【Haichuan Chemical Salary News】Hengli Petrochemical’s world’s largest hydrogenation plant has been successfully put into operation

Shanghai, China/Munich, Germany, August 15, 2019 – Clariant recently announced that its CATOFIN catalysts have been successfully deployed in the newly built mixed-feed hydrogenation plant of Hengli Group. Located in Dalian, China, this new plant utilizes a combined process technology of propane dehydrogenation (PDH) and isobutane dehydrogenation (BDH), with an olefin production capacity of over 1 million tons. It has now become the world’s largest plant to employ CATOFIN catalyst technology. The plant utilizes state-of-the-art processes that combine Clariant’s CATOFIN catalysts with the process technologies of Lummus, a company under McDermott. Compared to other PDH and BDH production methods, this process improves reliability and yield, enhances cost-effectiveness, and is easy to operate. In addition to the CATOFIN catalyst, the plant also uses Clariant’s innovative exothermic material (HGM) to produce its proprietary olefins.

Established in 1994, Hengli Group is one of China’s leading suppliers of petrochemical products. The new dehydrogenation plant it has built in Dalian, China, has a designed annual production capacity of 500,000 tons of propane and 800,000 tons of isobutane, which are used to produce propylene and isobutylene. Peng Guangqin, the chief engineer of Hengli Refining & Chemical, said, “We are extremely proud of the achievements our company has made in this groundbreaking project.” Without a reliable and experienced partner like Clariant, it would have been impossible for us to bring this world’s largest alkane dehydrogenation plant online so quickly, smoothly, and successfully. ” CATOFIN is a highly reliable light hydrocarbon dehydrogenation technology. This process can operate at reaction pressures and temperatures favorable from a thermodynamic perspective, thereby maximizing yield. With its highly selective CATOFIN catalysts and patented metal oxide heating material HGM, Clariant enables the highest conversion rates among all currently available process technologies. The successful commissioning of the Hengli plant marks the operation of Clariant’s 21st CATOFIN unit, bringing the company’s total olefin production capacity worldwide to 9 million tons. Stefan Heuser, Senior Vice President and General Manager of the Catalyst Business Unit at Clariant, added, “We are honored that Hengli has chosen our CATOFIN catalysts and exothermic materials for their new production facilities.” Together with our technical partner, Lummus Technologies under McDermott, we have once again demonstrated CATOFIN’s unparalleled advantage in propane dehydrogenation and isobutane dehydrogenation. ”

The 1.3 million tons per year C3/IC4 mixed dehydrogenation unit, constructed by China State Construction Installation Group Co., Ltd., is currently the largest such unit in the world. It utilizes the Ruums CATOFIN dehydrogenation process, offering advantages such as flexible feed handling, high conversion rates, and high selectivity. Designed to process 500,000 tons of propane per year (59.5 tons per hour) and 800,000 tons of isobutane per year (95.2 tons per hour), this unit serves as the core facility in Hengli Petrochemical’s 20 million tons per year integrated refining and chemical processing project. It plays a crucial role as a linking element between the refining and chemical processing sectors, and its importance is self-evident. Since the start of construction, it took 16 months for this facility to be brought online successfully on May 10, 2019. Throughout this period, China State Construction Installation maintained its corporate ethos of \"military spirit and craftsmanship,\" relying on an indomitable spirit and a commitment to excellence typical of a top-tier team. Working together with the Hengli Petrochemical project owner, it carried out meticulous organization, thorough planning, strict oversight of plan implementation, and uncompromising attention to quality control. As a result, a 4,000㎡ digital pipeline prefabrication plant was established, equipped with 19 sets of large-scale automated machinery such as pipeline cutting machines and magnetic plasma cutters. At the same time, China State Construction Installation Group utilized advanced construction techniques such as modular construction using steel structures, modular construction of custom-made equipment for waste heat boilers, and BIM-based factory prefabrication to advance the on-site construction processes. These techniques helped address issues such as limited on-site construction conditions, tight deadlines, and high quality requirements. The group successfully completed key construction tasks including the installation of 1,000-ton, 100-meter-high separation towers, the welding of high-temperature and high-pressure pipelines, and the installation of the world’s largest gas compressor of its kind, ensuring safe, high-quality, environmentally friendly, and efficient on-site construction.

