**Ethylene Cold Box**
The plate-fin heat exchanger group is a critical component in ethylene production. A 800,000-ton/year ethylene cracker typically requires around 20 plate-fin heat exchangers. The Hangzhou Oxygen Machinery Factory has adopted the design technology and key manufacturing equipment from the American SW Company, significantly enhancing its design capabilities and production standards to reach international levels. To date, the factory has successfully designed and manufactured over ten sets of ethylene cold boxes. This demonstrates that China now possesses the foundational conditions for producing large-scale ethylene cold boxes with capacities ranging from 800,000 to 1 million tons per year. The next step is to develop a cold box capable of handling a design pressure of 8 MPa.
**Polymerization Reactor**
Currently, the design of gas-phase reactors for towers remains challenging within China. However, foreign-designed 250,000-ton polyethylene gas-phase reactors have been successfully implemented in the Shanghai and Yangtze 700,000-ton/year ethylene upgrading projects. For low-density polyethylene ultra-high-pressure tubular reactors, which operate at pressures up to 345 MPa and temperatures of 315°C, several technical challenges exist, including ultra-high pressure tube cold bending, continuous outer casing thermal setting, stress elimination through heat treatment, fatigue self-reinforcement, and precise pipe end cutting. These processes are not yet fully mastered domestically. However, China has already manufactured a 200,000-ton/year ultra-high-pressure polyethylene pipe reactor for use in Yanshan’s 700,000-ton/year ethylene project. Meanwhile, the loop reactor used in polypropylene plants is entirely designed and manufactured in China. Despite this progress, challenges remain in producing large-diameter pipes and improving the wall thickness tolerance and elliptical accuracy of steel pipes.
**Extrusion Granulation Unit**
Large extrusion granulation units require a capacity of more than 50 tons per hour, equivalent to an annual output of 300,000 to 400,000 tons. Designing and manufacturing such units is extremely complex. Currently, only a few companies—such as German WP, Japanese Steel, Kobe Steel, and American Farrell—are capable of providing full design, manufacturing, installation, and commissioning services. In China, several 70,000-ton extrusion granulators were produced through foreign collaboration, but they lack performance. During the “Eleventh Five-Year Plan,†it was expected that more such units would be imported, although the high cost—ranging from 5 million to 7 million dollars—makes domestic development urgent. It is essential to introduce advanced technologies or engage in joint production as soon as possible.
**Distributed Control System (DCS)**
Petrochemical production facilities largely rely on imported DCS systems. Companies like Yokogawa and Honeywell hold significant market shares, while others such as Foxboro, ABB, and Bailey also play a role. Domestic research has been conducted, and some systems have been applied in petrochemical plants with limited control loops. However, no further industrial development has taken place. More effort is needed to advance local DCS technology.
**Needed Policy Support**
The design and manufacture of large-scale ethylene equipment with a capacity of one million tons is a major challenge, with many gaps compared to foreign counterparts. If China fails to seize the current growth opportunities in its ethylene industry, it may face long-term dependency on foreign technology. Over the past two decades, experience has shown that achieving localization requires either independent innovation or the absorption and improvement of imported technology. To accelerate this process, the government must provide support, including clear localization targets, procurement policies, funding, tax incentives, and encouragement for joint research between scientific institutions, manufacturers, and users. Additionally, preferential policies should be offered to users to reduce risks and promote the adoption of locally produced equipment. Finally, standardizing petrochemical equipment technology policies will help reduce barriers to innovation.
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