculture, Cropnosis. EU-15 includes Austria, Belgium, Denmark, Finland,
France, Germany, Greece, Ireland, Italy, Luxembourg, Netherlands, Portugal, Spain, Sweden, United Kingdom
Figure 486: Farm incomes vs. industry agchem volumes Figure 487: Crop prices vs. industry agchem volumes
15% 90
10% 250
10% 80 8%
200
70 6%
5% 4% 150
60 2% 100
0% 50 0%
50
-2%
-5% 40
-4% 0
1998
2000
2002
2004
2006
2008
2010
1998
2000
2002
2004
2006
2008
2010
Source: Deutsche Bank, *Inflation adjusted Source: Company data, Deutsche Bank, Cropnosis
Figure 488: The net yield gain goes through an optimum Figure 489: …which increases with wheat prices
The net yield gain goes through an optimum This optimum rises along with wheat prices
15
20
15 10
10
5
5
0 0
0 1 2 3 0 0.5 1 1.5 2 2.5 3
Source: ‘Reussir Cereales Grandes Cultures’, January 2008 issue, Arvalis, 45 trials, Deutsche Bank Source: ‘Reussir Cereales Grandes Cultures’, January 2008 issue, Arvalis, 45 trials, Deutsche Bank
People with more than $500,000 adjusted gross income from off-farm source not
eligible for subsidy payments
Payment limit of $40,000 per person for direct payments and $65,000 in counter-
cyclical payments.
However, no limits are placed on marketing loan benefits which was earlier capped to
$75,000 in 2002 farm act. 2008 US farm bill however still allows doubling of these limits
by having a spouse.
Set-aside in the UK 567 800 612 681 560 559 513 440 0 0
(000 hectares)
Source: UK agriculture, Deutsche Bank
Cost and complexity of registration also creates higher barriers to entry. Unlike in
Pharmaceuticals where generic applicants can provide an abbreviated new drug
application (ANDA) to prove that its product is equivalent to that already approved,
generic agrochemical companies have to provide a full set of data when registering a
molecule in the US and the EU. This has been deterring generics to invest in new
products and explains why the market share of generics has remained broadly stable for
agchems at broadly 23% vs. 50-80% in many Pharmaceutical markets. In addition, we
note product registration costs are high in agrochemicals (in the region of $12m over c7
years) and are a positive function of the number of crops the product is to be registered
for. Therefore, in order to limit the financial burden of product registration, some generic
companies tend to seek registration for one crop. Historically, this has not stopped
farmers to use the molecules on other crops for which the products was not registered,
but nonetheless efficient. With the increasing enforcement of the legislation in the field in
many EU countries, this practice is becoming increasingly difficult and therefore reduces
the market potential of generic agrochemicals. c60% of off-patent crop protection
products in the market are not generic and therefore fall into the category of proprietary
off-patent products. In this way, the EU registration system provides market exclusivity
for many old active ingredients and partly explains why off-patent product still enjoys
robust sales/margins progression unlike in Pharma.
New products achieve superior efficacy and tend to have a strong growth profile.
The strong growth profile of new products is driven by superior efficacy compared to
competing and previous generation products. In addition, resistance issues against
traditional agrochemical molecules have been creeping up over the past decade as many
farmers have not been following the recommended spray schedule and dosage in order
to save on costs. Examples of molecules facing resistance include triazoles, strobilurins
(fungicides), glyphosate etc We also note a resurgence of pest and disease such as the
soybean rust (and aphids) due to a combination of causes: 1) No-tillage encouraged by
glyphosate resistant soybeans, 2) Conservation tillage encouraged by widespread use of
herbicides, 3) Density of planting increased to push yields and 4) Lower crop rotation due
to favourable prices and/or subsidies encouraging continuous mono-culture. These
increasing resistance issues are increasing farmers’ appetite for premium products.
Only leading companies can afford developing new products. We estimate that the
cost of developing and launching a new active ingredient is in the region of $150-200m
(over a period of approximately ten years). The sheer cost of the R&D involved means
product development can only be sustained by those companies with substantial
resources. In the agrochemical sector Bayer, Syngenta and BASF are the leading R&D
players.
Figure 492: R&D spent by leading agchem players (2010E)
CP R&D (US$ m) CP R&D to CP sales
Syngenta 555 6.3%
Bayer 629 8.6%
BASF 523 9.7%
Du Pont 176 6.9%
Dow 261 6.4%
Total agchem average 429 7.6%
Source: Company data, Cropnosis, Deutsche Bank estimates
R&D intensity has been decreasing leading to a rise in the share of off-patent
sales… As shown on Figure 493, R&D agrochemical companies have been increasingly
allocating funds to ag biotech R&D (e.g. GMs) at the expense of Crop Protection. This
has caused an increase in the share of off-patent products amongst the overall
agrochemical market.
Figure 493: R&D / sales evolution (13 leading agchem Figure 494: Patented vs. off-patent sales
companies)
2,000 100% 10%
30% 30%
80% 40% 35%
1,800 50%
60%
1,600 40% 90%
70% 65% 70%
60%
50%
20%
1,400
0%
1,200
Syngenta
BASF
Monsanto
DuPont
Bayer
Dow
1,000
2003 2004 2005 2006 2007 2008 2009
Off-patent sales & proprietary off-patent sales
R& D Crop Protection (Euro m) Patented sales
R& D Seeds Biotech (Euro m)
Source: Cropnosis Source: Makhteshim Agan (from Philips Mc Dougal))
Figure 495: Patented sales have decreased… Figure 496: … but profitability has increased
25%
50% 20%
45% 15%
10%
40%
5%
35%
0%
30%
-5%
25% -10%
20%
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
Along similar lines to genetic modification (output traits - altering the crop to improve its
qualities) is the “smart breeding”- another practice used by the seed companies using
marker assisted selection. Although using the same principle as the cross-breeding
traditionally undertaken, smart breeding uses biotechnology to understand and select the
desired gene combination for breeding a product with desired attributes (rather than
genetically modifying the germplasm). Once a genetic sequence is identified, that is
linked to a particular trait (e.g. drought resistance); the producer can avoid testing every
offspring plant for this trait. They only need to look at the marker through a rapid DNA
test and can rapidly ascertain which plants have that trait or not. This significantly reduces
the development time and allows breeding of complex traits. Examples of this to date
include a seedless watermelon (Syngenta) and many smaller than normal products and
higher sugar content sugar beet from KWS Saat. This appears an area of strong growth
given higher public acceptance of these seeds.
In the future the growth of bio-fuels (bioethanol, biodiesel) should drive increased
demand for specific crops (sugar cane/sugar beet/maize and oil seed rape/canola
respectively). The US government has made a strategic decision to increase the role of
biofuels and specifically ethanol in the country’s energy mix. Today close to 40% of the
US corn harvest is used for ethanol production. While expansion in the ethanol industry
continues, smaller gains for corn-based ethanol are projected over the next 10 years than
seen in 2007/08, reflecting only moderate growth in overall US gasoline consumption and
limited potential for further market penetration of ethanol into the E10 (10% ethanol
blend) market (the blend wall).
Figure 497: US Maize usage in biofuels (m/t) Figure 498: US ethanol consumption near the blend wall
10% of gasoline use
14,000 50.0% 15.0
12,000 12.5
40.0%
Gallons (bushels)
10,000
30.0% 10.0
8,000
6,000 20.0% 7.5
4,000
10.0% 5.0
2,000
0 0.0% 2.5
US ethanol consumption
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
0.0
1995 1997 1999 2001 2003 2005 2007 2009
US Corn Production (m bushels)
% of Corn used for Ethanol
The agrochemical market saw significant consolidation in the early nineties/early 00s.
This includes the acquisition of American Cyanamid by BASF, Bayer’s acquisition of
Aventis CropScience (itself an agglomeration of Agr-Evo – Hoechst and Schering – and
Rhone-Poulenc) and the formation of Syngenta from Novartis and Astra-Zeneca. Post this
period of consolidation the sector has undergone a substantial cost cutting programme
(Syngenta has cut $1.3bn since its inception), BASF targeted $250m from its Cyanamid
acquisition, Bayer targeted E530m from 2002-2005). With a market share of over 80%
held by the top six companies we anticipate little large scale activity in agrochemicals;
however M&A action in fast growing seeds market cannot be denied as the companies
try to gain access to the new markets for GM seeds. Over the next five years we expect
the companies to continue to focus on new product development especially in GM
Seeds alongside cost cutting to offset the higher product development costs. Syngenta
has already announced $650m cost cutting from 2011-15 while Bayer has also
announced E800m cost cutting program targeted at its CropScience and Healthcare
divisions.
Herbicides
Figure 499: Herbicides at a glance
Long-term growth rate Approximately 1.5-2.0% pa
Growth rate relative to the sector Low for mature products, selective herbicides growing fastest
Supply/Demand Not applicable (except for glyphosate)
Margin prospects Stable
Watch out for ... New selective herbicides & emergence of glyphosate tolerant weeds
Source: Deutsche Bank, Cropnosis
Herbicides are chemicals used to control weeds or unwanted foliage. In 2010 the herbicide
market was estimated at just over $17.6bn. Over 50% of this market is accounted for by the
large markets of cereals, maize and soybeans. North America is the largest herbicides market
followed by Western Europe and Latin America. Herbicide usage is also increasing in Asian
countries like China/India mainly driven their need for improving the farm productivity to
ensure food security for their large population.
Herbicides are classified mainly according to their application usage. They can be selective
(for example, killing certain types of unwanted foliage) or non-selective herbicides (which kill
all foliage). Herbicides can be further sub-classified based on its time of application: pre-
emergent (before the crop breaks through the soil) and post-emergent or according to the
mode of action: contact herbicides (kills the unwanted plant when it comes in contact with
chemicals used in the herbicides) or translocated (kills the plant after their absorption by
accelerating/retarding the metabolic activity of the plant). The effectiveness of herbicides
depends on a number of factors including type of weed, time of application,
formulation/concentration of herbicides, soil type and concentration of spray material.
Figure 500: Breakdown of the herbicide market Figure 501: Herbicide market by crop (2010)
Other Crops
Cereals
Sugar Beet 14%
Non- 21%
3%
selectives
32% Oilseed
Rape
3%
Cotton
5% Soybeans
Rice 18%
Selectives 8%
68% Fruit & Veg
14% Corn
14%
Source: Cropnosis Source: Cropnosis
Others Monsanto
19% 19%
DuPont
6%
Syngenta
19%
BASF
9%
Dow Bayer
14% 15%
Source: Cropnosis, Deutsche Bank
Herbicides have seen the largest impact from GM products particularly in the markets of
soybean and corn. The development and launch of herbicide-tolerant plants (plants
resistant to one type of non-selective herbicide spray therefore allowing this herbicide to
be sprayed even when the plant has emerged without damage to it) initially increased the
usage of a small number of non-selective products for example glyphosate (Monsanto
trade name Roundup) at the expense of other non-selective and selective herbicides.
However the use of GM crops does not eliminate the need for all selective herbicides -
these herbicides still have to be used in conjunction with GM crops to maximise yields,
particularly in crops like maize and cotton.
The launch of GM products was initially thought to reduce the applications of herbicides.
However the latest studies have shown that the use of herbicides has increased
significantly in the last decade due to the emergence of glyphosate resistant weeds
particularly in Southern and increasingly Midwest parts of US. Farmers are responding to
this challenge mainly through increasing the application rates or applying additional
herbicide active ingredients. Companies are responding to this challenge by offering
products which has a mode of action different from glyphosate (e.g. 2,4-D and dicamba).
Interestingly, Monsanto has started offering rebates (as high as $12 per acre) on soybean
and cotton herbicides where resistance to Round herbicide have become evident.
Farmers can earn these rebates by using herbicides other than Round up.
We believe the emergence of glyphosate tolerant weeds represents a key challenge (for
older chemistries like glyphosate) as well as opportunity (development of new
formulations with a mode of action different from glyphosate) for agrochemicals
companies.
Figure 505: Global glyphosate capacity (total capacity is Figure 506: Glyphosate formulators market shares
1mt)
45%
35%
Monsanto 25%
36%
15%
5%
Nufar m/Agr i pec/Ex …
-5%
FMC
Ni der a
Chinese
Ci agr o
Teckman
Syngenta
Chi nese & Other s
Chemi nova
Hel m
Dow Agr oSc
Monsanto
DuPont
MAIN/Mi l eni a*
Al baugh/Atanor *
producers
64%
Insecticides
Figure 507: Insecticides at a glance
Long-term growth rate Approximately 3% pa
Growth rate relative to the sector Average for agrochemicals
Supply/Demand Not applicable
Margin prospects Good
Watch out for ... New product launches
Source: Deutsche Bank, Cropnosis
Insecticides are agents for controlling insects or pests and can be applied as sprays, dusts or
gases. Insecticides are generally classified by their mode of action: stomach poisons are
lethal to insects which ingest them; contact insecticides kill following simple bodily contact
and fumigants act on the insect's respiratory system.
Unlike the herbicide sector, where to a large extent the continued use of products is linked to
farmers’ or growers’ economics, usage of insecticides is more directly tied to the incidence
of insect attack. The key crop sectors for insecticide use are fruit and vegetables (mainly
citrus, apples and potatoes) cotton and rice. Asia is the biggest market for insecticides
(approximately 45% of global insecticide sales) followed by Latin America and North America.
After the herbicide market this is the second largest class of agrochemical with a market
value in 2010 of $11bn.
Figure 508: Players in the insecticide market Figure 509: Insecticide market by crop (2010)
Bayer Other
Others Crops
24% Oilseed
26% 15%
Rape
1%
Soybeans
3% Fruit & Veg
FMC 44%
6% Cereals
Syngenta 4%
DuPont 19% Maize
7%
Dow BASF 7% Rice Cotton
8% 10% 12% 14%
Source: Cropnosis Source Cropnosis
Insect-resistant genetically engineered crops have been cultivated since 1997 with the
incorporation of Bt genes into plants (in order for them to express toxins for inherent
insect resistance). This has particularly negatively impacted the use of insecticides in
soybean and maize plantations. This is not forecast to significantly reduce growth in
insecticides above and beyond the penetration seen to date.
Other key factors impacting the industry include regulatory pressure and generic
competition. However, restriction on environmentally harmful insecticides (e.g. aldrin,
chlordane, DDT) in developed countries has led to the development of new formulations
which are driving the market growth. Generic competition, we believe, will continue to
affect the sales of old chemistries however the R&D players will still be better placed on
the strength of their product innovation and extension of patent protection in certain
geographies (.e.g. through supplementary protection certificates (SPCs) in Europe which
extends the patent protection by a maximum of five years for existing products).
On a medium term basis, we believe, the increasing investment in insect control in fruit
and vegetables, growing usage of insecticides for seed treatment and new product
launches will continue to drive growth for the sector.
