【Ten Years of Great Progress in Chemical Technology】Breaking Technological Monopolies from 2011 to 2020! The history of domestic production of catalysts for polyethylene plants
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Ten years of rapid development in chemical technology – praise for China’s prosperity and strength. This is just a starting point; more participation from everyone will make things even more lively. HaiChuan becomes even better with your involvement; we welcome everyone to take an active part in the forum discussions. It’s hot in July, so be careful to prevent fires. ********************************************* In 2014, the BCE-H100 high-performance catalyst for ethylene slurry polymerization, developed independently by the Beijing Research Institute of Chemical Technology, was successfully tested on an industrial scale at Sichuan Petrochemical’s plant using the 300,000 tons per year Hostalen process. After more than a month of operation, over 23,000 tons of bimodal membrane material HM9455F1 were produced. This marked the first successful industrial application of a domestically produced catalyst in the Hostalen slurry polyethylene process, filling a gap in China’s technological capabilities. In 2016, the high-performance specialized slurry-process polyethylene catalyst PSE-CX1, developed independently by the China National Petroleum and Petrochemical Research Institute, was successfully put into industrial use at Daqing Petrochemical’s annual 240,000-ton Mitsubishi CX-process polyethylene plant. A total of 5,000 tons of the high-quality 5000S product, as well as 5,400 tons of the QL505P material specifically designed for chlorinated polyethylene, were produced. The application results show that the catalyst activity reaches as high as 30 kilograms of polyethylene per gram of catalyst, the polymer bulk density is >0.36 grams per cubic centimeter, and the overall performance of the catalyst is at the leading level in China. Suitable for Mitsui and Hearst slurry polyethylene production plants. This catalyst features high activity and low levels of polymer fines and oligomers, and can compete with imported catalysts. In 2016, the gas-phase polyethylene (PE) slurry catalyst (PGE-101), developed independently by the China National Petroleum and Petrochemical Research Institute, was put into industrial use under super-condensed production conditions at Jilin Petrochemical’s 274,000 tons per year linear low-density polyethylene plant, with its performance metrics reaching the level of imported catalysts. Compared with similar catalysts at home and abroad, PGE-101 features stable activity release, low content of fine powder in the polymer product, narrow particle size distribution, less caking in the reactor, sensitivity to hydrogen adjustment, excellent copolymerization performance, and good morphology of polymer particles.
On December 22, 2021, breakthrough progress was made in the localization of catalysts for Sichuan Petrochemical. A linear low-density polyethylene plant with an annual production capacity of 300,000 tons was equipped with the domestic DJD-PES main catalyst. After 48 hours of operation, the reaction load was increased to 40 tons per hour; the plant operated safely and stably, becoming the first Unipol gas-phase polyethylene plant in China to be put into operation using a domestic main catalyst. To shorten the supply cycle, reduce costs, and enhance the competitiveness of its plants, Sichuan Petrochemical initiated the process of using domestic catalysts for its polyethylene production units in November 2016, and tested three types of domestic main catalysts: XY-S, SEG, and DJD-PES. During the trial period, the plant technicians carefully documented the usage process and parameter adjustments for each type of main catalyst, and analyzed in detail the characteristics of each of them. In February 2017, domestic main catalysts were put into trial use in linear low-density polyethylene plants. To ensure smooth operation, imported main catalysts were used each time the plant was started up; after the reaction process was established, domestic catalysts were gradually introduced until the plant could operate smoothly and normally. Before resuming operations this time, in order to break this convention, the plant’s technical staff took into account the performance characteristics of the domestically produced DJD-PES main catalyst and developed specialized startup plans and emergency response procedures. Responsibilities were assigned to each technical and operational position, thereby laying a solid foundation for the safe and smooth operation of the plant using this domestically produced catalyst.
