【Ten Years of Rapid Development in Chemical Equipment】From 2018 to 2024, Liaoyang Petrochemical achieved domestication of the entire production chain for PETG copolyesters, from raw materials to finished products, through technological innovation
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Give praise and encouragement to the achievements made in China’s chemical technology and equipment sector; your participation in discussions is the greatest encouragement. **********************【Ten Years of Great Development in Chemical Equipment】Regularly updated summary posts are available – feel free to join the discussions: https://bbs.hcbbs.com/thread-3576046-1-1.html ***************** From July 24th to 26th, 2024, at the 2024 China (Dalian, Liaoning) International Petroleum and Chemical Industry Exhibition, the PETG (polyethylene terephthalate-1,4-cyclohexanedimethanol) copolyester products presented by Liaoyang Petrochemical Company attracted a lot of attention. After more than 20 years of effort, Liaoyang Petrochemical has achieved domestic mastery of the entire production chain for PETG copolyesters, from raw materials to finished products. This has enabled China Petroleum to become the third company in the world and the first in China to produce copolyesters, and it has also resulted in the development of various specialized material series such as extruded sheets, plates, packaging for cosmetics, heat-shrinkable films, and medical packaging. After years of research and development, the entire production chain for PETG copolyester has been established. This is a new chemical material with a crystal-like appearance, featuring properties such as being non-toxic and harmless, as well as being environmentally friendly; it is used in fields such as food packaging, healthcare, and electronics. Previously, PETG copolyester was subject to foreign embargoes for a long time and was considered a \"scarce item\" in the market. In 2012, Liaoyang Petrochemical began industrial pilot production of PETG copolyester. Zhang Jian, the chief engineer of the polyester department at Liaoyang Petrochemical, said, \"In response to the problems that arose during production, the R&D team proposed a number of corrective measures. The plant was optimized and modified on two occasions, which resolved the issue of continuous and stable catalyst injection in industrial production. Additionally, optimization strategies for polyester production under copolymerization conditions were developed, enabling the production of qualified products.\" ”The first production process was a milestone in the development of PETG copolyesters, providing a basis for design practices to facilitate subsequent improvements and modifications. During the major plant overhaul in 2023, Liaoyang Petrochemical optimized the catalyst system in the copolyester plant, ensuring a stable catalyst injection rate. After the production line was switched to producing copolyester products, researchers worked tirelessly on the front line to study and solve the problems encountered in improving quality. For the new coloration system, researchers conducted 4 hours of continuous sampling and analysis to optimize the process in a timely manner and determine the optimal ratio, thereby significantly improving the appearance characteristics of the copolyester products. During the production process, researchers repeatedly adjusted the ratio between the amount of catalyst used and the production load, as well as optimizing certain key quality control parameters. As a result, the haze level, heat resistance, and light transmittance of the final products reached or even surpassed those of similar foreign products. The overall quality of the LH690T product series achieved another significant improvement. Developing high-end, specialty new products: On the basis of establishing a complete industrial chain for PETG copolyesters, ranging from raw materials to final products, Liaoyang Petrochemical is focusing on developing differentiated, high-end, and specialty PETG copolyester products. In 2023, Liaoyang Petrochemical’s radiation-resistant medical PETG copolyester was put into industrial production. It passed the three standard biological evaluations for medical devices, further enhancing the overall competitiveness of the entire industry chain. The company successfully fulfilled the challenge of developing a new chemical material for PETG copolyesters characterized by high performance, excellent quality, and a wide range of varieties. It became the third company in the world and the first in China to produce a full range of PETG copolyesters, thereby contributing to the high-quality development of the polyester industry. To date, Liaoyang Petrochemical has produced a full range of new products in 9 different grades, including high-performance shrink films, materials for 3D printing, and food packaging materials. It has achieved 48 key technological breakthroughs across five major product series. The independently developed PETG production technology has been successfully applied in a production facility with an annual capacity of 100,000 tons, and the use of domestically produced raw material CHDM (1,4-cyclohexanedimethanol) has enabled stable production of all these products. Over the years, Liaoyang Petrochemical has dedicated effort to developing core technologies with independent intellectual property rights. By using its own produced copolyester raw materials, it has managed to maintain stable production levels; significant progress has been made in terms of the stability of key product parameters such as viscosity and B value. Additionally, a new product of the LH300 grade, suitable for use in medical packaging, was successfully developed, marking a