Fungicides
Figure 512: Fungicides at a glance
Long-term growth rate Approximately 4% pa
Growth rate relative to the sector Above agchem sector on average driven by new products and disease
proliferation
Supply/Demand Not applicable
Margin prospects High and Stable
Watch out for ... Development of new chemistries, increased use of strobilurin on corn (US) in
order to enhance yields
Source: Deutsche Bank
Fungicides provide plants with protection from fungal attack and other related diseases.
Fungicides can be broadly of two types: contact fungicides (they kill the fungi when sprayed
on its surface, generally low value products) and systematic fungicides (these fungicides are
absorbed by the plant first and then shows its effect, generally high value products). Some of
the active ingredients in fungicides include sulphur, neem oil, rosemary oil, jojoba oil and
bacterium bacillus subtilis. We estimate the global market for fungicides in 2010 was $11bn.
The major fungicide markets are Western Europe, Japan and Latin America where the damp
climate along with highly intensive agricultural practices provides the ideal conditions for
fungal and mould growth. The usage of fungicides in North America is relatively small
compared to the overall agrochemicals market mainly due to climatic conditions in this region.
The key crop outlets for fungicides are the fruit and vegetable sector (with major applications
in vines, potato and citrus) followed by cereals and rice.
Figure 513: Players in the fungicide market Figure 514: Fungicide market by crop
Others
Other Crops
13%
12%
Syngenta Cotton
DuPont
30% 1%
5%
Maize
Dow 2% Fruit & Veg
5% 50%
Rice
9%
BASF Soybeans
23% 8%
Bayer Cereals
24% 18%
Source: Cropnosis Source: Cropnosis
growing season (refer Figure 515). Syngenta is the leading player in Soybean fungicide
market with an estimated market share of 35%.
Figure 515: Soybean rust market evolution ($m) in Latin Figure 516: Fungicide application increasing in Latin
America America
Among the various classes of fungicides, the strobilurins is still the largest chemistry
group with significant usage in cereals and more lately in soybeans. However the
development of resistance (called Septoria resistance) against this class of fungicides has
led to expansion of triazole chemistry, another leading class of fungicides.
Over the next five years we expect a significant number of product launches in
fungicides, most notably from Syngenta, Bayer and BASF (which have shown significant
improvements in protection against competitor products) which will drive the market
growth.
Fruits and vegetables the biggest end market for fungicides should continue to grow due
to improving dietary standards in emerging countries which signals continued broad-
based demand from this product group.
Figure 517: Top three Fungicides globally
Product Company Sales ($, m)
Seed Treatment
Figure 519: Seed Treatment at a glance
Long-term growth rate High single digit percentage growth
Growth rate relative to the sector Above
Supply/Demand Not applicable
Margin prospects High
Watch out for ... Continued market penetration especially in NAFTA and Latin America
Source: Deutsche Bank, Cropnosis
With seeds generally taking up to six weeks for their defences to mature, the farmer is
increasingly seeking to protect them through the direct treatment of seeds (rather than the
emergent plant) with fungicides and insecticides. This is particularly the case with some of
the highly productive crop varieties where the breeding to maximise yield has created a
weakened defence mechanisms against fungal disease and insect attack. Seed treatment
provides good protection during the germination period, better stress tolerance during the
early stage of plant development and ensures high yield for growers. The basic seed
treatment process involves seed dressing, coatings and pelleting.
Seed treatment is a value-added, profitable and innovative product for the agrochemical
companies. There are synergies of selling seeds and also the fungicides and insecticides in
being able to combine these to the customer. Globally the market for seed treatment is
relatively consolidated with top four players occupying more than 80% of the market.
Compared to the remainder of agrochemicals seed treatment is relative small although
growing at a fast pace with an estimated market size of $2.5bn in 2010.
Figure 520: Seed treatment market by product area Figure 521: Seed treatment market by crop
Others
Sugar Beet 7%
Nematicides
4% /Cane Cereals
3% 29%
Rice
7%
Insecticides Potatoes
Fungicides 50% 7%
46%
Cotton
9%
Oilseeds
11% Maize
27%
Others
18%
Syngenta
34%
Chemtura
7%
BASF
9%
Bayer
32%
Source: Cropnosis
Figure 523: Global seed treatment market evolution $m) Figure 524: Global seed treatment market by region
(2010)
3,000
2,500 11.4% CAGR 2000-10 Asia-Pacific EAME
17% 30%
2,000
1,500
1,000
500
0 Latin
America
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011F
25%
North
America
28%
Conventional seeds
Figure 525: Seeds at a glance
Long-term growth rate 3% pa
Growth rate relative to the sector Slightly above agrochemicals
Supply/Demand Not applicable
Margin prospects Remaining strong
Watch out for ... Continued consolidation of seed companies
Source: Deutsche Bank, Cropnosis
Conventional Seeds are produced by the process of conventional breeding which involves
growing two plants together each having a separate desirable characteristic so that they
flower simultaneously. Seeing the flower and pollination time the two plants are crossed by
the process of artificial fertilization. The resulting fruit from such a plant will contain seeds
which will have the characteristics of both the plants. One disadvantage of conventional
breeding is that many undesirable traits are also transferred with the desired trait.
Germplasm, the genetics required to breed quality seeds, are the basis for biotechnology
developments and as such there is considerable over-lap at the company level between
traditional seed breeding and biotechnological research, development and marketing.
They provide access to the seed treatment industry which is a value-added, profitable
and innovative product for the agrochemical companies. There are synergies of selling
seeds and also the fungicides and insecticides in being able to combine these to the
customer.
The seed market has a market size of approximately $32bn in 2010 (excluding the value of
seed treatment). By area under acreage wheat and corn comprises approximately 48% of the
market; however by value of crop corn alone constitute 47% of the market followed by
soybean which occupies 18% of the market.
Figure 526: Seed world market by acreage Figure 527: Seed world market by value (Conventional
(Conventional +Biotech Seeds) +Biotech Seeds)
Barley
Sunflower Rapeseed Sunflower 2% Sorghum
3% 4% 3% 1%
Cotton
3% Rapeseed
Wheat 4%
Sorghum 28%
Cotton Corn
5%
8% 47%
Barley Wheat
7% 8%
Soybean Rice
12% Corn 9%
Rice 20% Soybean
18% 18%
Source: Deutsche Bank, BASF, Source: Deutsche Bank, BASF
The largest participants in conventional seeds are Monsanto, DuPont, Syngenta, Limagrain,
Bayer and Dow. It should be noted that this market is fragmented, with 14% of the seeds
sold by state owned/quasi state owned companies/cooperatives, 10% of seeds being farmer
owned (retained from previous crops) and a further 16% from a number of small producers.
Others
16%
Monsanto
24%
Farmer owned
10%
State/Co-ops
14% Du Pont
17%
Dow
3%
Bayer Syngenta
Limagrain 9%
3%
4%
Source: Cropnosis
We anticipate further consolidation in the seed market as a way to capture market for
companies producing GM plants. The key acquisitions in this direction includes Stoneville
and Athenix acquisition by Bayer in 2007 and 2009 respectively, acquisition of Triumph
Seed Co. Inc, and Dairyland Seed Co. Inc. & Bio-Plant Research Ltd. by Dow in 2008 and
acquisition of Nandi Seeds Private Limited by Dupont in 2009. Despite these acquisitions
the market still remains largely fragmented, particularly in Asia-Pacific although demand
for conventional seeds is expected to remain strongest in this region due to lower
adoption of GM seeds.
Along similar lines to genetic modification (output traits - altering the crop to improve its
qualities) is the “smart breeding”- another practice used by the seed companies using
marker assisted selection. Although using the same principle as the cross-breeding
traditionally undertaken, smart breeding uses biotechnology to understand and select the
desired gene combination for breeding a product with desired attributes (rather than
genetically modifying the germplasm). Once a genetic sequence is identified, that is
linked to a particular trait (e.g. drought resistance); the producer can avoid testing every
offspring plant for this trait. They only need to look at the marker through a rapid DNA
test and can rapidly ascertain which plants have that trait or not. This significantly
reduces the development time and allows breeding of complex traits. Examples of this
to date include a seedless watermelon (Syngenta) and many smaller than normal
products and higher sugar content sugar beet from KWS Saat. This appears an area of
strong growth given higher public acceptance of these seeds.
New areas of plant breeding (e.g. novels food, functional foods, naturaceuticals) and use
of plant for the production of biomolecules, including medically relevant substances
using biotechnology are some new opportunities for the seed companies although
research is still in its infancy stage in these areas.
Ag-biotech is the use of biotechnology to alter a plant’s genetic structure in order to improve
its inherent properties, for example create resistance to pests, diseases, chemicals or to
boost crop yields. Although ag-biotech research has been conducted for some time, its large-
scale commercialisation has occurred only since 1997. Since that time the ag-biotech has
grown to a value of $12bn in 2010.
Figure 530 shows an example of where a gene is extracted from a bacterium (blue square)
and inserted into the germplasm of a seed. In this case the gene transferred allows the plant
(once it has germinated) to produce a particular toxin. When the targeted insect eats any of
the plant it is poisoned and hence eats no more. This significantly reduces pest damage to
the plant and can be used as an alternative to spraying with insecticides.
Figure 530: Genes are taken from an organism and inserted into the germplasm of a
Seed in order to give that Seed a particular property such as insect resistance
Target cell
Source: Syngenta
There are distinct areas of ag-biotech focus, which are currently at differing stages of
development. Due to the large R&D commitment necessary to participate in any area, most
companies tend to focus only selectively.
Input traits. Scientists concentrate on the alteration of plant genetics in order to create a
stronger/more resistant plant, thereby increasing overall crop yield. The value to the farmer
may not only be increased yields but also lower costs of agrochemical products required to
generate that yield. Input trait alteration does not affect the final properties of the crop or
food produced. To date input traits are the most commercialised ag-biotech application and
are currently most prevalent in the crops of soybean, corn and cotton. The main companies
operating in the input trait market are Monsanto, Syngenta, Dow and Bayer.
Herbicide resistance: Twenty years ago after a crop had emerged from the ground only
certain selective herbicides could be used to control unwanted weed foliage. This
created the requirement for several different herbicides to be used to control the
multiple weeds encountered. By inserting a gene into a plant to make it resistant to a
certain type of non-selective herbicide, that one herbicide can then be used to kill the
weeds but leave the crop unharmed. The renowned examples include Monsanto's
Roundup ready (resistant to glyphosate herbicide) and Liberty Link (resistant to
glufosinate herbicide) from Bayer Crop Science.
Insect resistance: Plants are given a resistance to certain insects through the insertion
of a gene that allows the plant to create its own internal insecticide. Leading products
that include insect resistant traits are Smartstax, Bollard III for cotton and Roundup ready
for sugarcane.
Output or quality traits. This activity uses genetic engineering to change the chemical or
nutritional ‘quality’ of the final crop/product. Innovations include corn with higher oil or amino
acid content, corn with higher ethanol yield (e.g. amylase corn from syngenta), higher omega
3 oil in soybean, vegetables (including tomatoes) with improved food qualities (for example
flavour, shelf life, and so on) or enhanced pro-vitamin A in golden Rice. These traits can
create value for animal feeders (reduced costs due to higher energy value of grain) or
personal care companies (oils for soaps and gels). Over time this market may also develop to
include nutraceuticals (foods with beneficial health effects). Major players in output trait
technology include Monsanto, Syngenta, Dow and BASF.
Value for the ag-biotech/chemical producer can be achieved in two ways (separately or in
combination).
A royalty (gene fee) can be charged for each bag of genetically modified seed sold to the
farmer. In a number of cases this tends to be the only method of payment, for example
insect resistance, output traits.
Value can be captured through selling larger quantities of chemical herbicide (which is
used in combination with the modified crop), for example Monsanto and Roundup
(glyphosate).
Figure 531: Global value of the biotech seed market ($ in Figure 532: Biotech seeds market by player (2011E)
billions)
Others
14 11%
12 Dow Agro
10 6%
Monsanto
8
38%
6 Syngenta
4 12%
2
0
1996
1998
2000
2002
2004
2006
2008
2010
DuPont
33%
Source: : ISAAA Brief 42, Cropnosis, Deutsche Bank Source: Cropnosis
Figure 533: Global biotech seed market by crop, 2010 Figure 534: Global biotech seed market by trait, 2010
(area planted) (area planted)
Canola
Cotton 5% Insect
14% resistance
varities
18%
Soybean
49% Double &
Herbicide
triple stack
Tolerant
22%
Maize 60%
32%
Source: ISAAA Brief 42, Deutsche Bank Source: ISAAA Brief 42, Deutsche Bank
Figure 535: Global biotech seed market by crop, 2010 Figure 536: Global biotech seed market by trait, 2010 (by
(by value) value)
Others
Canola 1% Insect
3% resistance
Cotton 10%
11%
Herbicide
Maize Tolerance
50% 47%
Figure 537: Global GM seed sales by region (2010E) Figure 538: Global GM seed sales by region (2015E)
N orth
N orth America
America 79%
79%
Since its commercial inception in 1997 the ag-biotech seed market has grown to a value
of $11.7bn by 2010, an impressive CAGR of 16% from 2000-10. This represents 22% of
the US$51.8 billion global crop protection market in 2010, and 33% of the approximately
US$34 billion commercial seed market. 2010 biotech seed sales increased by 10% YoY.
Going forward growth is anticipated to continue albeit only at a mid-single digit level,
driven by adoption of biotech seeds in other countries (12 more countries expected to
adopt biotech seeds from 2011-2015), further penetration of biotech seeds in four
leading crops (maize seeds, cotton and canola) outside US and a spate of new product
launches from major players.
Globally, Soybean has the highest planted acres for GM seeds in 2010 (at 49%)
followed by Maize at 32% and Cotton at 14%. In terms of traits herbicide tolerant traits
has been the most common trait across all traits (60%in 2010), followed by double and
triple stack product (22%) and insect resistant traits (18%).
GM corn penetration in the US has grown rapidly in last five years reaching 86% in
2010; however global corn penetration is still very low (26%) with significant growth
potential in Latin America, particularly in Brazil, and Argentina.
GM cotton penetration in the US reached 93% in 2010 which is significantly above the
global average (49%). Bt cotton penetration in key producing countries like India (86%)
and China has also increased in the recent years (69%).
Stacked traits is the fast emerging segment in the biotech seeds as most of the top
producers are now focusing their R&D budgets on these products. Stacked seeds,
including double stack (provides resistance to one pest and herbicide tolerance), triple
stack (resistance to two pests plus herbicide tolerance) and multi stack seeds (e. g.
biotech maize seed Smartstax which has eight genes that include resistance against
several pests alongside herbicide resistance traits), provide more variety to the farmers
for effective pest control besides improving yield. There is now a wider choice of traits
available, not only from Monsanto but also from other major players such as Syngenta,
Dow Agrosciences - Mycogen, Bayer BioScience and DuPont - Pioneer.