In October 2020, Yangzi Petrochemical’s No. 2 polyethylene plant successfully used the BSG catalyst developed by Beijing Institute of Chemical Technology to produce high melt index grades YLJ-2520 and YLJ-2650. During the trial period, the production ran smoothly and the product quality was satisfactory. The successful application of BSG catalysts marks a new milestone in the localization of catalysts for Yangzi Petrochemical’s linear low-density polyethylene production facilities. It helps these facilities reduce their dependence on foreign catalysts, lower the costs associated with catalyst procurement, and ensure long-term stable operation of the facilities – aspects that are particularly important in the context of current international trade tensions. The specialty materials produced by Yangzi Petrochemical’s No. 2 polyethylene plant are mainly of the high melt index grades YLJ-2520 and YLJ-2650. The production of these products presents issues such as sticky polymer powder and poor fluidity; a high content of fine powder can lead to clogging of the filter bags at the top of the degassing chamber, affecting the plant’s ability to operate for extended periods. For a long time, imported catalysts have been used in the production of these high melt index grade products. The BSG catalyst is an improved version developed by the Beijing Institute of Chemical Technology based on the BCS-02 catalyst. During the 11-day production period, all operational parameters of the plant remained stable, the screening data was normal, and the fine powder content was under control. Compared with imported catalysts in terms of catalyst activity, powder particle size distribution, powder bulk density, and various physical properties of the final product, the BSG catalyst can fully replace imported catalysts.
On March 24, 2017, the polyethylene unit of Zhenhai Refining & Chemical’s Chemicals Department completed the first round of testing with domestically produced catalysts. The trial use of the domestic catalyst began on February 27, with a total of 15 tanks of the domestic catalyst being added over a period of 26 days. During the trial period, the device operated stably, all product qualities met the standards, and the expected goals were achieved. To ensure a safe and secure testing of this domestic catalyst, during the trial period, team members involved in the testing, including those responsible for catalyst technical support, monitored the process throughout. A WeChat group was established for information exchange, allowing for timely summary and analysis of the progress at each stage of testing. The operating crew intensified their inspections and monitoring of the equipment, operated with care, and strictly followed the testing plan and operational instructions. It is reported that this trial use of the catalyst has laid a solid foundation for completing the research project undertaken by the headquarters aimed at breaking the monopoly held by similar imported catalysts in the technology related to the use of such catalysts in high-melting-index polyethylene products. Going forward, Zhenhai Refining & Chemical Co., Ltd. and Shanghai Lide Catalyst Co., Ltd. will conduct a comprehensive review of the results of this catalyst trial, and through improvements to the catalyst, they will explore its application in the production of the specialized material M2320 with high melting index.
On July 14, 2020, good news came from the polyethylene production unit of Shaanxi Yanchang Petroleum Yan’an Energy Chemical Co., Ltd.: the use of domestic catalysts in place of imported catalysts was successful. During the trial period, the device operated stably, and all performance parameters of the product met the standard requirements, achieving the intended goals and marking a new breakthrough in the use of domestic catalysts in the Basel HOSTALEN ACP process. Image: This trial period started on June 29 and lasted for 15 days, during which two types of products were manufactured: tube material 23050 and hollow material ACP5531B. To ensure the safe and stable operation of the equipment during the trial period, the Olefin Polymerization Center established a technical task force. It held several technical meetings with catalyst manufacturers to thoroughly discuss various properties of the catalysts as well as potential issues, and developed a comprehensive trial plan. Throughout the trial period, the task force monitored the operation of the device continuously, increased the frequency of inspections, strengthened product quality analysis, constantly identified issues, and adjusted parameters in a timely manner. Thanks to the joint efforts of all involved parties, the catalyst was successfully tested.
【Ten Years of Great Progress in Chemical Technology】The third-generation methanol-to-olefins (DMTO-III) technology was approved as a scientific and technological achievement between 2011 and 2020. https://bbs.hcbbs.com/thread-4201725-1-1.html (Source: Haichuan Network)