Just after the Spring Festival, Sinopec Qilu Petrochemical Company received news that its “Ten Long†research project—specifically the 200,000-ton-per-year styrene plant at Qilu Petrochemical Plastic Factory—had successfully implemented a new environmentally friendly and efficient polymerization inhibitor. This innovation led to a 38% reduction in polymer production within the styrene distillation tower reactor and a 1.5% increase in styrene yield. The change marked a significant improvement over traditional nitro-styrene inhibitors, which were known for their high toxicity, poor performance, and large quantities needed. With the new product, energy and material consumption dropped substantially, resulting in annual energy savings and efficiency gains exceeding 3.2 million yuan.
The innovative inhibitor was developed by Beijing Spiral Technology Development Co., Ltd. It has achieved international advanced standards and is now protected by an invention patent from the State Intellectual Property Office. This green product is non-toxic, free of metals, halides, and nitrogen oxides, making it safer for both workers and the environment. Its strong ability to capture free radicals, disperse effectively, and deactivate metals helps prevent unwanted polymerization in the styrene purification system. As a result, it improves styrene yield and extends the operational cycle of the equipment.
In the 1980s, the Plastics Plant of Sinopec Qilu Branch introduced the Lums EP process technology from the U.S. and built a 60,000-ton/year styrene plant. By 2004, the capacity had expanded to 200,000 tons per year. Initially, the plant used DNPC or DNBP as recommended by the patented technology, but these traditional inhibitors had low activity and struggled to control polymerization effectively. They required large dosages and posed significant health and environmental risks.
In recent years, more advanced and efficient inhibitors have been adopted globally. In August 2005, Qilu Petrochemical’s Plastics Factory commissioned the Sinopec Qilu Petrochemical Research Institute to evaluate the Spiro-developed styrene distillation inhibitor. Testing began in March 2006, and the product has now operated continuously for 22 months. Results show that compared to the previous use of DNPC or DNBP, the new eco-friendly inhibitor reduces polymer formation by 38% under similar conditions. It also cuts the total dosage by 45% to 50%, lowers tar viscosity, and shortens tar loading time from 7.8 to 3.8 hours. Additionally, it extends the reboiler's operating cycle, reduces nitrogen oxide emissions, and minimizes equipment corrosion.
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