Further growth of biotech seeds hinges on the adoption of biotech traits in key cereal
crops like rice and wheat. Although biotech rice (also called “golden rice”) is close to
commercial approval in Philippines (expected to be available in 2013) biotech wheat is
still far from reality with the first commercial product expected only in the second half of
this decade.
Europe has the lowest planted acres of GM seeds (approximately 1.5m hectares).
Significant growth of generically modified product is not anticipated in the near term
mainly due to conservative stance taken by EU and respective governments on biotech
seeds. The trigger for greater acceptance could be the development of output traits (e.g.
biotech potato “Amflora” which provides higher starch content already approved in EU)
– where the customer can see the benefit.
The ongoing research on new traits targeted at alleviating abiotic stress e.g. enhanced
drought tolerance/water optimization and improved nitrogen efficiency offers new
market growth opportunity (e.g. Syngenta launched AgrisureArtesian in 2010, the first
product offering water saving in irrigated areas) for biotech seed companies.
Fertilizers
Figure 541: Fertilizers at a glance
Long-term growth rate 2-3%
Growth rate relative to the sector Below the chemical sector on average
Supply/Demand Tight short-term due to high crop prices but likely to weaken beyond 2011 due
to new capacity
Margin prospects Should moderate long-term from current ‘’peak type’’ levels
Watch out for ... New Middle Eastern nitrogen capacity in 2012, high European natural gas prices
could squeeze European nitrogen producers margins, new potash capacity in
2012-15 and large phosphate Ma’aden project start-up in H2 2011, further
consolidation, new entrants (potash and phosphate)
Source: Deutsche Bank
Figure 543: US farmer production costs (2011E)* Figure 544: Consumption of fertiliser (N+P+K) by crop
While a variety of nutrients are necessary, the global fertiliser industry centres around the
three primary nutrients – nitrogen (manufactured through a chemical process), phosphorus
and potassium (both mined).
Nitrogen is produced from natural gas and may be applied to the soil in gaseous form
(ammonia) or more commonly solid (urea, ammonium nitrate) or liquid (nitrogen
solutions) form. Nitrogen is involved in protein formation and is a major component of
chlorophyll. Use of nitrogen is critical in the improvement of crop size (growth and yield).
Due to leaching and volatility losses, nitrogen must be applied every growing season
except for certain crops, such as soybeans (fix nitrogen from the atmosphere).
After nitrogen, phosphorus is the second most consumed plant nutrient and helps to
promote crop quality through encouraging proper root growth, cell division and fruit and
seed production. Phosphorous is vital to the transfer of energy during photosynthesis.
The most common forms of commercial phosphourus fertilizers are monammonium
phosphate (MAP), diammonium phosphate (DAP) and triple superphosphate (TSP).
Potassium is used by plants improvement of crop quality through plant growth, starch
activation, protein formation and other physiological functions. The most common form
of potassium is potash (salt mined directly from underground and marine deposits).
Nitrogen is the most important nutrient. Of all the nutrients, nitrogen is the most
important nutrient for the plants, accounting for 61% of total consumption. Each nutrient has
its own set of benefits and is required for specific functions of the plants.
Figure 545: Fertilizer consumption by nutrient type Figure 546: Nutrients characteristics
The fertilizer sector is expected to achieve nearly $80bn of sales in 2011, almost twice as
much as the global agrochemicals market. Among the key listed players in the fertilizer
market are Yara, Potash Corp (PCS), Mosaic (IMC & Cargill), Agrium, Israel Chemicals (ICL),
CF industries (acquired Terra Industries), and K+S (Kali und Salz). Other fertilizer companies
include Sinochem (China), IFFCO (India), Eurochem (Russia), Phosagro (Russia), SAFCO
(Saudi Arabia), Egyptian Fertilizer Company (EFC) and Arab Fertilizer and Chemicals Company
(AFCCO) (Egypt), Uralkali and TogliattiAzot (Russia), Cherkassy (Ukraine) and Koch (US).
25
20
15
10
0
Potash MosaicBelaruskali OCP Yara CF Agrium Israel Silvinit Uralkali
Corp Industries Chemicals
The fertilizer industry continues to be relatively fragmented. However, over the past
years there have been a degree of consolidation and a great deal of improved focus
(with a number of spin-offs onto the market and privatization). Significant moves in the
market in recent years include the acquisition of Terra by CF, the sale of DSM agro to
Orascom, the merger of Uralkali/Silvinit, the acquisitions of GrowHow and Sasferko by
Yara, the acquisition of Potash One by K+S. In addition, BASF recently announced its
intention to sell its nitrogen fertilizer business.
The potash market is likely to be the most stable of the three nutrients given the more
concentrated ownership structure of the industry. In addition, the fastest growing
countries in Asia (China/India) lack their own production sources and will require imports
to satisfy growing domestic needs. The nitrogen industry is particularly susceptible to
boom and bust periods given the relatively modest barriers to entry.
Nitrogen
Figure 549: Nitrogen at a glance
Long-term growth rate 2-3%
Growth rate relative to the sector Below the chemical and fertilizer sectors on average
Supply/Demand Tight short-term due to high crop prices, delay in new capacity and high Chinese
export tariffs but likely to weaken beyond 2011 due to new capacity
Margin prospects Should moderate long-term from current ‘’peak type’’ levels
Watch out for ... Significant Middle Eastern nitrogen capacity in 2012, high European natural gas
prices which could squeeze European nitrogen producers margins, further
consolidation, especially in Western Europe and US
Source: Deutsche Bank
The different types of nitrogen-based fertilizers can be classified into three main categories:
basic nitrogen-based fertilizers, multi-nutrient products and specialty fertilizers.
Ammonia: used as a fertilizer and a raw material for other nitrogen products, including
intermediate products for industrial applications and finished fertilizer products.
Ammonia, a gaseous material contains 82% nitrogen and is injected into the soil as a
gas. Anhydrous ammonia (82% N) can be injected directly into the soil. The direct
application of ammonia requires a considerable investment by farmers in pressurized
storage tanks and injection machinery.
Urea: is a combination of ammonia and carbon dioxide (CO2) and is normally produced
as a solid product (containing 46% nitrogen). Urea can be combined with ammonium
nitrate solution to make liquid nitrogen fertilizer (UAN).
Ammonium sulphate (AS) has a relatively low N content (21%) and contains sulphur
(24%). It is used where the lack of sulphur in the soil is a limiting factor in plant growth.
Blended fertilizers or bulk blends: These are obtained by the dry mixing of several
materials and do not involve any chemical reaction. They involve the mixing of granules
of consistent size, weight and surface treatment to avoid segregation, which is
undesirable because it reduces the agronomic efficiency of the product.
Complex fertilizers are more efficient in achieving balanced nutrition as they contain a
declared grade of primary nutrient in each granule and allow an even application owing to
their stable granule quality and consistent granule size. While these are more expensive
products, their contribution to greater crop yield and quality (mainly in case of cash crops)
more than offset the cost and offers higher margins than blends.
3) Specialty Fertilizers
Specialty fertilizer products (such as calcium nitrate and potassium nitrate) are beneficial for
cash crops. The most advanced applications integrate fertilizer application and drip irrigation
and adjust input (i.e., the amounts and mix of major and minor nutrients, and trace elements)
to optimise plant performance continuously. There has been a growing demand
(approximately 5% per year over the last several years) for speciality fertilizers due to better
margins from cash crops as compared to food crops. Their use increases the grower’s
return, helps meet the market demand for quality crops, and enables higher margins than
those normally achieved with high-volume fertilizers. The most common types of specialty
fertilizers are:
Calcium nitrate (CN): produced by dissolving a calcium salt such as limestone or the
calcium phosphate of phosphate rock in nitric acid. In the latter case, it is a co-product
with nitrophosphate products. CN is used to remedy plant deficiencies in calcium and
ameliorate soil acidification. It contains 15.5% nitrogen in nitrate form and 19% water-
soluble calcium. The product is water soluble and particularly suited for water-born
fertilizer application systems.
Potassium nitrate (PN): produced by reacting sodium nitrate with potassium chloride.
Potassium nitrate is used as a potassium and nitrogen fertilizer. Potassium nitrate
contains 13.5% nitrogen and 45% water-soluble potassium as K2O. The water suitability
makes it particularly suited for liquid-based applications. Because of their chemical
similarity, AN, CAN, CN and PN are often collectively referred to as “nitrates.”
Nitrogen fertilizer production process
Urea: Carbon-di-oxide from ammonia process is reacted with ammonia at high pressure
and temperature to form a urea solution.
Nitric acid: Ammonia in the presence of air is passed over a platinum catalyst at high
temperature to produce nitrous oxide. The nitrous oxide is reacted with oxygen to form
nitrogen dioxide, which is then cooled and absorbed in water to form nitric acid.
Ammonium Nitrate: Nitric acid is neutralized with ammonia to form ammonium nitrate
solution
Phosphorus is produced from phosphate rock by digesting the latter with a strong acid.
It is then combined with ammonia to form Di-ammonium phosphate (DAP) or Mono-
ammonium phosphate (MAP) through a process called ammonization.
Natural Gas
Ammonia plant
Air CO2
NH3 Urea
Salts of K, Mg, S
NPK Fertilizers
H2PO4
H2SO4 DAP/MAP
Nitrate is the most commonly used fertilizer in Europe while urea is most important in
warm regions such as India and China. Urea first needs to be transformed to ammonium
and then nitrate while ammonium and nitrate are readily available to plants. The
transformation process is slow and difficult to predict with resulting nitrogen and efficiency
losses. On the other hand, nitrates are easily absorbed by the plants with minimum losses.
Hence, nitrates are the most suitable fertilizer for European conditions. Field trials have
shown that higher nitrate content in the fertilizer results in higher yield especially in arable
crops and high value cash crops such as fruits and vegetables.
Figure 552: Nitrogen fertilizer usage globally Figure 553: The more nitrate, the higher the yield
Other
9.0
Ammonia 11%
4%
Source: IFA 2009/10 (nutrient total) and 2008 (product split), Yara Source: Levington Agriculture, UK (1999) 15 trails from 1994-1998 on winter wheat in UK on a nitrogen
application of 160kg/ha
NPK
UAN
19%
25%
Source: Yara Source: Yara
Figure 556: Nitrogen consumption in China Figure 557: Nitrogen consumption in India
ABC NPK
26% 6% Other
6% Other
Nitrates 15%
(AN/CAN)
1% NPK
3%
Urea
Urea 82%
61%
Figure 558: Nitrogen consumption by crop, 2010E Figure 559: Global nitrogen use by country, 2010E
Wheat RoW
Other 17% 18%
coarse
grains Other
5% crops
Brazil
18%
Other 4% China
oilseeds Corn
Germany 45%
5% 17%
5%
France
Fruits & 6%
Vegs Rice
15% Sugar cotton 16% US
crops 4% 22%
3%
Source: IFA, Deutsche Bank Source: International Fertilizer Industry Association
Nitrogen typically displays a more stable demand profile compared to other nutrients
This is due to a shorter ‘’life expectancy’’ as nitrogen is a volatile nutrient which is not
retained in the soil beyond a few months of application. In addition, the yield response to
nitrogen is fast and direct (before the optimum point) unlike potash and phosphate However,
yield benefits do diminish when nitrogen application has passed the optimum point. These
factors result in nitrogen being applied every year at stable application rates.
Figure 560: Steep initial response of US corn yields to Figure 561: Yield benefits diminish at higher levels of N
N*
180
160
140
120
Bushels/acre
100
80
60
40
20
0
0 50 100 150 200 250
lbs/acre of nitrogen applied
US Corn Yields
Source: Iowa State University 2006. * based on 5-year averages of yield trials, 2006 Source: International Potash Institute
Figure 562: Nitrogen fertilizer consumption by type of product (1000 tonnes nutrients)
50,000
45,000
40,000
35,000
30,000
25,000
20,000
15,000
10,000
5,000
-
1994/95
1995/96
1996/97
1997/98
1998/99
1999/00
2000/01
2001/02
2002/03
2003/04
2004/05
Urea Com pounds (NPK…)
Nitrates (AN, CAN) Other straight N
Nitrogen solutions Am m onia direct applic.
Am m onium sulphate
Source: IFA, Deutsche Bank
Urea (most widely used and traded nitrogen fertilizer) is the key determinant for other
nitrogen fertilizer prices. International urea prices are influenced by the following key
factors:
The market supply/demand balance; i.e. what price the market will bear at any
particular time. When the international market is strong, the supply/demand balance
rather than the level of costs is the primary influence on prices.
The cost profiles of major export suppliers; i.e. determining the level of prices at
which individual exporters will stop selling in the international market. This is important
when the market is weak. Ukranian suppliers and increasingly Chinese suppliers are the
major source of marginal export supply.
The cost profiles of domestic suppliers in free markets; i.e. determining the level of
import prices at which domestic suppliers will stop producing. This is important when
the market is weak. North American producers are the major source of domestic supply
which in the past have been vulnerable to displacement by low priced imports.
The largest urea producing countries are also the largest consuming ones, namely
China and India. While China is self sufficient in line with the government’s policy, we note
India is the second largest importer of urea in the world (see Figure 567). The urea market is
very fragmented with the top 7 players accounting for less than 15% of global capacities.
Figure 563: 11 largest urea producers, mt, 2011E Figure 564: 10 largest urea consumers, mt, 2011E
60 60
50 50
40 40
30 30
20
20
10
10
0
0
US
China
India
Indonesia
Pakistan
Bangladesh
Canada
Iran
Germany
Brazil
China
India
Russia
Pakistan
Iran
Indonesia
Arabia
US
Canada
Egypt
Saudi
Figure 565: Top urea producers (by company) m tonnes urea (2010)
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
Yara
NFL
Qafco
Pusri
Potash
RCF
IFFCO
industries
Kaltim
Agrium
Corp
CF
Source: Fertecon, Yara, Company Reports. Note: March ending 2010 data for NFL, RCF and IFFCO, 2009 data for Kaltim and Pusri
The main urea exporters are gas rich countries/regions with small domestic markets,
with the exception of China. Between 2005 and 2010, new urea capacity in China has
increased by 55% (due to the government’s desire to achieve self sufficiency) which has
caused a significant oversupply in the domestic market. Due to the size of its urea market,
China is seen as a significant risk to the global urea balance as small deviations in the
domestic balance can create large waves in the global market, when the domestic surplus is
exported or the deficit is made up by imports. However, most of this surplus has and is
expected to stay within China due to prohibitive export tariffs. During the period of strong
domestic demand this export tax generally increases. For 2011 the window for lower export
taxes have been reduced from 6 to 4 months (7% urea export tax from 1st July 2011 to 31st
October 2011 and 110% export tax for the remaining part of the year) in light of the urea
production curtailments as a part of Chinese government move to improve energy efficiency.
