Polypropylene Fibres in Global and Russian Markets

Abstract

Polypropylene (PP) fibres and yarns are sometimes called polyolefin (PO) when, along with PP, reference is made to polyethylene (PE), which comprise a minor part of them or fibres based on ethylene and propylene polymers. Currently, in terms of global production volume, PP fibres occupy the second place among all types of chemical fibres, lagging much behind polyester fibres [1], but taking part in realization of a growing raw material potential (Fig. 1) that will maintain the trend toward rising demand and capacities of the original polymer for a foreseeable period [2]. In Europe, to which PO fibres owe their origin, they comprise, according to European Textile Polyolefin Association data, 45.2 % of the chemical fibres produced [3]. On the average, about 12 % of the PP granulate produced is processed into fibres and yarns in the world, including Russia, although higher figures are often cited in some sources, which depends on specific regions, the range of products manufactured there, technological direction, level of development of the processing branches, and other factors. In 2011, all polyolefins (PO) of most widespread types of fibre products (Table 1), primarily film yarns, registered growth (+3 %) [4]. Outputs of complex yarns, which include BCF carpet tow, monofilament, and spunbond, attained a high level in Western Europe, China, USA, and Africa, and India, Canada, and South America recorded the highest growth rate. Large PP staple fibre production plants are concentrated in Western Europe, USA, and China (the growth rate relative to 2010 was the highest in the latter). In addition to spunbond, the most actively growing textile products from PP are film yarns (raffia) where China, Western Europe, Africa, Turkey, USA, South America, and Eastern Europe remain the leaders in terms of production volume, and South America, Japan, and Africa, in terms of growth rate in 2011 (+9, +7, and +5 %, respectively). From an analysis of Table 1 we find that a marked decline in production of all types of PO fibres in USA and Mexico. In USA, for example, complex yarn production capacity shrunk by 6 % over the past five years [5], and production of other yarns remained practically at the same level (Table 2). Let us describe in some more detail the situation in the European market since it significantly affects the Russian market. The share of PP fibres in the demand for all types of textile raw material in Europe is 38.9 % and in chemical fibre output is 44.3 % [3]. In this continent, 24.1 % of PP granulate is used for producing fibrous materials (Fig. 2). In the above-noted figures the share of polyethylene is minuscule. New PP spunbond production capacities are being actively introduced in Europe, especially in its eastern part, primarily in Russia where the annual growth rate is the highest in the world, and in Turkey (Table 3). In the context of the European Commission Directive 94/62/EC, PP spunbond must substitute PE film for making packages because it has the best performance properties (high strength, attractive exterior look, and wide-ranging decorative possibilities), reduces deleterious effect on the environment, the packages are capable of being used in a variety of ways and of undergoing secondary processing. Production of PP spunbond has been rising steadily: since 2010 the number of applications from different continents rose to 23 for installation of high-efficiency plants with total capacities of 400,000 tons/yr, which will meet in the period 2012-2015 the rising demand for this relatively light and strong material [6]. Appearance of new plants in South Africa, China, South America, and Indonesia is contributing to the growth of PP spunbond output in these regions. Among the known methods of nonwoven materials (spunlaid, airlaid, carding, spunlace, etc.) production, spunbond is the most popular right now. It accounts for almost one-half of the global production of all types of nonwoven materials (NM), more than 36 % of which is manufactured from PP (Fig. 3). In output volume, the second place belongs to NM produced by carding technique (cloth making from staple fibre) with an output of 3.4M tons in 2012 [4]. Needle-