China’s largest propane dehydrogenation unit uses Honeywell UOP technology – Chemical Online, May 5, 2017. On May 4, Honeywell announced that China’s largest single-unit propane dehydrogenation unit had successfully completed its trial operation and was now in full operation. 　　The propane dehydrogenation unit of Wanhua Chemical Group Co., Ltd. utilizes Honeywell UOP process technology to convert propane into propylene, with an annual production capacity of 750,000 tons. Propylene is a key raw material for producing plastics, packaging materials, and synthetic fibers. With the successful commissioning of this plant, Honeywell UOP’s Oleflex process technology has increased global annual propylene production to around 6.8 million tons. 　　Liu Maoshu, General Manager of Honeywell UOP in China, said, “This facility is the largest operating Oleflex plant in China. Its successful commissioning not only represents a significant increase in China’s propylene production capacity but also marks another major step forward in meeting the local demand for propylene.” Compared to Honeywell UOP Oleflex’s high-quality propylene production process, no other technology currently achieves the same level of efficiency and output. ” 　　Historically, 70% of the world’s propylene has been a by-product of the production of ethylene from oil. Ethylene is another raw material used in plastic production. In recent years, ethylene producers have increasingly begun using ethane from natural gas to produce ethylene, with very little propylene byproduct generated in this process. The shift in ethylene production methods has led to a shortage of propylene supply, prompting manufacturers to adopt Honeywell UOP technology and invest in dedicated propylene production facilities. According to the U.S. Energy Information Administration, China accounts for over 15% of global propylene consumption, and this demand is growing at a rate of more than 4% per year. 　　Since 2011, out of a total of 47 new propane and isobutane dehydrogenation projects worldwide, 40 have chosen Honeywell UOP’s Oleflex process technology. 　　Honeywell UOP’s C (3) Oleflex process uses catalytic dehydrogenation technology to convert propane into propylene. Compared to competing technologies in the same category, this technology has been proven to have the lowest cash production costs and the highest return on investment. 　　In addition to technical licensing, Honeywell UOP also provides engineering design, equipment, personnel training, technical services, and catalyst products for this project. This Oleflex unit is part of Wanhua Chemical’s large-scale integrated production complex, which also includes a liquefied petroleum gas hydrogenation unit from Honeywell UOP, a Butamer™ C(4) isomerization unit, and a PSA pressure swing adsorption unit for producing high-purity hydrogen.

May 2, 2018 – Clariant, a global leader in specialty chemicals, announced today that it has won a contract for a project undertaken by Jinneng Technology Co., Ltd. The company will work together with CB&I to design the world’s largest propane dehydrogenation plant. The factory is located in Qingdao, Shandong Province, China, and upon completion, it will have an annual propylene production capacity of 900,000 tons. 　　 This project is based on CB&I’s advanced CATOFIN propane dehydrogenation technology, combined with Clariant’s customized CATOFIN catalyst and heat-generating material (HGM). Previously, the two parties have collaborated on numerous projects, designing and constructing multiple propane dehydrogenation units in China and other parts of the world. 　　 The effective and reliable CATOFIN technology uses lightweight paraffin as raw material to produce olefins such as propylene and isobutylene, offering reliable and efficient operation. Based on Clariant’s high-quality catalysts, the CATOFIN technology enables optimization of the reactor’s operating pressure and temperature, resulting in maximum conversion of raw materials and thus increased production while reducing operational costs. Combining this technology with Clariant’s patented metal oxide heating material (HGM) can further improve the selectivity and yield of the catalyst, while also contributing to energy savings and emission reduction. 　　 Jinneng Technology Co., Ltd. is an important manufacturer of fine chemical products and coal chemical products. With sustainability at the core of its business strategy, Jinneng Technology integrates energy efficiency, environmental protection, and innovative circular practices into all aspects of its production processes. 　　 Qin Qingping, founder and CEO of Jinneng Technology, said, “By utilizing advanced CATOFIN technology to build the world’s largest single-propane dehydrogenation facility and production base, we can achieve greater economic benefits as well as meet the company’s long-term development goals.” ” 　　 Stefan Heuser, Senior Vice President and General Manager of Clariant’s Catalysts business unit, also welcomed this partnership. He said, “Clariant is honored to be involved in building the historic JinNeng Technology project.” We also pursue sustainability and consider it an indispensable part of the innovation chain. Clariant’s CATOFIN custom catalysts and heating materials are perfect examples of our ongoing efforts to update and improve our products and services to meet customer needs. ”