North America, India, LatAm and South East Asia are the main importing regions.
Figure 566: Urea: 10 largest exporters, mt, 2011E Figure 567: 10 largest importers, mt, 2011E
6 7
5 6
4 5
4
3
3
2 2
1 1
0 0
Mexico
Venezuela
Brazil
Egypt
Turkey
China
Russia
Arabia
Qatar
Ukraine
Iran
India
Canada
Thailand
Bangladesh
Australia
France
US
Oman
Vietnam
Saudi
Figure 568: Short-term urea balance impacted by Figure 569: Main urea flows, 2009
Chinese export taxes
200% 1600
180% 1400
160% 1200
140%
120% 1000
100% 800
80% 600
60% 400
40%
20% 200
0% 0
May
May
May
May
May
Jan-06
Jan-07
Jan-08
Jan-09
Jan-10
Sept
Sept
Sept
Sept
Sept
Jan-11E
Monthly urea exports Chinese export duty
The long-term visibility on urea additions (4-5 years lead time for a typical urea
investment) means that the risk of supply exceeding our forecasts is low.
Higher capital & gas costs reducing the profitability of new projects. Rising capital and
gas costs in historically low cost region are reducing the profitability of current projects which
could continue causing delays and cancellations as has been seen recently:
Higher capital costs…: As there are only 3 main suppliers of infrastructure (Kellog
Braun Rook – KBR – is the largest one, German company Uhde and Italian company
Snamprogette) serving many more industries that just ammonia/urea and a highly
significant increase in the number of projects, investment costs and lead times have
been increasing. The investment cost for a world-scale greenfield 1m tonnes integrated
ammonia/urea plant has doubled recently from below US$1bn to US$1.5bn.
… and gas costs: Middle Eastern ammonia/urea production is increasingly competing
with more economically attractive gas supply projects. With higher international oil & gas
prices, growing domestic demand and the desire for greater diversification, gas
producers are looking more carefully at the comparative economics of gas monetisation
alternatives such as LNG, local utilities, gas-to-liquid schemes some of which being more
economically attractive projects on gas supply, in particular LNG (though the LNG upfront
investment cost is significantly higher than for ammonia/urea).
Increasing oil & gas prices in historically low-cost regions - further capacity closures or
project cancellations cannot be ruled out. Surging natural gas prices in the US and Western
Europe have resulted in the closure of a significant portion of urea capacity in these regions in
the early 2000s. The same could happen to China and Eastern Europe which have become
the highest cost producers globally.
The same is true for some Eastern European players who produce urea out of oil-linked
contracts and could therefore be forced to close non-economic urea capacity.
Technical start-up issues and problems with utility supply cause delays: Due to new
technologies involved in the construction of new plants and the speed at which they are
being built as well as issues with local utilities supply, pretty much every new capacity that
has come on stream has been impacted by significant delays notably in the Middle East (up
to several years). Ramp-up times have often been very slow, taking sometimes up to 18
months. Although the incidence of technical start-up issues should diminish as the
technology becomes more established, we note issues with local utilities supply continue to
delay capacity (e.g. the Iran plant expected to come on stream in April/May 2010). In addition,
the speed of construction and number of projects are likely to continue causing disruption.
Nitrogen fertilizer prices are seasonal and tend to increase the most towards Q1 as
these have to be applied to arable crops mainly during the period of active crop growth,
which is usually in the spring (other nutrient types do not necessarily have to be applied
during such a short period although a peak usually occurs in spring as these nutrients are
usually applied in combination with nitrogen). When demand is strong, urea prices can peak
as early as Q4 due to inventory build-up in anticipation of the season.
Other nitrogen fertilizer prices should move in line with urea prices. Most other nitrogen
fertilizer prices are linked to urea prices. In particular, as shown in Figure 570, usually with a 4
to 6 months lag on average, we note there is a strong correlation between urea prices and
European nitrate prices.
Figure 570: Most other nitrogen fertilizer prices are Figure 571: Strong correlation between European nitrate
linked to urea prices prices and global urea prices (US$/tonne of N)
1000
2500
800
2000
600
1500
400 1000
200 500
0 0
Mar-95
Mar-96
Mar-97
Mar-98
Mar-99
Mar-00
Mar-01
Mar-02
Mar-03
Mar-04
Mar-05
Mar-06
Mar-07
Mar-08
Mar-09
Mar-10
Mar-11
Jul-09
Jul-10
Jan-03
Jul-03
Jul-04
Jan-07
Jul-07
Jan-08
Jul-08
Jan-09
Jan-10
Jan-11
jan-04
jan-05
jul-05
jan-06
jul-06
Source :Yara, FMB, Deutsche Bank Source: Yara, FMB, Deutsche Bank
Long-term, the nitrate premium (above urea price) tends to be stable. European farmers
are willing to pay only a certain premium for the preferred nitrate products than for urea, and
therefore European nitrate prices reflect a relatively stable margin (in US$ per tonne of
nitrogen) above the urea price.
Figure 572: CAN margin vs. urea (US$/tonne of N) Figure 573: Seasonality of the nitrate premium (based
on CAN prices)
36%
70%
60%
50% 32%
40%
30%
20% 28%
10%
0%
-10%
24%
Mar-95
Nov-97
Mar-99
Nov-01
Mar-03
Nov-05
Mar-07
Nov-09
Mar-11
Jul-96
Jul-00
Jul-04
Jul-08
20%
CAN over urea price premium
May
Jan
Feb
Jun
Aug
Sep
Nov
Mar
Apr
Dec
Jul
Oct
Potash
Figure 574: Potash at a glance
Long-term growth rate 3-4%
Growth rate relative to the sector Slightly higher than the average of fertilizers but below chemicals
Supply/Demand Tight short-term due to high crop prices and a catch up in demand after 1-2
years of reduced potash application but likely to weaken beyond 2011 due to
new capacity and normalization of demand
Margin prospects Should moderate long-term from current ‘’peak type’’ levels
Watch out for ... New brownfield/greenfield capacity in 2012+, consolidation, new entrants
Source: Deutsche Bank
Potash is produced from ore deposits located deep underground, using either conventional
mining techniques, or the more energy and cost intensive solution mining process. Potash
can also be harvested from salt lakes or seas. Production costs depend on geological
conditions, ore depth and thickness, energy costs, K2O content, operational capacity and
degree of automation. Mine flooding risk a risk inherent to the industry as water is probably
rock salt’s biggest enemy (e.g. as happened to the Uralkali mine in 06).
Figure 575: Potash production process
Ore from Mine
Sizing Dewatering
& drying
Crystallization Compaction
Industrial
Source: Deutsche Bank, Potash Corp
Potash is mainly used in fruits and vegetables, corn and rice. Potash helps plants develop
strong root systems and retain water and also contributes to higher yield and greater
resistance to disease and insects. Potash also helps to improve the taste and nutritional value
of food. Fruits and vegetables are extremely nutrient intensive crops and consume significant
amounts of potash. Besides fruit and vegetables potash is also used in corn, rice, sugar crops
and soybean although in lesser quantities. There are significant variations in the usage of
potash across different crops with banana, sugarcane, tomatoes and palm oil having the
highest usage per hectare. Potash application/hectare also differs from one region to another
due to the variations in the soil condition e.g. soybean production requires more potash in
Brazil than US.
Figure 576: Potash consumption by crop Figure 577: Potash uptake for selected crops (kg/ha KCl)
Potash demand more volatile than other nutrients. As shown on Figure 578, potash
fertilizer demand tends to be more volatile than nitrogen (especially in more difficult times)
due to the possibility for farmers to take potash ‘holidays’, i.e. skipping potash application
(or reducing the quantity applied) for one or more seasons, as the yield impact from not
applying potash is not immediate, at least for relatively potash rich soils. Indeed on many
crops, one can skip or lower potash application for 2 to 3 years (depending on the crop, the
quality of the soil and the weather) and not impact the yield. The year 2009 provides the best
illustration as yields increased to (near) record levels in many regions after 1 to 2 years of
sub-optimum potash application (see Figure 579). However, after successive years of sub-
optimum potash application, yields falls steeply (see Figure 580 & Figure 581) and it takes
even more years to replenish the soil with the appropriate potash content.
Figure 578: US fertilizer use: annual percentage change Figure 579: 2009 yields at (near) record levels despite a
20-30% fall in potash application
18 6 60000
15 5 50000
4 40000
Number of Years
12
3 30000
9 2 20000
6
1 10000
0 0
3
1985
1987
1989
1991
1993
1995
1997
1999
2001
2003
2005
2007
2009
0
>10% 5 to 10% 0 to 5% -5 to 0% -10 to -5% <-10% Potash Deliveries ('000 tonnes KCl), Rhs
Fertilizer Use Potash Use Corn Yield (MT/HA)- Global, Lhs
Source: PotashCorp (AAPFCO/TFI) Source: British Sulphur, USDA
Figure 580: Effect of continued elimination of K use on Figure 581: Effect of continued elimination of fertilizer
soybean yield on sandy soil in Brazil use on rice yield in various Asian countries
Figure 582: Room for improvement in corn yields Figure 583: Potash under-applied in China/India/Brazil
Bu/acre mt
100 China India Brazil
160
80
120 60
40
80
20
40 0
Current
Current
Current
Potential
Potential
Potential
0
India China Brazil US
We forecast potash capacity to increase by approx 5% p.a. between 2012 and 2015. This
capacity increase will consist largely of brownfield projects from existing potash players
(especially PotashCorp, accounting for 42% of planned capacity expansion) with only one
large greenfield mine, the Eurochem one (2.3mt) included in our 2011-14 capacity forecast.
Most of the new capacities should be concentrated in Canada and in Russia/Belarus.
The potash market should remain relatively balanced for the foreseeable future. We
forecast potash operating rates at 89% in 2011 due to strong demand after two seasons of
lower application and high crop prices as well as limited capacity additions. In 2012-15, we
forecast operating rates to average 85% due to an acceleration of new supply. This remains
consistent with a tight market. Based on historic observation, 80% capacity utilization is
considered as acceptable, 85% is good to very good and >90% can cause temporary stress.
Figure 584: Global Potash supply demand (million tons)
1994 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011E 2012E 2013E 2014E 2015E
Capacity 55.55 55.4 55.4 55.4 57.1 59.8 60.9 62.3 63.5 65.8 65.8 67.3 70.8 73.5 78.4 81.4
- growth -1.5% -0.3% 0.0% 0.0% 3.1% 4.7% 1.8% 2.3% 1.9% 3.6% 0.0% 2.3% 5.2% 3.8% 6.7% 3.8%
Demand 40.1 43.9 45.5 49.1 54.2 54.4 50.7 58.7 54.5 31.0 55.0 60.0 61.2 63.3 65.6 67.9
- growth 10.6% 9.6% 3.6% 7.9% 10.4% 0.4% -6.8% 15.8% -7.2% -43.1% 77.4% 9.1% 2.0% 3.5% 3.5% 3.5%
Operating rate 72.1% 79.2% 82.1% 88.6% 94.9% 91.0% 83.3% 94.2% 85.8% 47.1% 83.6% 89.2% 86.4% 86.2% 83.6% 83.4%
Source: Deutsche Bank estimates, K+S, British Sulphur, Potash Corp
Figure 585: Global Potash capacity growth (%) Figure 586: Global Potash capacity vs. operating rates
7.0% 80 100%
6.0% 75
70 80%
5.0%
4.0% 65 60%
60
3.0% 40%
55
2.0% 50
1.0% 20%
45
0.0% 40 0%
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2011E
2012E
2013E
2014E
1990
1991
1992
1993
1994
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
Source: Deutsche Bank estimates, K+S, British Sulphur Source: Deutsche Bank estimates, K+S, British Sulphur
Potash supply is controlled by seven large producers. Potash largest producers control
81% of global capacity and the two marketing organizations (comprising of five producers)
control 64% of the market. This makes it easier for the players to manage supply with a
significant market impact when necessary (as it has been the case in 2009 when approx 50%
of global capacity was taken out of the market). Whilst potentially new entrants (EuroChem,
BHP) could affect this degree of concentration, the long lead-times (5-7 years construction
lead-times) means that supply risk is very low in the 2010-2015 period.
Figure 587: The 6 largest potash producers control 83% Figure 588: 2 marketing potash organizations (Canpotex,
of global capacity (2011E) BPC and IPC) control c70% of global capacity (2011E)
Others
Arab 5% Potash
Potash Corp ROW
5% Potash Corp
17%
Agrium 3% Arab Potash
China 3% 17%
3% 8%
ICL
China ROW Canpotex Mosaic
Uralkali* 10%
8% 36% 32% 12%
16%
ICL K+S BPC* Agrium
10% 10% 32% 3%
Ukralkali*
K+S Belaruskali 16%
10% 16%
Mosaic Belaruskali
12% 16%
Source: British Sulphur, *Pro forma including Silvinit Source: British Sulphur, IFA, PotashCorp, *Pro forma including Silvinit
Supply risk limited. The rate of new potash capacity increase appears high however we
believe the risk to global potash prices is low given 1) the majority (42%) of the 2012-15E
supply addition will be brownfield expansions from PotashCorp which controls 1/3 of the
market through Canpotex and 2) the risk of delay due to technical problems and/or
cancellations as seen in the past cannot be ruled out.
Potash industry has high barriers to entry. Due to the lack of economically viable and
quality deposits, construction costs for a new greenfield mine are substantial (typically at
least $2bn for a new 2mt capacity excluding roads, rail lines, utilities, port facilities and other
infrastructure costs – 2mt usually being the minimum size for a new greenfield project – see
Figure 589). In addition, we note the pay-back period is high (it takes a minimum of 7 years to
generate positive free cashflow out of a new mine vs. 3-4 years for nitrogen and phosphate).
Figure 589: A typical greenfield potash mine (2mt) can cost $2.5-3.5bn
Potash greenfield economics Investment
Brownfield expansion is the preferred route. Of the 13.2mt of new capacity scheduled to
come on stream between 2011 and 2014, all but 2.6mt are brownfield expansions.
Brownfield projects tend to be far less expensive than greenfield projects although prices can
vary very significantly depending on the type of investment (see Figure 557). We estimate
brownfield capacity costs approx $500m for 1mt.
We expect potash prices to remain above production cash costs. Potash prices are
currently over 3.5 times higher than the 2005 price level when operating rates were similar.
This is due to the significant market discipline with players’ willingness to sustain low
operating rates in order to support prices (as was seen in 2006 and 2009). We believe that
this market discipline has been enhanced as private ownership has eclipsed government
control (e.g. Canada) leading to a greater focus on return on capital and driving greater short-
term discipline in the face of demand fluctuations. Going forward, we expect long-term
potash prices to remain comfortably above operating cash costs (currently prices are 3-3.5x
higher than average cash costs) due to the players’ discipline and re-investment economics.
