The 200,000-ton-per-year polypropylene plant at Dalian Petrochemical Company has been successfully launched and is now fully operational. This state-of-the-art facility showcases four key technological advantages that significantly enhance its production efficiency and product quality.
As the second-largest polypropylene unit within China Petroleum Corporation, the plant utilizes advanced second-generation technology from BASF, a global leader in polypropylene production. The process involves a liquid-phase macro-loop reaction system, which includes catalyst preparation, prepolymerization, and polymerization, among other eight units. After establishing small, high-pressure, low-pressure, and large cycles, the catalyst initiates the polymerization process, producing a polypropylene slurry. This slurry is then flash-vaporized, deactivated, dried, and finally extruded into granules to form the final product.
The reactor system consists of one prepolymerization reactor and two series loop reactors, while the extrusion granulation unit features two fully automated packaging and palletizing lines. The catalyst system comprises titanium-based catalysts supported on magnesium chloride, triethylaluminum (TEAL), and an electron donor, all working together to ensure efficient polymerization. Prepolymerization occurs in a small loop reactor, while homopolymerization takes place in two serial loop reactors. Each reactor is equipped with three safety measures: emergency polymerization inhibition, bottom discharge, and a safety valve connected to a high-pressure discharge system.
The four major process features provide significant production benefits. The fourth-generation catalyst system allows for the production of bimodal polypropylene with high rigidity, crystallinity, and clarity. Adjusting pressure levels during prepolymerization and polymerization increases hydrogen content in the loop reactor, broadening the MFR range and improving product strength and performance. The dual-loop reactor design enables the production of both bimodal and narrow molecular weight distribution products. The use of loop reactors and liquid-phase bulk polymerization ensures better heat control and more uniform reactions. Additionally, metallocene catalysts reduce the need for major plant retrofits, shorten residence time, improve reaction volume utilization, and enhance degassing, steaming, and drying systems.
Dalian Petrochemical Company has selected T30S and T36F grades, known for their stable production and strong market demand. It has also developed BOPP special materials tailored to the process characteristics. With a crude oil processing capacity of 20.5 million tons per year, a catalytic cracking capacity of 5.8 million tons, and nearly 280,000 tons of propylene available annually, the company has expanded its polypropylene product range from 24 to 56 varieties, enabling full-range and multi-product manufacturing.
The products are widely used in packaging, automotive plastics, and daily consumer goods, significantly boosting the company’s propylene processing concentration and competitiveness in the chemical market. By transforming refinery gases into chemical raw materials, the company has elevated its role in the petrochemical industry to a new level.
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