breakthrough in the development of key domestic technologies for PETG copolyesters. Indicator optimization creates new advantages. Liaoyang Petrochemical adheres to a customer-oriented approach, providing comprehensive and multi-faceted technical support services throughout the entire process, from product testing to final production, thereby establishing a competitive edge. The company’s process optimization team starts from the actual conditions of the production process, adheres to independence, scientifically optimizes production plans, strictly maintains quality control standards throughout the manufacturing process, and works closely with sales staff to provide after-sales service. By breaking away from conventional thinking, they conduct in-depth research on the changes that occur during polymerization reactions, identifying areas where process adjustments can be made. They have also boldly improved fluid premixing technology, continuously enhancing key parameters such as product haze and viscosity; the stability of catalysts has been greatly improved. During the new product development phase, they proactively engage in discussions regarding application areas and processing conditions to stay ahead of market trends. The process optimization team has a \"zero-tolerance\" policy toward factors that affect product quality; it identifies issues at an early stage and at their source, strictly controls process parameters, and carefully tunes various metrics ； By implementing hierarchical control at the device, team, and position levels for key quality indicators, the stability of the quality parameters for various grades of PETG copolyester has been significantly improved, with the product qualification rate remaining at 100% throughout. “Only by making products specialized and high-quality can one gain a say in the market. ”Liaoyang Petrochemical adheres to the principle of building the company on a technological foundation. Focusing on strengthening the chemical product supply chain by extending and enhancing it, the company endeavors to research and develop new PETG copolyester products such as materials suitable for high-temperature resistant, NPG-modified thermoshrinkable films, in order to maintain its leading position in the production of high-end polyester products in China.
From contributing to the development of the industry for the benefit of the country to striving to build a strong nation through science and technology, using high-quality technological innovation to help China National Petroleum Corporation become a world-class enterprise has always been the unwavering goal of the people at Liaoyang Petrochemical. From laboratory research and development to the transformation of engineering technologies and then to market deployment, Liaoyang Petrochemical has become the third company in the world and the first in China to produce copolyesters. There are countless people and endless stories surrounding the development of copolyesters at Liaoyang Petrochemical, from their inception to growth; among them, Chen Ying’s story is the most touching. Chen Ying is the deputy director of the Liaoyang Petrochemical Research Institute and former deputy director of a polyester factory. She has received honors such as Outstanding Party Member of Central State-Owned Enterprises, Outstanding Expert of Liaoning Province, Innovative Leadership Talent under the Xingliao Talent Program, Model Worker for Achieving Success in the Petroleum Industry in China, and Outstanding Science and Technology Worker in the national petroleum and chemical industry. Working together to pursue dreams in the field of copolyesters – breaking through barriers in high-end technology. As a representative of green and healthy materials, copolyesters are important raw materials for producing precision chemical products such as baby bottles, cosmetic packaging containers, and sports water bottles. In China, before copolyesters could be manufactured domestically, reliance on imports was absolute; price increases and shortages were entirely determined by foreign companies. In 2002, Chen Ying heard about copolyesters for the first time. At that time, foreign companies had a monopoly on copolyester products for nearly 20 years; they kept production and sales strictly confidential, and prices remained high. Liaoyang Petrochemical was one of the leading polyester manufacturers in China in the 20th century, and the patriotic spirit associated with \"seven-foot cloth\" originated there. With the support of a solid foundation, developing copolyesters and challenging this \"gem\" at the crown of polyesters became Chen Ying’s dream of achieving a technological breakthrough. Shouldering the mission and responsibilities of a Party member, Chen Ying dedicated herself wholeheartedly to this task. She worked late into the night, reviewing numerous journal articles, reaching out to and consulting experts and scholars from her alma mater as well as various other sources, and finally concluded that: “To break through the patent barriers, it is necessary to study the core catalyst technology.” ” Subsequently, she quickly carried out a series of experiments. “At that time, every aspect of scientific research was a challenge to the limits of our knowledge! Year after year, day after day, thick volumes of experimental records, numerous data points, and strings of reaction formulas all documented the challenges faced by Chen Ying’s team along the way. During the research process, Chen Ying and her team encountered many unimaginable difficulties, but through continuous exploration and innovation, breakthroughs were finally achieved in this technology. In 2005, the pilot plant test was successful, and a Chinese invention patent was granted.