Potash producing countries are not the key consumers of potash. Potash production is
primarily controlled by former Soviet Union (mainly Russia and Belarus), Canada and Germany
due to the availability of potash ore in these regions. However, most of the potash
consumption is located outside these regions with China, US, Brazil and India as key
consumers of potash. So, in addition to supplying the local consumers, producers in FSU,
Canada and Germany also supply to Latin America and Asian countries. Since 80% of the
potash produced is exported, transportation cost is also as also a key influence on potash
prices.
Figure 591: Leading Potash producers (2011E) Figure 592: Leading potash consumers (2011E)
Others
Jordan 6% China
4% Others 19%
US
28%
3% Canada
Israel 37%
6% Malaysia
3% US
China
17%
6%
Russia
3%
Germany
7% Indonesia
3% India Brazil
FSU 12% 15%
31%
Source: Deutsche Bank, British Sulphur Source: Deutsche Bank, British Sulphur
Phosphate
Figure 593: Phosphate at a glance
Long-term growth rate 2-3%
Growth rate relative to the sector Below the chemical average
Supply/Demand Tight short-term due to high crop prices but likely to weaken beyond 2011 due
to new capacity
Margin prospects Should moderate long-term from current ‘’peak type’’ levels
Watch out for ... Ma’aden project start-up in H2 2011
Source: Deutsche Bank
Phosphate is an important plant nutrient and plays a key role in photosynthesis and provides
improved root growth, increased yields, higher crop quality, earlier maturity of grains and
better water use efficiency. Commercial phosphate fertilisers are produced in a multi-step
process. Production of phosphate requires three key raw materials phosphate rock, sulphur
and ammonia. First, phosphate rock is reacted with sulphuric acid to create phosphoric acid.
Typically, a further reaction with ammonia leads to MAP (MonoammonIum Phosphate) or
DAP (Diammonium Phosphate). Alternatively, combining phosphoric acid with additional
phosphate rock creates TSP (Triple Super Phosphate). DAP is the most important
phosphate fertilizer. It has an N-P-K composition of 18-46-0. MAP is a solid fertilizer with a
typical N-P-K composition of 13-52-0. TSP is a solid fertilizer produced from phosphate rock
and phosphoric acid and has a typical N-P-K composition of 0-46-0.
phosphate rock
sulphuric acid
phosphoric acid
am m onia
TSP DAP M AP
triple superphosphate diam m onium phosphate m onoam m onium phosphate
Most of the phosphate rock is used for the production of fertilizers for use in agriculture
while a small amount for phosphate (15%) is also used for the non-fertilizer applications
mainly as feed grade phosphate in animal feed apart from some industrial applications.
Figure 596: Phosphoric acid (P2O2) uses Figure 597: Phosphate fertilizer use by crop
Other crops
Food & 15% Fruits &
Oil Palm
Industrial 1%
Vegetables
Feed 9% 17%
DAP Sugar crops
6% Wheat
35% 4%
16%
Cotton
Other
4%
fertilizer Rice
Other coarse 13%
19%
grains
5%
TSP Other oil
5% MAP seeds Soybean Corn
26% 5% 7% 13%
Figure 598: Phosphate rock reserves by country, million Figure 599: Phosphate rock production by country,
tons (2008) million tons (2008)
25,000 80
70
20,000
60
15,000 50
40
10,000 30
5,000 20
10
- 0
US
China
Russia
Australia
Syria
Tunisia
Canada
Israel
Brazil
Senegal
RoW
Morocco
South
Jordan
Egypt
Togo
US
China
Russia
Tunisia
Syria
Australia
Canada
Israel
Senegal
Brazil
RoW
Jordan
South
Togo
Morocco
Egypt
Figure 600: About 1/3 of phosphate rock production Figure 601: Key phosphate rock export companies (2008)
goes to non-integrated producers
Domestic ROW
sales 23%
12%
Phosagro,
Russia OCP,
Exports 5% Morocco
18% 45%
Ferphos,
Algeria
6%
Integrated JPMC,
Gecopharm
producers Jordan
, Syria
70% 11%
10%
Global trade in phosphoric acid and fertilizers. Downstream of phosphate rock, significant
amounts of phosphoric acid and fertilizers are traded annually. High-grade phosphate
deposits that are also close to sulphur and ammonia supplies and port facilities are not very
common. The two most important exporting regions for phosphates are Morocco and the
United States. On a global scale, the United States is the leader in DAP/MAP exports while
Morocco leads in phosphoric acids. As with rock, India dominates trading in phosphoric acid
importing 6.1mt of phosphate in 2010. A key feature of the health of the phosphate industry
is demand in China and India, which can represent two-thirds of US DAP exports. Given the
uncertain policy issues surrounding fertilizer subsidies, import quotas and so on, this can lead
to dramatic swings in producer fortunes.
Figure 602: Phosphoric acid exports by country (2011E) Figure 603: Phosphoric acid imports by country (2011E)
Others
China
6%
4% Others
Jordan 25%
5%
Senegal
7% Brazil
Morocco
3%
USA 47%
France India
9% 4% 58%
Turkey
South 4%
Africa
Pakistan
10% Tunisia
6%
12%
Figure 604: Top 10 DAP+MAP exporters (000s mt., Figure 605: Top 10 DAP+MAP importers (000s mt.,
2011E) 2011E)
6.0 10.0
5.0 Top 10 total =21.9mt 8.0 Top 10 total =15.6mt
4.0 Rest of World=0.4mt Rest of World=6.6mt
6.0
3.0
4.0
2.0
2.0
1.0
0.0 0.0
Brazil
Turkey
Australia
India
Pakistan
Argentina
Canada
Thailand
China
Vietnam
Mexico
Morocco
Russia
China
Arabia
Tunisia
Lithuania
USA
Jordan
Australia
Saudi
Phosphate demand should grow at 3% p.a. in 2011-15. By region through 2019 we expect
global phosphates demand growth to be led by Latam, driven by strong growth in Brazil
which currently imports roughly 1/3 of its phosphate needs.
Figure 606: We forecast global phosphates demand will Figure 607: Forecast increase in phosphate (P2O5)
increase at 2.8% annual rates through 2019E demand 2010-2019E by region
60 50 4.0
50 3.5
40 3.0
40 2.5
30
30 2.0
20 1.5
20
10 1.0
10 0.5
0 0 0.0
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2016E
2017E
2018E
2019E
Middle
South
SE Asia
FSU
Europe
Africa
East
Central
America
America
America
Asia
Western
Central
Europe
Asia
East
South
North
Phosphate Demand (LHS)
DAP, product tons (RHS)
MAP, product tons (RHS)
India subsidies support strong demand (for now). Through the ups and downs of global
fertilizer prices/demand, consumption in India has remained high, and India’s share of global
phosphate imports has risen from 1/3 in 2008 to c37% in 2010. This resilience has been
largely driven by India’s government subsidy system, which pays manufacturers and
importers a subsidy to compensate them for losses plus a return on capital. Indian
government introduced the nutrient based subsidy (NBS) system in 2010 linking all
phosphate prices to the base price for DAP. The new system has decontrolled the phosphate
prices to the farmers and replaced the old maximum retail price system that was fixed by the
government. However government still watches the retail price so that the prices does not
increase more than 5% in any year. The current retail price of subsidized fertilizers at the farm
is currently at c$220 which is significantly below international phosphate prices of $620.
Small farmers in India represent just over 50% of total fertilizer consumption, and this
subsidy system is thought to strongly underpin their fertilizer demand as well as their total
crop output. However given the huge subsidy burden Indian government has no option but to
reduce the subsidies (although gradually as this is a politically sensitive issue) over time.
$30
$25
$20
$15
$10
$5
$-
00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 09-10
DAP and MAP capacity growing 2.1% and 2.3% respectively worldwide. Over the 2011-
2015 period British Sulphur expects global DAP capacity will grow at a 2.1% annual rate led
by the Ma’aden project in Saudi Arabia which will add 2.9mt, or 6%, to global DAP supply
and 18% to the 16mt traded DAP market when it comes on-stream in Q2 2011 although
commercial production is expected to began in Q3 11 (reaching full capacity in 2012). We
expect additional significant DAP expansions over this timeframe will occur in China (5% of
2010 capacity) and Africa (Egypt and Morocco, adding 3%). Meanwhile, British Sulphur
expects MAP capacity will grow at 2.3% CAGR during this period, led by expansions in
Morocco and Saudi Arabia. This may look modest following a 10% increase in global MAP
capacity in 2010 driven mainly by the Chinese expansions. With DAP prices exceeding the
roughly $350pt and $400pt required to justify brownfield and greenfield integrated DAP plant
construction, respectively, we expect the majority of planned expansions will proceed.
10
PotashCorp
CF Industries
Mosaic
OCP
Phosagro
GCT
EuroChem
Agrium
MAP+DAP capacity global ranking MMT p.a.
Source: Eurochem
Chinese exports limited by export tariffs. Historically, China has been the world’s biggest
importer of phosphate fertilizers. Due to the government’s policy of becoming self-sufficient
(as for urea), phosphate capacities have increased substantially, from virtually nothing in 1993
to 16.6m tones in 2010 (34% of global capacity). Self-sufficiency was achieved in 2006 and
China became a major net phosphate fertilizer exporter in 2007 as supply grew faster than
demand. However, similarly to urea, in order to keep its phosphate resources for the local
agriculture and keep local prices as low as possible, the Chinese government has increased
export duties on phosphate fertilizers. Export tariffs on MAP/DAP currently stand at 110%
during the peak of the season (January to May and October-December) and 7% from June to
September. TSP tariffs are at 7% through the year. For 2011 total DAP and MAP exports are
expected to decline 9% year-on-year due to shortage of phosphate rock and reduced
operating rates which is likely to restrict supply to the domestic markets.
Figure 610: Chinese phosphoric acid capacity (m tones) Figure 611: Chinese DAP and MAP trade (m tones)
25 5.0
20 4.0
3.0
15
2.0
10
1.0
5 0.0
0 -1.0
2007
2008
2009
2010
2011E
2012E
2013E
2014E
2015E
2016E
2017E
2018E
2019E
-2.0
2007 2008 2009 2010 2011E 2012E 2013E
Integrated producers have a cost advantage. Phosphate fertilizer producers that are not
integrated to rock and/or sulfur face significantly higher costs. With 30% of global rock output
going to non-integrated producers, these producers represent the marginal capacity in
phosphate, and the input costs they face are a key driver of DAP pricing. Note that the
overwhelming majority of new production capacity in phosphate fertilizer is coming from
producers who are integrated into rock.
700
600
500
400
300
200
100
0
Integrated Non-Integrated Scenario # 1 Non-Integrated Scenario # 2 Non-Integrated Scenario # 3
Rock = $75/mt Rock = $150/mt Rock = $225/mt
Source: Deutsche Bank, Potash Corp. Other costs assume a large plant operating at capacity and freight to port
Industrial Gases
Figure 613: Industrial gases at a glance
Growth rate 400-500 bps above Industrial production
Industry background
A disciplined and consolidated industry. The industrial gases industry has undergone
significant structural change since the investment excesses of the 1990s. Consolidation and
management change at the top six companies have underpinned improved investment
discipline with companies increasingly focusing on either products or regions to drive
improved returns. Despite lower over-the-cycle capex, the rate of annual growth for the tier
one global players accelerated to 8% through 2006-2008 supported by new less capital
intensive, higher growth gas applications emerge (such as hydrogen, healthcare and
consumer applications) alongside on-going strong growth in emerging markets (Eastern
Europe, Asia and increasingly Middle East). Through the financial crisis the higher focus on
long-term take-or-pay contracts (on-sites) alongside the growing shift towards less GDP
dependent end-users culminated in a sales decline of only 5-8% in 2009 for the global
majors. Helped by an easy base effect, growth in 2010 for the industry was around 12%.
Industry growth has accelerated through the past five years. Despite lower over-the-
cycle industry capex through the past few years, we believe the rate of growth for the global
tier one players has accelerated to 7-8% per annum (excluding the impact of the financial
crisis). 2010 was a year of c.12% growth (helped by the easy 2009 base) which implies
global industry sales of approximately $70bn. While this is partly driven by improvement in
macro demand on a low 2009 base, we believe this is also supported by new less capital
intensive, higher growth gas applications (such as hydrogen, healthcare and consumer
applications) alongside strong growth from emerging markets (Eastern Europe, Asia –
particularly China and Middle East) driven not only by local GDP but also the on-going
migration of customer capacity to these regions.
Figure 614: Sales by market share (2011E) Figure 615: Industry sales by region (2011E)
Other
Others 5%
Air Liquide
20% 24%
Asia Am ericas
26% 36%
Airgas
6%
TNS
4%
Air Linde
Products 22%
11% Praxair Europe
13% 33%
Source: Deutsche Bank estimates, company data, Spiritus Consulting. TNS = Taiyo Nippon Sanso. Data Source: Spiritus Consulting, Deutsche Bank estimates, company data
includes share of sales from associate participations and JVs
The industrial gases market is a ’local’ global market. The industrial gases market is a
global market – an issue that has driven consolidation over the past few years – but it is
primarily managed on a local basis because of high distribution costs involved in the industry.
Most industrial gases are not traded across borders and oceans like traditional chemicals.
Most industrial gas players are not yet truly global with exposure to key regions still missing –
such as Air Products (Europe, part of Latin America and Asia), Praxair (parts of Asia, Europe),
Airgas (Europe, Asia, Latin America), Air Liquide (parts of Asia, Latin America) and Linde
(limited exposure to North America, particularly southern US petrochemical region)
We note the on-going trend of buyers towards globalised preferred supplier relationships in a
bid to strengthen their client relationships and improve efficiencies. While this is not a pre-
requisite for strong financial performance at the moment, global relationships between
customers and industrial gas companies are becoming more prevalent.
Global players still making the best margins in regions of highest market share (often
‘home’ regions). The local nature of businesses and the increasing role of IT and logistics
mean that critical mass in a small region is key to maximising profitability. We note that most
of the global players are strongest (and most profitable) in their home regions, or where they
have the greatest market share – Linde in Germany/UK/Scandinavia, Praxair in Latam and Air
Liquide in France. We estimate that companies can generate 200-500bps higher margins in
the areas with strongest local dominance. With critical regional mass as a key determinant of
profitability, the global gas players are constantly rationalising activities and exiting countries
where they do not have the required critical mass.
The industrial gases market is highly concentrated. The wave of consolidation in the
industry in the late 1990s and early 2000s further concentrated the industry and the industry’s
highly consolidated nature has been a key factor reducing the possibilities for consolidation.