On January 30, 2015, in Tuscaloosa, Illinois, United States – Honeywell (NYSE: HON) UOP announced today the successful commissioning of its second UOP C3 Oleflex™ propane dehydrogenation unit in China, which produces propylene, a key raw material for plastics. The C3 Oleflex unit at Zhejiang Shaoxing Sanjin Petrochemical Co., Ltd. is the second propane dehydrogenation unit to be transferred and put into operation in China by UOP. The UOP OleflexTM olefin production plant generates 900,000 tons of propylene per year in China. As a result, globally, the production capacity of propylene manufactured using UOP technology has reached 3.8 million tons per year. Traditionally, propylene has always been a by-product obtained during the production of ethylene. However, as global demand continues to rise, traditional production methods can no longer meet it. The shortage of propylene has led to investment in research and development of processes for producing propylene from propane, also known as specialized propylene production technologies. Since 2011, UOP has transferred the C3 Oleflex process technology to more than a dozen producers to meet the growing demand for propylene, most of whom are located in China. China is the world’s largest energy consumer, accounting for over 15% of the global consumption of propylene, with that figure increasing at a rate of 5%-6% per year. “By 2020, 20% of the world’s propylene will come from dedicated propylene production facilities, and we are extremely proud that the UOP Oleflex process will play a leading role in driving transformation and progress in this important petrochemical sector. ” Huang Zhiming, General Manager of Honeywell UOP in China, said, “For over 20 years, the Oleflex process has been a reliable and comprehensive solution for producing high-quality propylene, helping to increase production in China and around the world.” ” In addition to the transfer of process technology, Honeywell UOP also provides engineering design, catalysts, adsorbents, process equipment, personnel training, and engineering services for this project. The equipment supply includes UOP Calvert low-nitrogen burners, which are manufactured by the UOP Calvert factory in Shanghai. This burner utilizes Kellert staged gas supply and groove-type flame stabilizer ring technology, as well as a patented refractory brick design, to achieve a compact and robust flame profile. The propylene production facility of Zhejiang Shaoxing Sanjin Petrochemical Co., Ltd. is located in Shaoxing City, Zhejiang Province, with an annual production capacity of 450,000 tons. The parent company of Shaoxing Sanjin Petrochemical is Zhejiang Fuling Holding Group, which is also located in Shaoxing, Zhejiang. The company was established in 2003 and mainly produces polyethylene products, with an annual production capacity of 600,000 tons. “We chose UOP based on an overall assessment of the stability of its process technology, its cost-effectiveness, its ability to integrate with polyethylene production processes, and its flexibility in processing. ”Mr. Zhong Jianming from Zhejiang Shaoxing Sanjin Petrochemical Co., Ltd. said, “UOP’s local service and support team worked closely with us, working together to ensure the successful commissioning of the project.” ” For over the past 20 years, the propane dehydrogenation process of UOP Oleflex has remained at the forefront of the industry. The C3 Oleflex process converts propane into propylene through catalytic dehydrogenation. Compared to other similar competing products, the UOP C3 Oleflex technology offers the lowest production costs, the highest return on investment, and the least environmental impact. Its excellent operational performance is reflected in low capital investment, high propylene yield, low consumption of energy and water, as well as the use of a complete recyclable platinum-based alumina catalysis system. In addition to the C3 Oleflex process, UOP has also developed the C4 Oleflex technology, which uses butane dehydration to convert isobutane into isobutylene.

