Zhejiang Petrochemical — CCR (2019) — 12,650 kW Direct Cooling System for Continuous Catalytic Reforming

Zhejiang Petroleum & Chemical Co., Ltd. operates a 40 Mt/a integrated refining and petrochemical complex on Yushan Island, Zhoushan, Zhejiang Province — one of the largest single-site facilities in China. Built in two phases, the complex integrates atmospheric and vacuum distillation, hydrocracking, catalytic cracking, and a full suite of downstream petrochemical units including ethylene, propylene, aromatics, and polyolefin production.

Customer	Zhejiang Petroleum & Chemical Co., Ltd.
Plant / Unit	Continuous Catalytic Reforming (CCR)
Equipment	Direct Cooling Compressor Package
Design Institute	Luoyang Petrochemical Engineering Design Co., Ltd.
Design Code	GB
Cooling Capacity	12,650 kW per unit
Motor Power	4,500 kW
Refrigerant	R1270 (Propylene)
Quantity	2 sets

Customer Background

Zhejiang Petroleum & Chemical Co., Ltd. operates a 40 Mt/a integrated refining and petrochemical complex on Yushan Island, Zhoushan, Zhejiang Province — one of the largest single-site facilities in China. Built in two phases, the complex integrates atmospheric and vacuum distillation, hydrocracking, catalytic cracking, and a full suite of downstream petrochemical units including ethylene, propylene, aromatics, and polyolefin production.

The CCR (Continuous Catalytic Reforming) unit is a core component of the aromatics chain. Unlike semi-regenerative reformers that require periodic shutdown for catalyst regeneration, the CCR process continuously circulates catalyst between the reactor stack and a regeneration tower, enabling sustained high-severity operation at lower pressure. This maximizes aromatics yield but generates significant heat loads in the reactor effluent that must be removed before downstream separation. The refrigeration system is therefore a critical utility — any loss of cooling capacity directly reduces reformer throughput.

Challenges and Engineering Requirements

Process Temperature Control in petrochemical processing

Zhejiang Petroleum & Chemical Co., Ltd. required precise low-temperature cooling for Direct Cooling Compressor Package service in the petrochemical processing sector. The brine chiller system must maintain stable outlet temperatures within narrow tolerances despite variable process heat loads. Fluctuations in feed composition, ambient temperature swings, and seasonal load variations all affect the refrigeration duty — the system must respond to these changes while protecting compressor operation from surge and liquid carryover.

Refrigerant Selection and Safety

The choice of R1270 (Propylene) reflects the balance between thermodynamic efficiency at the target evaporating temperature, compatibility with the plant’s existing refrigerant infrastructure, and safety classification under the applicable code. Each refrigerant brings specific considerations: flammability limits for hydrocarbon refrigerants, operating pressure ranges that affect component sizing, and oil miscibility that influences compressor lubrication system design.

Integration with EPC Engineering

The chiller packages were specified and documented by Luoyang Petrochemical Engineering Design Co., Ltd. as part of a larger process unit. This means every interface — brine supply/return connections, electrical load requirements, control signal protocols, and physical footprint — must match the EPC’s plot plan and P&ID exactly. Any deviation requires formal design change management, adding time and cost to the project.

Why Zhejiang Petroleum & Chemical Co., Ltd. Selected Lmart

Integrated refrigeration package capability. Lmart designs and manufactures complete refrigeration systems — compressor selection, heat exchanger sizing, piping layout, control logic, and skid-frame engineering — as a single-source supplier. This eliminates the interface risks that arise when the chiller vendor, vessel fabricator, and system integrator are separate companies.

Process refrigerant experience. Lmart has delivered refrigeration packages using propylene, propane, ammonia, R134a, and other process refrigerants across petrochemical, chemical, and marine applications. This experience base means the engineering team understands the specific requirements of each refrigerant — safety classifications, oil management, capacity control methods — without a learning curve.

Repeat performance. Lmart has delivered equipment to Zhejiang Petroleum & Chemical Co., Ltd. and similar clients in the petrochemical processing sector, demonstrating consistent quality and on-time delivery performance across multiple projects.

Engineering and Manufacturing Solution

Lmart engineered and fabricated Direct Cooling Compressor Package for Zhejiang Petroleum & Chemical Co., Ltd. to GB. The scope of supply included complete detail design, material procurement, fabrication, inspection, testing, and documentation.

Key engineering considerations for this project included thermal-hydraulic performance optimization, material selection for the specific process environment, and compliance with GB requirements for design, fabrication, and inspection.

The equipment was manufactured at Lmart’s Zhangjiagang facility, which provides full-cycle fabrication capabilities including plate rolling, head forming, machining, welding (SAW, GTAW, SMAW), post-weld heat treatment, and NDE — all under a single quality management system.

Manufacturing and Quality

Each 12,650 kW direct cooling package was assembled as a complete skid at Lmart’s Zhangjiagang facility, including the screw compressor, oil separator, condenser, evaporator, economizer, oil cooler, control panel, and all interconnecting piping and wiring. Factory assembly and full-load testing prior to shipment eliminates the risk of field assembly errors and reduces on-site commissioning time from weeks to days.

Quality control milestones included:

• Pressure vessel fabrication and testing per GB 150 for all heat exchangers and separators
• Compressor performance verification at rated conditions on the factory test stand
• Complete skid leak testing with nitrogen at 1.1× design pressure
• Electrical and instrumentation loop testing including DCS interface simulation
• Vibration analysis and alignment verification for the 4,500 kW motor-compressor coupling

Results and Business Impact

Lmart successfully delivered Direct Cooling Compressor Package to Zhejiang Petroleum & Chemical Co., Ltd., meeting the project’s quality, schedule, and documentation requirements. The equipment was manufactured to GB standards, with full documentation packages accepted by the client and applicable inspection authorities.

This project reinforces Lmart’s position as a qualified manufacturer for petrochemical processing applications, demonstrating the company’s ability to deliver equipment that meets international quality and certification standards.

Customer Voice

“The equipment was delivered on schedule and the documentation package was complete. The quality of fabrication met our inspection requirements.”

— Zhejiang Petroleum & Chemical Co., Ltd. project team (paraphrased from project review)

Note: Lmart respects client confidentiality. Specific contact references are available upon request during the qualification process.