The top five players now account for 76% of the global market compared to 51% in 1980 –
Figure 617 below shows the steady consolidation of the industry over the past 30 years. This
“global” share analysis only tells half the story as the industry is a local industry so looking at
the local market share positions the shares are even higher with most industrial basins in the
world covered by just two gas players. In our view, further global mergers are unlikely for
anti-trust reasons but piecemeal disposal of non-core businesses and local scale
consolidation is still possible, but on a much smaller scale than in the past decade.
Air Liquide 15% 14% 19% 19% 20% 22% 22% 22% 23% 24%
BOC 10% 16% 17% 14% 13% 13% 13% 0% 0% 0%
Praxair/Union Carbide 13% 14% 11% 14% 14% 13% 14% 15% 14% 13%
Linde 3% 3% 4% 11% 11% 11% 10% 21% 21% 22%
APD 10% 11% 9% 9% 9% 11% 11% 11% 12% 11%
Airgas 0% 0% 3% 3% 3% 3% 4% 5% 6% 6%
'Top 5' market share 51% 58% 63% 70% 70% 73% 74% 74% 76% 76%
Source: Spiritus Consulting, Deutsche Bank estimates
Distribution methods
Industrial gases are distributed in three main ways: On-site/pipeline, merchant (bulk)
and cylinder (packaged). The type of distribution method used is dependent on the volume
required and the distribution distance:
On-site/pipeline is used for high volume users – such as chemical plants – where the
product is piped into a site directly or is produced by an on-site unit. The high capital
commitment is offset by a long-term take-or-pay contract (15–20 years).
Cylinder refers to the lowest volume requirement and can be used for higher-value
gases. This method is more people intensive, but does involve a more stable income
flow due to rental income from the cylinder which can account for around 15%–20% of
the total revenue from the cylinder.
Capex boomed in the mid-to-late 1990s. Gas industry capex boomed through this period
due to a mixture of lower management controls, aggressive globalisation strategies and
surplus cash driving expansions into new regions. Given the time lag between building new
capacity and achieving profits, this led to an inevitable depression of RoCE. In addition, the
competitive expansion policies also led to pricing erosion, particularly in Northern Europe/US.
The new investment discipline is here to stay. A spate of senior management changes at
all industrial gas companies in the early 2000s (Air Liquide, BOC, Praxair, AGA, Air Products,
Linde and Messer) prompted the change towards capital discipline. This led to improved
internal controls and a more disciplined investment process that persists today. As a result,
despite modestly rising capex, we expect the discipline to remain. Through the boom of the
1990s, Messer and AGA were aggressive investors but these were consolidated away a long
time ago (AGA was bought by Linde, Messer by Air Liquide).
Figure 620: Capex/sales for AGA and Messer were the Figure 621: AGA/Messer invested particularly heavily in
most aggressive capex investors the US
30% 16%
25% 12%
20% 8%
15% 4%
10% 0%
1996 1997 1998 1999 AGA M esser APD Praxair AL BOC
AGA & Messer average Industry average
CaGR in US LIN/LOX capacity - 1995 to 2000
Source: Company data Source: Spiritus Consulting
Industry RoCE should continue to improve. Industry RoCE weakened through the late
1990s due to the higher capex spend and the more aggressive price cutting. Looking
forward, with an increased focus on investment discipline and lower over-the-cycle levels of
capex RoCE for the industry should now steadily improve.
Figure 623: Capex is now increasing very modestly… Figure 624: …but should not stop RoCE from
improving in the industry
25% 20%
16%
20%
12%
15%
8%
10%
4%
5% 0%
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
2008
2009
2010
2011E
2012E
Source: Company data, Deutsche Bank estimates. Source: Company data, Deutsche Bank estimates. Data for Linde is shown excluding intangibles from the
BOC acquisition.
There are three key methods of price increases implemented by gas companies:
The capital argument. Following price erosion through the 1990s, prices became so
low that new investments could not be justified. Companies have now reverted to asking
customers (including the GDP-sensitive ones) for price increases. Companies have
shown their customers (with whom they often have longstanding relationships) that if
price increases are not successful, they cannot justify the capital commitment to their
customers. Due to the local nature of the industry (the distribution radius for gases is
200km at maximum) customers have been more willing to accept higher prices.
The service/value-added argument. While the capital argument has been used most
readily over the past decade (particularly in US merchant gases), the customer is also
beginning to ask for more value in return for higher prices. This is being addressed in the
form of extra services, better quality, etc. Electronic gases provide an example of
potential 'value-added' pricing. The cost of industrial gases in the manufacturing process
of a semi-conductor is around 1–2% of the total manufacturing costs. However, given
that gases are critical for purity of the semi-conductors, there is considerable room here
for price increases if companies demonstrate improvements in efficiency. Similar
examples can be seen in Healthcare.
Raw material pass-through (electricity). For some types of gas distribution agreement
there can often be a specific contract clause stipulating the straight pass-through of
higher energy costs to the customer. Often this is linked to a local energy index. This
type of contract agreement is typical for all long-term on-site investments and is also
common for most US merchant contracts. However, in cylinders and merchant (outside
the US) these contracts do not tend to exist which means that the company’s ability to
pass through the higher energy costs is based on individual customer discussions.
Pricing discipline continued through the downturn. Despite the volume slowdown in
2009 all of the major gas names delivered positive pricing progression. Air Liquide reported
2.5% pricing growth in their merchant business while Linde also highlighted positive pricing
(we estimate 1-2%) for 2009. US peers also reported pricing growth through 2009 with Air
Products reporting a pricing growth of 1% while Praxair also reported pricing growth of 2%
2009. Pricing discipline has continued through 2010 with both Air Liquide and Linde
highlighting positive pricing.
Despite modestly increasing capex we do not expect a cessation of the price discipline.
Positive momentum for price increases exists within the industry and we expect it to
continue despite the current increases in capex. The important issue to note is that the new
capex invested is almost totally directed to dedicated customer investments where the gas
product is effectively pre-sold (mainly on-site) rather than the more speculative merchant
free-standing units, which are often built and then the product is aggressively sold in the
market (as seen in the late-1990s). This should ensure that even if economic demand
weakens materially the industrial gas industry should not end up dumping surplus gas
product onto the market.
Neon
0.0018%
Helium
0.0005%
Hydrogen
0.00005%
Krypton
0.0001%
Nitrogen
78.08% Xenon
0.000009%
Source: Linde
Cryogenic Process. The cryogenic air separation process produces purified gases and liquids
by taking air from the atmosphere. The air is compressed and purified then cooled and then,
relying on different boiling points, separated into its elemental components in the form of
liquid oxygen, argon and nitrogen. However, there could be different variations in the process
depending on what gases are required to be produced (whether simply oxygen or nitrogen,
both oxygen and nitrogen, or nitrogen, oxygen and argon), degree of purity etc. The process
has the following features:
Compression: This step involves filtering and compressing atmospheric air to remove
dust. Since the compressor heats up the air, it is cooled again in a heat exchanger to
ambient temperatures. In some cases it is cooled in a mechanical refrigeration system to
a much lower temperature. This leads to a better impurity removal, and also minimizing
power consumption, causing less variation in plant performance due to changes in
atmospheric temperature seasonally.
Purification: The processed air is generally passed through a molecular sieve bed, which
removes any remaining water vapour, as well as carbon dioxide. They are to be removed
before the air enters the distillation portion of the plant which would freeze in the
cryogenic equipment otherwise. There are two basic methods to get rid of water vapor
and carbon dioxide - molecular sieve units and reversing exchangers.
Cooling & Distillation: Process air is passed through an integrated heat exchanger and
cooled against product (and waste) cryogenic streams. The air is then cool enough to be
distilled in a distillation column. The formation of liquid air in the cryogenic equipment
requires some refrigeration. Cryogenic air separation units are built to provide one or
both of nitrogen and oxygen although argon is also often produced. Liquid nitrogen "LIN",
Liquid oxygen "LOX" and liquid argon can be produced if sufficient refrigeration is
provided for in the design. Finally the product gases are warmed against the incoming air
to ambient temperatures.
Product supply and storage: There are a number of distribution methods for produced
air gases including pipelines to large industrial users adjacent to or nearby to the
production plant or through cylinders (for smaller quantities). If a viable pipeline system
does not exist, long distance transportation of products is usually done as a liquid
product for large quantities.
Non-cryogenic air separation. While cryogenic technology is a more traditional method and
requires large sized plants for its processing, the non cryogenic process is considered to be a
convenient, efficient, and economical method to buying gas in high pressure cylinders or for
purchasing bulk liquid products to be vaporized. This process is preferable for many small
scale users of oxygen or nitrogen. There are three main technologies involved in non
cryogenic process. They are Pressure Swing Adsorption (PSA) used in nitrogen and oxygen
generators, Vacuum-Pressure Swing Adsorption (VPSA) used in oxygen generators and
Membrane Separation, used to produce nitrogen gas. Non cryogenic gas processing is
growing though it remains the less used technology.
Figure 629: Industry capex was weighted equally to on- Figure 630: Industry cpaex now weighted heavily to on-
site and merchant/cylinder site (2011E)
Cylinder Cylinder
15% 10%
Merchant
20%
Onsite
50%
Merchant
35% Onsite
70%
Source: Deutsche bank estimates, company data Source: Deutsche bank estimates, Spiritus Consulting
Energy prices
Electricity is a key input cost for industrial gases. Electricity is a key raw material for
industrial gas companies and can account for up to 50% of industrial gas companies’
production costs. The question on whether these higher electricity prices can be passed onto
customers requires a discussion centering on the type of distribution method used for
industrial gas. In general, much of the electricity price increase can be passed onto
customers due to energy price clauses in most supply contracts in the on-site business.
However, passing these costs onto customers in the cylinder and the merchant gas business
is generally more difficult. We discuss each of these distribution methods separately:
Cylinders: We estimate that this method has the lowest exposure to energy prices—
these costs are equivalent to approximately 10% of sales—as the labour costs and
associated distribution costs are proportionally higher. The ability of a company to pass
these costs onto customers generally depends on the strength of a company’s position
in the local market as there is normally no pricing clause in customer contracts.
On-site: This method of distribution has the highest emphasis on energy costs (up to
50% of sales), but the contracts will almost always include specific clauses for the
transmission of higher (or lower) energy costs through to the customer. Therefore, the
net impact on the gas company of higher (or lower) energy costs should be immaterial.
60%
50%
40%
30%
20%
10%
0%
On -site M erch an t Cy lin d ers
Oxygen (28%) Reactive properties Steel (decarbonisation of cast iron to produce steel), chemicals (plastic production), metal
f bi i ( i d ldi ) i l (bl hi f l l li )
Sustaining life Medical (treatment of respiratory insufficiencies, intensive care), fish farming, waste-water
Nitrogen (20%) Inert properties Electronics, chemicals (protection of products and facilities), food processing (preservation
d i ) l f b i i (h f i l )
Cryogenic properties Food freezing, healthcare (low-temperature preservation of living tissues and cells)
Hydrogen (11%) Reactive properties Refining oil, enhanced oil recovery, fibre–optics, food processing (production of food oils),
l f b i i (h ) l d i ( li hi )
Fuel Space programme (fuel for cryogenic rocket motors), fuel cells (transport fuel)
Argon (9%) High–temperature inert properties Stainless steel, metal fabrication (protection of welds against oxidation; fume reduction).
Carbon dioxide (8%) Inert properties Metal fabrication (protection of welds against oxidation), steel, chemicals, food processing.
Solubility properties Beverage carbonation.
Acetylene (6%) Reactive properties Metal fabrication (cutting and welding), glass production (lubrication of glass moulds).
Helium (3%) Cryogenic properties Research, aerospace (cryogenic tank pressurisation), superconductivity.
Inert properties Diving breathing mixtures, electronics
The focus on ‘higher-value’, ‘higher-growth’ and less GDP sensitive customers is increasing.
Along with the increased focus on less capital intensive activities, many gas companies have
also been actively increasing their relative exposure to higher growth and less GDP sensitive
end-users, as shown in Figure 633. This is not only to increase the growth rates of the
underlying businesses, but also an effort to reduce the inherent cyclicality of corporate
earnings. A transition away from traditionally cyclical end-users such as the steel industry
(although this is still a large end-user for many companies, particularly Praxair) and an
expansion into areas such as medical gases and consumer type end-users (e.g. carbon
dioxide and high purity oxygen in food) are clear examples of this. As a result, while the
industry remains exposed to heavy cyclical end-users such as chemicals and steel, it is
important to note that many of the numerous end-users are not that cyclical or GDP
dependent such as Healthcare, some consumer applications, green energies etc).
Figure 633: End-user profile is changing—less emphasis on GDP and IP sensitive end-users
30%
25%
20%
15%
10%
5%
0%
Manufacturing
H/C
Metallurgy
Food
Others
Electronics
Consumer
Chemicals
Industry
Annual growth for the tier one gas companies has accelerated to approximately 7-8%
from 5-6% in 1990s/early 2000s. Numerous key end-users offer sustainable growth rates in
excess of 2x Industrial Production and should continue to support high single-digit top-line
growth forecasts for many of the individual industrial gas companies. Some of these
applications offer gas demand of double digit, whereas some also offer the potential for non-
gas revenue growth (such as in the services area — e.g. customer training). We note
tightening regulations in many areas are driving structural growth (e.g. Hydrogen). We have
highlighted in Figure 634 some examples of these types of uses for industrial gases.
Figure 634: Examples of higher-growth applications for industrial gases
Industry Application/driver Annual growth
Environmental Energy conservation, control of emissions, water quality >10%
Refining and petroleum Hydrogen for clean fuels & upgrading heavy crudes, enhanced oil recovery >10%
Foods & beverage Ready meals, food safety, process technology, Asia 5-10%
Medical Regulatory environment, cost pressure, home therapy, improving living >5%
Hospitality Outsourcing, safety legislation, industry restructuring, product quality 5-10%
Electronics New technology, communications, compound semi-conductors >10% (long-term)
Source: Deutsche Bank, company data.
Gas intensity increasing. While demand for gas continues to accelerate we also note that
the intensity of the amount of gas used in basic industrial processing continues to increase.
Industrial gases are often synonymous with the quality of the end product and with
increasing demand across most end-users for better quality end-product, the use of gases is
becoming more intensive. An example of this is in steel and highlighted below in Figure 635.
In addition to this as economies develop and the consumer power grows we also note that
the amount of “gas” used by an individual consumer also increases strongly (Figure 636).