Working together to pursue dreams in the field of copolyesters – breaking through barriers in high-end technology. As a representative of green and healthy materials, copolyesters are important raw materials for producing precision chemical products such as baby bottles, cosmetic packaging containers, and sports water bottles. In China, before copolyesters could be manufactured domestically, reliance on imports was absolute; price increases and shortages were entirely determined by foreign companies. In 2002, Chen Ying heard about copolyesters for the first time. At that time, foreign companies had a monopoly on copolyester products for nearly 20 years; they kept production and sales strictly confidential, and prices remained high. Liaoyang Petrochemical was one of the leading polyester manufacturers in China in the 20th century, and the patriotic spirit associated with \"seven-foot cloth\" originated there. With the support of a solid foundation, developing copolyesters and challenging this \"gem\" at the crown of polyesters became Chen Ying’s dream of achieving a technological breakthrough. Shouldering the mission and responsibilities of a Party member, Chen Ying dedicated herself wholeheartedly to this task. She worked late into the night, reviewing numerous journal articles, reaching out to and consulting experts and scholars from her alma mater as well as various other sources, and finally concluded that: “To break through the patent barriers, it is necessary to study the core catalyst technology.” ” Subsequently, she quickly carried out a series of experiments. “At that time, every aspect of scientific research was a challenge to the limits of our knowledge! Year after year, day after day, thick volumes of experimental records, numerous data points, and strings of reaction formulas all documented the challenges faced by Chen Ying’s team along the way. During the research process, Chen Ying and her team encountered many unimaginable difficulties, but through continuous exploration and innovation, breakthroughs were finally achieved in this technology. In 2005, the pilot plant test was successful, and a Chinese invention patent was granted.
Industrial-scale production: a remarkable transformation to break monopolies. From pilot tests using a continuous process with a capacity of 20,000 tons per year to industrial trials with a capacity of 100,000 tons per year, there was not only an increase in production scale but also more complex process transformations, posing serious challenges for Chen Ying in terms of developing the necessary engineering solutions. During the mass production of copolyesters, she focused on understanding the characteristics of the manufacturing process, studied flow diagrams, and analyzed material balances; she gave up all her holidays and dedicated herself entirely to the engineering aspects of this process. On the Mid-Autumn Festival night in 2012, the moon was especially bright; her family was looking forward to her with great anticipation, yet she remained alone in the office, going through relevant documents. That very night, the work on the polyester process package with an annual production capacity of 100,000 tons, as well as 12 technical standards, which was led by Chen Ying, came to a successful conclusion. The gap between the laboratory and the production line is too large, and many problems arise during industrial testing: catalyst hydrolysis, filter breakdown, dark spots in the product… Chen Ying’s team did not go home for over ten days straight. Through relentless efforts, the continuous production process was finally established, enabling good coordination between research and manufacturing during the industrial testing phase, and allowing for an effective balance between molecular weight and product color. In 2017, as green consumption in China improved, the demand for copolyesters surged. In response to these market changes, Liaoyang Petrochemical decided to resume copolyester production at an old manufacturing facility that had been out of use for 5 years. At the same time, Chen Ying’s role changed – from a research and technology expert to an assistant plant manager in charge of technology at the polyester factory. She took on the responsibility of coordinating production and research efforts, thereby giving new impetus to the existing manufacturing facilities. She tried to apply production-oriented thinking to develop technologies for stable production; production technicians learned to use data patterns in their work, and together they managed to create high-quality polyester. This effort broke the industry monopoly held by the United States and South Korea, enabling Sinopec to become the third company in the world capable of mass-producing copolyester. Their products were recognized as important products of independent innovation by China National Petroleum Corporation, awarded the second prize for technical inventions at the group company level, and listed among the top ten innovative achievements of employees in Liaoning Province.
