On November 8th, a reporter was informed by the Jinzhou Petrochemical Company of China National Petroleum Corporation that, through the collaborative efforts of the Jinzhou Petrochemical Design Institute, Research Institute, and the isopropyl alcohol plant, a major milestone had been achieved. Over the past three years, the 100,000 tons/year isopropyl alcohol process package was successfully developed and tested, with key components verified in laboratory settings.
This new isopropanol process represents a significant advancement over existing methods. It addresses long-standing issues of high energy consumption in isopropyl alcohol production, which has a substantial impact on product profitability and the competitiveness of national industrial products. According to Dr. Zhang Yudong, head of the Jinzhou Petrochemical Research Institute, the newly developed process incorporates numerous integrated innovations and has been validated through both industrial plants and laboratory pilot facilities. Compared to traditional processes, the new method increases the single-pass yield of isopropyl alcohol by 10%, reduces material consumption by 5%, and cuts overall energy consumption by 49.2%.
In recent years, the demand for isopropyl alcohol in China has surged. Apparent consumption rose from 97,000 tons in 1998 to 196,000 tons in 2005, reflecting an average annual growth rate of 9.2%. Despite multiple expansions, the Jinzhou Petrochemical Company's isopropyl alcohol plant has struggled to meet domestic demand, leading to increasing imports each year. When reaching out to foreign technology holders, the company only received discussions on market cooperation without any technology transfer.
To address this gap, Jinzhou Petrochemical opted for independent development and planned to build a new 100,000-ton production facility during the "Eleventh Five-Year Plan" period. This initiative aims to establish large-scale production and enable joint production of propyl ether, while developing various downstream isopropyl alcohol products. The company aims to become Asia’s largest producer of isopropyl alcohol. By 2008, China's total isopropyl alcohol production capacity was expected to reach 230,000 tons.
Jinzhou Petrochemical’s isopropyl alcohol products are known for their stable quality and high purity, meeting international standards set by companies like Shell and Exxon. They have gained recognition from users in Japan and Southeast Asian countries. However, the current process suffers from inefficient energy use during reaction and separation, resulting in higher energy costs and reduced market competitiveness.
To enhance competitiveness, the new process not only improves product quality but also significantly lowers energy consumption. The 100,000-ton isopropyl alcohol technology package was developed using a combination of computer simulations and industrial and lab testing. While the basic refining process remains unchanged, an additional impurity removal step was introduced without simplifying the refining method. The new technology optimizes process conditions, reduces unnecessary steps, and enhances energy efficiency.
The optimized heat exchange system in the reaction process was validated in a 50,000-ton/year plant, while the improvements in reaction and tower separation were confirmed through a laboratory pilot plant. The heat exchange process in the separation stage was further validated using three different software tools. This comprehensive validation ensures the reliability and effectiveness of the new process, paving the way for more sustainable and competitive production.
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