Which is better compared to UOP’s technology?

【Technology】China successfully develops 10,000-ton/year propane dehydrogenation technology, breaking a monopoly. Original article by Zhang Xinggang, China Chemical Industry News, June 30, 2016. On June 28, reporters from China Chemical Industry News learned from the Key Laboratory of Heavy Oils at China University of Petroleum (Huadong) that an industrial demonstration unit for propane/butane dehydrogenation (ADHO) with an annual production capacity of 10,000 tons, developed by this laboratory, has been successfully put into operation at Shandong Hengyuan Petrochemical Co., Ltd. The results of the industrial-scale tests show that the one-pass conversion rate of alkanes, as well as the yield and selectivity of olefins, are on par with those of the introduced technology, successfully breaking the foreign technological monopoly in this field and filling a gap in domestic capabilities. 　　It is understood that China possesses abundant liquefied petroleum gas resources. Liquefied petroleum gas is primarily composed of propane, n-butane, and isobutane. Hydrogenating these alkanes to produce olefins not only increases the added value of the products and reduces reliance on cracking processes for olefin production, but it also generates hydrogen with higher added value, thereby improving the overall utilization efficiency of petroleum and gas resources. At present, all propane and isobutane dehydrogenation technologies in our country are imported from abroad. Moreover, the catalysts used in industrial propane and isobutane dehydrogenation units are generally supported noble metals such as platinum or toxic chromium-based catalysts; these catalysts are not only expensive but also require thorough purification of the raw materials, posing serious environmental problems. 　　To address this challenge, the research team led by Professor Li Chunyi at this **Key Laboratory for Heavy Oil** spent 7 years on research and successfully developed non-precious metal oxide catalysts that are non-toxic and non-corrosive. They also designed an efficient circulating fluidized bed reactor to enable continuous dehydration reactions as well as the coking regeneration of the catalysts. Professor Li Chunyi told reporters that the new propane/butane dehydrogenation technology they have developed has the following features: the feedstock can be fed directly into the reactor without any pretreatment, eliminating the need for complex processes such as desulfurization, dearsenification, and lead removal ； It is applicable to both the separate dehydration of propane and isobutane, as well as the mixed dehydration of propane and butane ； The reaction and catalyst regeneration proceed continuously, resulting in high production efficiency ； The catalyst is a non-precious metal refractory oxide, which offers advantages such as low cost, no need for oxygen chlorination during regeneration, non-corrosiveness, high mechanical strength, and low dosage requirements, all of which contribute to the safe and stable operation of the facility over extended periods of time ； The heat generated from catalyst regeneration can be returned to the system for reuse, allowing the reaction temperature to be controlled based on the circulation volume. Moreover, no hydrogen is required for the entire reaction process, resulting in low energy consumption and high heat transfer efficiency. 　　Compared to foreign technologies, the new propane/butane dehydrogenation technology developed by this research team requires less investment; the capital cost for a plant with an annual production capacity of 250,000 tons is 300 million yuan, whereas foreign technologies require 1.6 billion yuan. Moreover, the circulating fluidized bed reactor is not limited by scale, allowing the capacity to be determined based on raw materials and market conditions. Professor Li Chunyi explained that this technology can be implemented by modifying existing units such as catalytic crackers, allowing full utilization of existing utility systems and thus reducing investment costs.