Shouldering the mission of research, development, and production is an honor accompanied by a great deal of responsibility. At the beginning of 2018, in order to find new markets, Chen Ying organized key party members to visit markets in South China. There, she learned that one customer used a large amount of copolyester, so she took the initiative to get in touch with them. However, this major client questioned her, saying it was impossible for a domestic company to produce copolyester. Her first attempt to enter the market ended in failure, making her realize that it is a long road ahead before the new product can gain recognition in the domestic market. So, she bent down to gather market information. At the local Plastic City, whenever a product’s label mentioned \"copolyester,\" she would promote it to them and provide trial technical support. During the promotion process, in the face of users’ doubts, she did not back down; instead, she provided attentive service, showcased the company’s rich heritage through its unique corporate culture, explained the company’s products in a professional and compelling manner, and used her confident and assured attitude to dispel users’ concerns. Finally, the market opened its doors to her. A company that had previously refused to communicate reached out on its own. After meeting, the other party’s manager asked, “When do you think you’ll be able to fully catch up with foreign countries?” Chen Ying replied sincerely, “The speed at which we can catch up depends on the level of support you provide.” Only by continuously using our products can we keep identifying problems and progress more rapidly! That’s how, initially, copolyester was sold in small packs; later it was sold in larger packs, and eventually in whole trucks’ worth. Once Liaoyang Petrochemical’s copolyester entered mass production, the market reacted immediately, with the prices of imported products from abroad dropping by one-third per ton. This further strengthened Chen Ying’s determination to build a successful national brand.
Keeping the instructions in mind and staying true to our original aspirations, we move forward. Chen Ying remembers the instructions from the Party and **, and leads the R&D team to continuously improve the catalyst formulas and optimize production processes. This has enabled us to overcome the challenges of improving quality and ensuring stable production; the product standards have reached world-class levels, with 26 companies becoming our customers. In 2020, there was an urgent need for melt-blown fabric, the key material used in masks for epidemic prevention. Chen Ying responded to the Party’s call, adhering to the principle of **producing whatever is needed**, and devoted herself to the construction of the high-demand melt-blown non-woven fabric project. Under her leadership, everyone worked day and night to improve their skills in this field; the production of melt-blown fabric was carried out with a focus on technological advancement. In just 38 days, the facility was built and all preparations for production were completed. The quality of the product kept improving, and it passed the testing and certification conducted by CNAS laboratories. From being dependent on others to achieving technological independence, on the path of independent innovation, Chen Ying led her team to endure loneliness, withstand pressure, and stay true to their original aspirations. With the determination to be patient even for ten years, they managed to make breakthroughs in China’s polyester technology; they filed 3 core invention patents, achieving a historic leap from a state of nothingness to international advanced levels.