Figure 635: Gas consumption increasing with the Figure 636: Gas intensity still low in emerging markets
technology development
O2 Demand/ ton Steel Gas Value Intensity
O2 Consumption
Developed Markets
Developing Markets
Technology Development
Source: Spritius Consulting Source: Spritius Consulting
Source: World Energy Outlook 2009 (International Energy Agency IEA), Linde
Industrial gases are leveraged to many of the new energy drivers. The advent of new
energy sources alongside the constant drive towards cleaner fuels and reduced emissions is
creating massive opportunities for the industrial gas industry – most of these will have a
material impact in the coming 5-10 years. These so-called “mega energy” trends will
continue to support the long-term growth in gas industry. Some of the key examples of these
technologies includes carbon sequestration (carbon storage, capture and disposal), increased
focus on environmental friendly oxy-fuel combustion technology, coal-to-chemicals and coal-
to-liquids, biomass to liquid, desulphurization, enhanced oil recovery, LNG, GTL,
photovoltaics to fuel cells. Although some of these opportunities (e.g. carbon capture
technologies) may be 5-10 years away from commercialization others are impacting order
books now. We expect these areas to be a big driver of the industry’s growth in the coming
years and so have discussed the various opportunities across this space in the coming
pages. In Figure 638 overleaf we have provided a summary of the seven areas of investment
opportunity and expected timescale.
Figure 638: A summary of the opportunities in “mega energies” over the next ten years
Product Type Global industry investment opportunity Timescale
Natural Gas Liquid Natural Gas (LNG) Euro 10bn+ 2010-2020
Gas-to-liquids (GTL) Euro 10bn+ 2012-2020
Hydrogen HyCO (syngas) HyCO market should continue to offer strong growth – we 2010-2020
estimate around 10% per annum with a strong focus on
emerging markets
Desulphurisation Market should offer 10%+ growth per annum depending on 2010-2020
the rate of refinery capacity expansion
Photovoltaics and Silicon Silane Market should offer 5-10% growth per annum 2010-2020
Photovoltaics Market should offer at least 10% growth per annum 2010-2020
depending on energy prices and tariff support
Biomass Biomass to liquids and Potentially more than Euro 1bn 2015-2020
biofuels
Many energy investments will be large – plant only sale of JVs may reduce the risks.
For many of the opportunities the investment cost in the gas site could be in excess of Euro
500m which for some of the gas companies may present too high an initial upfront
investment cost, particularly if the investment is within a region where the prospect of further
industrial investment is low and so the chances of maximizing returns by providing additional
gases to other end-users is also low. In these situations gas companies may also go down
the “plant only” sale route or look to JVs (with the customer) to diversify risk.
Natural rubber
Figure 639: Natural rubber at a glance
Long-term growth rate GDP
Growth rate relative to the sector Average
Supply/Demand Tight
Margin prospects Healthy
Watch out for ... Further supply shocks, long term substitution to synthetic rubber
Source: Deutsche Bank
Natural rubber (NR) is a naturally occurring elastomeric polymer of isoprene. The tire market
dominates world consumption of natural rubber. It has excellent resistance to abrasion,
impact, tear and heat build up. However, natural rubber is not very resistant to oxidation,
ozone, weathering, and a wide range of chemicals and solvents.
Figure 640: Share of world NR production Figure 641: Natural rubber TSR 20 prices ($/ton)
Other
4% 6,000
5,000
Other Asia Thailand 4,000
25% 31%
3,000
2,000
1,000
0
Jan-01
Jan-02
Jan-03
Jan-04
Jan-05
Jan-06
Jan-07
Jan-08
Jan-09
Jan-10
Jan-11
Jan-12
Malaysia
11%
Indonesia
29% North America Southeast Asia
Natural rubber prices have been very volatile, increasing significantly with strong demand
from China and the US (better than expected growth in automotive segment) further
exacerbated by production declines due to poor weather (heavy rains in rubber producing
countries such as Thailand, Malaysia, India). Supply constraints may persist due to ageing
plantations and the low level of replanting. This volatility is supportive to synthetic rubber
long-term as customers will over time substitute to synthetic rubber to avoid volatility in raw
materials costs and benefit from more stable pricing.
Synthetic rubber
Figure 642: Synthetic rubber at a glance
Long-term growth rate 1.5xGDP
Growth rate relative to the sector Slightly higher
Supply/Demand High performance rubber to remain tight,low cost (ESBR) tightening from low base
Margin prospects High perf stable at a high level due to tight supply, others stable but lower
Watch out for ... Asian auto growth rates, tyre labeling legislation
Source: Deutsche Bank
Synthetic rubber is primarily produced from petrochemicals and its main end use is in the
manufacture of tyres. The tyre market itself comprises OEM (c.30% of the market) and the
replacement market (c.70% of the market) with the majority of tyres sold being replacement.
Demand for tyres, (where the majority of synthetic rubber is used) remains robust with 5%
CAGR forecast globally for 2010-2015, with over 9% CAGR in Asia forecast in the same
period.
There are two different types of styrene-butadiene rubber: solution (S-SBR) and emulsion (E-
SBR). E-SBR is not used in performance rubber applications as it does not have the
appropriate characteristics. S-SBR, polybutadiene rubber (PBR) and butyl are performance
grade rubbers.
Figure 643: Styrene Butadiene rubber prices expected to Figure 644: Poly-butadiene rubber prices expected to
remain strong (US$/ Metric tonne) remain strong (US$/ Metric tonne)
4,000 5,000
3,500 4,000
3,000
2,500 3,000
2,000 2,000
1,500
1,000 1,000
500 0
0
Jan-00
Jan-01
Jan-02
Jan-03
Jan-04
Jan-05
Jan-06
Jan-07
Jan-08
Jan-09
Jan-10
Jan-11
Jan-12
Jan-00
Jan-01
Jan-02
Jan-03
Jan-04
Jan-05
Jan-06
Jan-07
Jan-08
Jan-09
Jan-10
Jan-11
Jan-12
Drivers for the industry are mobility, urbanization and a growing middle-class in emerging
countries. There is a general trend towards using more high performance tyres due to their
beneficial fuel efficiency, longer lifetimes, better wet grip and lower exterior noise. We
expect tyre labeling legislation to result in a positive impact on growth as it makes innovation
in rubber grades visible to the customer.
Historically, the replacement tyre market has grown on average 200-250bps higher than
global auto growth due to an increase in the number of miles driven shortening replacement
times. Furthermore, high performance rubber should grow faster than this due to increased
number of miles driven, increased use of its performance rubber, supported by tyre labeling
legislation in Europe and our expectation of voluntary adoption in other regions/countries.
Figure 645: Limited substitution risk from natural rubber Figure 646: Oil, natural and synthetic rubber prices
show some degree of correlation
Low substitution risk High substitution risk 700
600
500
EPDM 400
300
NBR 200
100
E-SBR
0
Feb-90
Feb-92
Feb-94
Feb-96
Feb-98
Feb-00
Feb-02
Feb-04
Feb-06
Feb-08
Feb-10
Feb-12
S-SBR
PBR1
There is a limited short term substitution between natural rubber and synthetic rubber.
Natural rubber and synthetic rubber are two distinct and separate products with different
properties influencing the applications. In tyres for instance, truck tyres use mainly natural
rubber (>80% by weight) since it has a better resistance to sharp impacts than synthetic
rubber. Synthetic rubber though is the main raw material in passenger tyres with over 90% of
the rubber in a tyre being synthetic because of its superior wear, rolling resistance and wet
grip as compared with natural rubber. It is because of these different properties that only
limited substitution is possible between natural and synthetic rubbers, approximately 5%.
E-SBR is produced via emulsion polymerization and is not used in performance rubber
applications as it does not have the appropriate characteristics. S-SBR is produced via
solution polymerization. E-SBR and S-SBR are produced through the copolymerization of
butadiene with styrene at a ratio of about 3:1.
70% of SBR rubbers are used in tyres with the rest used in mechanical and other
applications. Just over half of performance butadiene rubber demand is from Asia-Pacific,
with the other half more or less evenly split between the Americas and EMEA.
Figure 648: SBR rubber end market split Figure 649: Worldwide E-SBR market 2010
Kumho
Other Group
13%
10%
SINOPEC
8%
Mechanical
Goods ISP
17% Other 7%
Tyres and 47%
Tyre Lanxess
Products 6%
70% Goodyear
6%
CNPC
Gazprom TSRC 6%
5% 5%
Source: Deutsche Bank, SRI Source: Deutsche Bank, CMAI
Figure 650: PBR end uses Figure 651: Top 15 PBR/SSBR producers (2011E)
Lifestyle &
Technical leisure 20%
rubber* 6%
15%
7%
10%
5%
Plastics
16% 0%
Lanxess
Goodyear
Styron
Michelin
KKPC
Sibur
JSR
Petrochina
TSRC
Asahi
BSFS
Sinopec
NKNK
Efremov
Ploimeri
Tire
71%
Source: Deutsche Bank estimates, LANXESS, *e.g. industrial and mining Source: LANXESS, CMAI, Deutsche Bank
Most producers have multipurpose production units that can be used to produce BR or SBR
or/and other related polymers. Thus, plant capacities can vary depending on market
conditions.
Figure 653: Supply/demand for PBR Figure 654: Top Nd-PBR producers (2011E)
60%
50%
40%
30%
20%
10%
0% Lanxess
Sibur
KKPC
NKNK
Polimeri
Carbochem
Source: LANXESSestimates based on CMAI, SRI, LMC Source: LANXESS, CMAI, Deutsche Bank
Increasing demand for PBR and Nd-PBR is driven by trends towards greater mobility and
the demand for higher environmental and safety standards in performance tyres. Nd-PBR
reduces energy consumption and tyre abrasion also enhancing fuel efficiency and wet
grip compared with conventional SBR tyres.
Butyl rubber
Butyl is a high quality rubber that is impermeable to gas and moisture with high chemical
resistance and excellent mechanical properties. Butyl rubber is mainly used in the tyre
industry as an inner liner for car, truck, bus and airplane tyres. Special applications include
protective clothing, medical devices and chewing gum. The market in 2011 will be worth
around E2.2bn globally.
The butyl market is oligopolistic with key competitors including ExxonMobil Chemicals,
Sinopec, Nizhnekamskneftekhi and Sibur Holding.
Figure 655: Butyl rubber end uses 2010 Figure 656: Butyl rubber market
Others
Gum 9% 600 50%
4% 500 40%
400
Pharma 30%
300
11% 20%
200
100 10%
0 0%
Exxon
Lanxess
JSR
Sibur
NKNK
Sinopec
Tire
76%
There are two types of butyl rubber, regular butyl rubber (Butyl) and Halobutyl rubber
(chlorobutyl, bromobutyl). It is manufactured from isobutene and isoprene. Key butyl rubber
products include regular butyl and halo butyl. Halobutyl, used in the innerliners of tyres, is a
more profitable product for rubber producers.
We expect global supply/demand for butyl rubber to remain tight for the foreseeable
future helped by steady demand growth and disciplined capacity expansions. We
forecast industry operating rates to remain above 90% in 2011 and 2012 before easing
slightly in 2013 when new capacity comes on-stream. We expect supply/demand for
halo butyl rubbers (chloro and bromo butyl) to remain tighter as the majority of new
capacity (except Lanxess) is focused production of regular butyl rubber.
Polymerization C hlorination
( Poly-) C hloroprene
Butadiene & chlorine C hloroprene m onomer
rubber (CR)
Polymerization
Ethylene & propylene Ethylene-propylene
& diene monomer diene rubber ( EPDM)
Polymerization
Ethylene-vinyl acetate
Ethylene & vinylacetate
rubber (EVM)
The market has grown at approximately 4-5% from 2011-2015, driven by Asia (~8%) and
EMEA and Americas at around 2-3%. These products are used in automotive, engineering,
construction, electronics, oil exploration, and aviation industries. They end up being used in a
wide range of applications – seals, hoses, profiles, cable sheathing, special films &
adhesives.
Figure 660: Other rubber end uses Figure 661: Other rubber global demand 2010
Others
17%
Americas
Construction Automotive 28%
38% Asia Pacific
4%
40%
Plastics
5%
Electro/
electronics
6%
Footwear EMEA
13% Mechanical
engineering 32%
17%
Source: Deutsche Bank estimates, LANXESS Source: Deutsche Bank, LANXESS estimates
Autocatalysts
Catalytic converters are fitted to exhausts to reduce emissions
A catalytic converter or catalyst is used to reduce emissions from an internal combustion
engine. Catalysts are fitted to passenger cars, heavy duty diesel (trucks and vans) and non-
road diesel (construction and mining equipment). The four main exhaust pollutants that
catalysts reduce are carbon monoxide (CO), hydrocarbons (HC), oxides of nitrogen (NOx) and
particulate matter (PM). Emissions limits of all four are regulated.
Hydrocarbons (HC) include known carcinogens and photochemically active species that
contribute to the formation of ground level ozone and smog.
Nitrogen oxides (NOx) emissions are associated with smog, acid rain and health risks
such as respiratory problems.
Particulate matter or soot (PT) is solids emitted by an engine. Soot contains a large
number of ultra-fine particles that are invisible to the naked eye. PM comprises mostly of
carbon and absorbed hydrocarbons. These smaller particles, when inhaled are
aggravating and cause lung and heart conditions. Diesel engines tend to produce more
PM than petrol engines.
Catalysts convert emissions to carbon dioxide, water and nitrogen
Catalysts installed in engine exhausts will cut these pollutant emissions either by oxidizing or
reducing them to carbon dioxide (CO2), water (H20) and nitrogen. Catalysts can reduce car
emissions by over 90%. A catalyst is the active component of the catalytic converter. It
consists of a substrate with a large surface area coated in an extremely thin coating of finely
dispersed, very small particles of precious metal, such as platinum, palladium or rhodium is
coated onto this support. The main objective is to minimize the amount of precious metal
used but maximize the amount of precious metal surface area for gas molecules to come into
contact with. Catalysts are not consumed but actively promote reactions.
Selective catalytic reduction (SCR) systems work by chemically reducing NO and NO2
using a reductant such as urea solution, which is added to exhaust gas.
NOx adsorber catalysts (NACs) remove NOx from a lean gas stream by chemical
adsorbtion onto a catalyst and subsequent removal under stoichiometric or rich
conditions. Adsorbtion is the adhesion of a thick layer of molecules to the surface of a
solid or liquid.
SCR systems
For ammonia SCR systems, urea is the most common source of ammonia. Ammonia SCR
systems combine ammonia (NH3) with NOx to form nitrogen and water. For hydrocarbon
SCR systems, diesel fuel is the source of hydrocarbon. Hydrocarbon SCR systems use
hydrocarbons as a reductant. These may already be present in the exhaust gas or added to it.
Catalysts and filters should last for the lifetime of the vehicle
They remain effective for the whole period as long as the vehicle is serviced properly.
Vehicle emissions regulations contain a durability requirement in that the emissions must
remain within the limits for a given mileage. This varies around the world but can range from
80,000 km to double that.