PETG is a new type of polyester resin that boasts excellent mechanical properties, high transparency, and good processability. It also features environmental friendliness, recyclability, and ease of processing. “When it comes to PETG, many people seem unfamiliar with it, but in fact it has a very wide range of applications and is used in various aspects of daily life. ”Lin Yanyan spoke at length. Medical device packaging, cosmetic bottles… At the Liaoyang Petrochemical Research Institute, there is a wide range of products made from PETG copolyester as raw material. “In addition to these, PETG copolyesters are also widely used in the production of ID cards, suitcases, 3D printing, and other fields. ”As introduced by Lin Yanyan. The numerous advantages of PETG copolyester enable it to find wide applications in the economic and social spheres. It is precisely such a chemical product that is closely related to daily life; before it could be produced on a large scale in China, it relied entirely on imports. Lin Yanyan faced such a situation right at the beginning of her work. “Once, only two companies in the United States and South Korea possessed the technology for producing copolyesters; as a result, copolyesters were regarded as the ‘pearl on the crown’ of polyester products, and they were subject to foreign restrictions throughout the entire process, from raw materials to finished products and related technologies. ”Lin Yanyan said. The significant changes in the domestic polyester industry landscape have prompted Liaoyang Petrochemical to pursue a path focused on specialty polyesters; furthermore, the public’s urgent demand for new materials drives Liaoyang Petrochemical to stand out in this field. In 2002, Liaoyang Petrochemical began to initiate research on this topic. “Through years of dedicated research and continuous exploration by their predecessors, who made steady progress in the field of copolyesters and achieved numerous results, a solid foundation was laid for the launch of the PETG copolyester project. ” In 2009, after graduating from Liaoning University of Petroleum and Chemical Technology with a degree in chemical engineering and technology, Lin Yanyan joined Liaoyang Petrochemical as a young oil industry professional. In 2010, the industrialization trial project for PETG copolyester at Liaoyang Petrochemical was launched, and Lin Yanyan was immediately selected to join the core team of this major scientific research initiative. From establishing a simulation experiment platform, conducting pilot and scale-up experiments, to drafting plans for industrial production startup as well as calculating material balances and basic data required for startup, Lin Yanyan worked diligently and with great enthusiasm. To everyone’s surprise, this seemingly unremarkable young talent was always able to come up with the best solutions; her mind functioned like a ready-made \"repository of solutions,\" enabling her to tackle even the most intractable problems one by one. From \"attempting to develop\" it to a stage where success was within reach, overcoming each \"challenge\" relied on Lin Yanyan’s \"new approaches\" and \"new ideas\"; ultimately, through the joint efforts of the team, the development of the 100,000 tons per year PETG process package was completed.
Stay grounded and persevere over the long term. Since 2016, through years of learning and training, Lin Yanyan has evolved from a key technical specialist to a project leader, taking charge of the industrialization trial project for PETG copolyesters. “During the experimental process, there are many parameters that can be adjusted. To accurately determine the optimal experimental conditions, these parameters must be adjusted one by one. Moreover, the synthesis process of polyester is lengthy, with each batch of experiments taking more than 7 hours. ”Lin Yanyan took action right away; she led her team to work day and night, through more than 300 experiments, and achieved a breakthrough in the catalytic system. They developed a second-generation high-efficiency catalyst formula, successfully solving the problem of difficult uniform distribution of the catalyst on the production line. After finally producing high-quality PETG pellets and successfully transitioning the research technology from pilot scale to industrial production, Lin Yanyan and her team were overjoyed. They are well aware that overcoming the technical challenges associated with this project has enabled the company to become the first in China and the third in the world to produce PETG copolyester on a continuous production line, thus achieving a historic leap from nothingness, from a situation of no such production in China, to a level of advancement on the international stage. Starting in 2019, in order to address the challenges related to new materials, Lin Yanyan decided to lead her team to start from scratch and conduct in-depth systematic research, aiming to overcome the technical difficulties that affect parameters such as the haze and base color of products. Through more than 500 targeted experiments, the team improved the catalytic system, achieving another upgrade to it; they developed a new generation of high-efficiency catalyst formulations along with corresponding processing techniques, thereby enhancing the thermal stability of the products. In 2021, PETG copolyester products entered the high-end injection molding application sector for the first time. In 2022, Lin Yanyan and her team, through strenuous research efforts, overcame the challenges related to the formulation of key composite additives and the synthesis processes, and developed medical-grade products once again. This marked a breakthrough for polyester products in China as they were able to enter the high-end medical applications sector, enabling a transition from a situation where such products did not exist at all to one where they could be produced with high quality.