Structure of industry
There are four main catalyst markets at different stages of maturity. These are autocatalysts
(light duty; either gasoline or diesel), heavy duty diesel catalysts (HDD), non-road diesel
catalysts (NRD) and process catalysts. Autocatalysts are the most established, being
catalysts to reduce emissions on gasoline and diesel passenger cars (light duty). The effect of
tightening emissions legislation on heavy duty diesel and non-road diesel should drive growth
over the next 10 years. Autocats will still have growth potential because of tightening
emissions legislation and auto production but this is likely to be below HDD and NRD.
Autocat market: Johnson Matthey, Umicore and BASF have equal shares
The main players in the autocatalyst market are Johnson Matthey, Umicore and BASF all with
relatively equal market shares of around 30% and other producers accounting for 8% of the
market.
Figure 665: % of global auto production by region (2010) Figure 666: Global autocatalyst market shares (2010)
Western
Europe North
16% America Umicore
17% 31%
Source: Deutsche Bank, JD Power Source: Deutsche Bank
Others
8%
BASF
22%
Umicore
5% Johnson Matthey
65%
Thrifting reduces costs to the OEM and drives further autocatalyst profit growth
More importantly, cutting the high level of precious metal content in an autocat is key to
winning new business. Tighter standards require ever higher rates of precious metals which
drive up costs for the OEM. Successful thrifting (lowering precious metal content) reduces
OEM costs, helping an autocat company to win production platforms while potentially
boosting the coating charge (by receiving a share of the achieved savings through thrifting)
and the autocat company’s EBIT margin. Thrifting is an ever present part of the autocatalyst
industry and is necessary since it is not feasible without doing it due to high cost of PGM’s.
For example with tougher legislation now in place, it might be expected that the average
catalyst loading would be much higher than the early 1980s, however better technology and
thrifting means that PGM loadings are similar today despite the much tougher legislative
requirements. Even with thrifting the average PGM loading per catalyst (which varies with
type of catalyst and application) is 4-6g. This business model is practicable for as long as
emissions standards continue to tighten- at least ten years in our view.
Breakdown of catalyst materials
Autocatalyst manufacturers have traditionally used platinum as the precious metal
component since this has the greatest effect in reducing emissions from engines. However
over time advances in technology have allowed the use of less efficacious but cheaper
materials to replace platinum and still maintain the efficiency of the overall catalyst unit, a
trend which is exacerbated by high platinum prices. In particular palladium has replaced
platinum to a large degree in gasoline catalysts and is beginning to replace platinum in diesel
catalysts as well (although to a far lesser extent).
Figure 670: Global autocat cost by substrate, PM and Figure 671: Thrifting drives profitability- Precious metal
coating charge content and cost is reduced- coating charge rises
100
Subs trate c ost
100 Subs trate c ost
Subs trate c ost
80 C oa ting charge
80 C oa ting charge C oa ting charge
60
60
Prec ious metal cost Prec ious metal cost
20 20
0
0
Autocat cost structure Start Point Post-Thrifting
Source: Deutsche Bank and Johnson Matthey Source: Deutsche Bank and Johnson Matthey
Figure 672: HDD emissions legislation by region has Figure 673: Number of vehicles affected by HDD
tightened for Particulates (y-axis) and NOx (x-axis)* legislation (2010 and 2012E)
* China is expected to implement EUIII regulations in selected cities from 2008 while India is expected to Source: Deutsche Bank, JD Power
implement EU III nationwide in 2010. Source: Johnson Matthey
Figure 674: Global HDD Market Size (US$m)by region Figure 675: Global HDD Market size (US$m)by truck
(2005-2015E) type (2005-2015E)
1500 1500
1200 1200
900 900
600 600
300 300
0 0
2005
2006
2007
2008
2009
2010E
2011E
2012E
2013E
2014E
2015E
2005
2006
2007
2008
2009
2010E
2011E
2012E
2013E
2014E
2015E
USA W.Europe New EU-10 Japan Korea China India
GVW 3-6t GVW 6-15t GVW 15t+
The author of this report wishes to acknowledge the contribution made by Rajiv Dalal,
Sanjeev Sharma and Mohit Khandelwal employees of Evalueserve, a third-party provider to
Deutsche Bank of offshore research support services.
Aromatics An organic compound that has a benzene (hexagonal) ring of carbon atoms, for example
Benzene.
Base chemical Building blocks, such as Ethylene and Benzene, from which many downstream products are
made.
Brownfield A site that has an existing industrial development located on it. Industry often refers to
brownfield redevelopment.
Builder A type of chemical used in the manufacture of detergents. It keeps soil away from fabrics in a
wash, once a surfactant has separated the soil from the clothes.
Capacity utilisation The percentage of available capacity being used for production. Capacity Utilisation =
(Production/Capacity)*100%.
Captive market A market that over the short term has only limited choice as to its supplier (maybe an internal
company demand).
Catalyst (& inhibitor) A substance which alters the rate of chemical reaction, making it faster (catalyst) or slower
(inhibitor) without undergoing any change itself over the reaction cycle.
cGMP A production facility that is registered as having current good manufacturing practice.
Approval bodies such as the US FDA give this certification.
Complex intermediates Intermediates that have undergone further refining and processing.
Comonomer A monomer added to the starting material to alter the final product.
Compound A substance that is made of two or more elements chemically bonded together.
Cracker Production facility for the manufacture of large volumes of petrochemicals from oil or gas
feedstocks.
Cracking The process of splitting mixtures of long chains of organic molecules (typically naphtha) into
smaller molecules (ethylene, propylene and so on).
Crimp The curl, or waviness, placed in synthetic fibres by chemicals or mechanical action.
Denier A measure of the weight of fibres per unit length, defined as the weight in grams of 9,000m
of fibre.
Drying Removal of small quantities of water/solvents from a sample by physical or chemical means.
Effluent The waste product produced during a chemical process. It is usually a liquid or in a solution
(see Soluble).
Electrolysis The passing of an electric current through a solution which then attracts negative ions to the
positive terminal (anode) and positive ions to the negative terminal (cathode).
Element A pure substance that cannot be broken down chemically, into anything simpler.
Ethylene A two-carbon molecule with a reactive double bond that can be broken to add other
molecules, that is, C = C (chemical formula C2H4 ).
Feedstock The raw material substance that is fed into a manufacturing plant for synthesis into another
product.
Fermentation The production of alcohol from sugar or similar substance, usually utilising yeast.
Fractional distillation A form of distillation that enables several substances to be separated from a mixture
simultaneously. This is the method used to split crude oil into various derivative fractions.
Greenfield A potential site location that has not previously been developed.
Halogenation The addition to a molecule of a halogen atom, that is, fluorine, chlorine, bromine, iodine or
astatine.
Hydrodealkylation (HDA) A method used to remove alkyl groups using hydrogen, for example in the production of
benzene.
Inorganic chemicals Non-carbon-based molecules and some small carbon-based molecules such as a carbon
dioxide (CO2 ).
Isotopes Different forms of the same element. The different forms behave identically in a chemical
manner but have a different mass.
Latex A stable aqueous dispersion used to synthesise rubbers as well as paper coatings and carpet
backing.
Liquefied Petroleum Gas One of the main feedstocks for a petrochemical cracker. It is obtained by the fractional
(LPG) distillation of crude oil.
MDI
A form of polyurethane (see Polyurethane chapter in main document).
Merchant market The external (that is, free) market in which a product may be sold.
Monomer A single molecule or unit that is often linked to many others. Examples include ethylene and
propylene, which are 'polymerised' into polyethylene and polypropylene respectively.
Mothballing The closure of a plant with a view to re-opening and starting manufacturing at a future date.
Naphtha One of the main feedstocks for a petrochemical cracker. It is obtained by the fractional
distillation of crude oil.
Natural gas One of the main feedstocks for a petrochemical cracker. It is obtained directly from natural
gas fields.
Neutralisation The process by which an acid and an alkali mix to produce neutral substances.
Original equipment Initial production market rather than a repair or secondary market. Often used in reference to
manufacture (OEM) the automobile market.
Olefin A product with straight chain hydrocarbons which may have one or more double bonds
conferring reactivity.
Organic chemicals Most, but not all, carbon compounds that at some historic point were part of living matter
(for example, oil, coal). Some small carbon compounds such as carbon dioxide (CO2 ) are
classed as inorganic.
Organometallics Compounds in which carbon or organic groups are attached to metal or metalloid atoms.
Oxidation A type of reaction where electrons are removed from a molecule or where oxygen atoms are
added to a molecule.
Physical properties Melting point, boiling point, hardness, strength and so on. Properties not concerned with the
chemistry of a product.
Pigment Coloured, insoluble substance (either organic or inorganic) used to impart colour.
Polymer Substances created by linking individual molecules (monomers) into long chains (polymers).
Otherwise known as plastics.
Polymerisation The process of creating a polymer (long chain of molecules) from a monomer (individual
molecules).
Propylene A three carbon molecule with a reactive double bond, that is, C=C=C (C3H6 ).
Soluble If a substance will dissolve in a given liquid it is said to be soluble. The result is a solution.
Surfactant Short for 'surface active agent’, a molecule that has both 'water-loving' and 'water-hating'
properties.
Synthesis gas A mixture of carbon monoxide, hydrogen, carbon dioxide and other gases.
Appendix 1
Important Disclosures
Additional information available upon request
Disclosure checklist
Company Ticker Recent price* Disclosure
BASF BASFn.DE 64.14 (EUR) 12 May 11 1,6,7,8,14,15,17
Air Liquide AIRP.PA 94.93 (EUR) 12 May 11 6,14,17
*Prices are sourced from local exchanges via Reuters, Bloomberg and other vendors. Data is sourced from Deutsche Bank and subject companies.
6. Deutsche Bank and/or its affiliate(s) owns one percent or more of any class of common equity securities of this company
calculated under computational methods required by US law.
7. Deutsche Bank and/or its affiliate(s) has received compensation from this company for the provision of investment
banking or financial advisory services within the past year.
8. Deutsche Bank and/or its affiliate(s) expects to receive, or intends to seek, compensation for investment banking services
from this company in the next three months.
14. Deutsche Bank and/or its affiliate(s) has received non-investment banking related compensation from this company within
the past year.
15. This company has been a client of Deutsche Bank Securities Inc. within the past year, during which time it received non-
investment banking securities-related services.
6. Deutsche Bank and/or its affiliate(s) owns one percent or more of any class of common equity securities of this company
calculated under computational methods required by US law.
7. Deutsche Bank and/or its affiliate(s) has received compensation from this company for the provision of investment
banking or financial advisory services within the past year.
17. Deutsche Bank and or/its affiliate(s) has a significant Non-Equity financial interest (this can include Bonds, Convertible
Bonds, Credit Derivatives and Traded Loans) where the aggregate net exposure to the following issuer(s), or issuer(s)
group, is more than 25m Euros.
For disclosures pertaining to recommendations or estimates made on securities other than the primary subject of this
research, please see the most recently published company report or visit our global disclosure look-up page on our
website at http://gm.db.com/ger/disclosure/DisclosureDirectory.eqsr.
Analyst Certification
The views expressed in this report accurately reflect the personal views of the undersigned lead analyst about the subject
issuers and the securities of those issuers. In addition, the undersigned lead analyst has not and will not receive any
compensation for providing a specific recommendation or view in this report. Tim Jones
Strong Buy
Buy
100.00 1 Market Perform
Underperform
Not Rated
80.00 Suspended Rating
S ec ur it y P r ic e
17 Current Recommendations
15 16
14
13 Buy
60.00
1011 Hold
2 7 8 9 12
6 Sell
4 5 Not Rated
40.00 Suspended Rating
3
*New Recommendation Structure
20.00 as of September 9, 2002
0.00
May 08 Aug 08 Nov 08 Feb 09 May 09 Aug 09 Nov 09 Feb 10 May 10 Aug 10 Nov 10 Feb 11
Da t e
1. 26/6/2008: Buy, Target Price Change EUR54.00 10. 9/4/2010: Buy, Target Price Change EUR53.00
2. 27/6/2008: Buy, Target Price Change EUR58.00 11. 29/4/2010: Buy, Target Price Change EUR55.00
3. 31/10/2008: Buy, Target Price Change EUR35.00 12. 2/7/2010: Buy, Target Price Change EUR57.00
4. 30/7/2009: Buy, Target Price Change EUR38.00 13. 28/10/2010: Buy, Target Price Change EUR60.00
5. 4/9/2009: Buy, Target Price Change EUR40.00 14. 12/11/2010: Buy, Target Price Change EUR63.00
6. 12/10/2009: Buy, Target Price Change EUR43.00 15. 9/12/2010: Buy, Target Price Change EUR68.00
7. 3/12/2009: Buy, Target Price Change EUR47.00 16. 25/2/2011: Buy, Target Price Change EUR70.00
8. 15/1/2010: Buy, Target Price Change EUR49.00 17. 6/5/2011: Buy, Target Price Change EUR76.00
9. 25/2/2010: Buy, Target Price Change EUR51.00
Strong Buy
13 14 15 Buy
100.00 10 Market Perform
1 2 11 12
9 Underperform
8 Not Rated
80.00 3 7 Suspended Rating
S ec ur it y P r ic e
4 5 6 Current Recommendations
Buy
60.00
Hold
Sell
Not Rated
40.00 Suspended Rating
0.00
May 08 Aug 08 Nov 08 Feb 09 May 09 Aug 09 Nov 09 Feb 10 May 10 Aug 10 Nov 10 Feb 11
Da t e
1. 12/6/2008: Hold, Target Price Change EUR85.00 9. 3/12/2009: Hold, Target Price Change EUR84.00
2. 10/7/2008: Hold, Target Price Change EUR84.00 10. 26/4/2010: Hold, Target Price Change EUR92.00
3. 6/10/2008: Hold, Target Price Change EUR83.00 11. 28/5/2010: Hold, Target Price Change EUR86.00
4. 23/10/2008: Hold, Target Price Change EUR76.00 12. 2/8/2010: Hold, Target Price Change EUR88.00
5. 2/12/2008: Hold, Target Price Change EUR72.00 13. 26/10/2010: Hold, Target Price Change EUR90.00
6. 28/4/2009: Hold, Target Price Change EUR65.00 14. 9/12/2010: Hold, Target Price Change EUR96.00
7. 30/7/2009: Hold, Target Price Change EUR68.00 15. 15/2/2011: Hold, Target Price Change EUR98.00
8. 12/10/2009: Hold, Target Price Change EUR74.00
Notes:
1. Newly issued research recommendations and target Companies Covered Cos. w/ Banking Relationship
prices always supersede previously published research.
European Universe
2. Ratings definitions prior to 27 January, 2007 were:
Buy: Expected total return (including dividends) of 10%
or more over a 12-month period
Hold: Expected total return (including dividends) between
-10% and 10% over a 12-month period
Sell: Expected total return (including dividends) of -10% or
worse over a 12-month period
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