25+ Refrigeration and Compression Systems for Zhejiang Petrochemical: Mega-Scale Propylene Chillers Up to 14,400 kW for China’s Largest Private Refining Complex

From 2019 to 2023, Lmart delivered over 25 industrial refrigeration units to Zhejiang Petroleum & Chemical Co., Ltd. (“Zhejiang Petrochemical”, 浙石化) — one of China’s largest integrated refining and petrochemical complexes. The supply scope includes a 14,400 kW acrylonitrile brine chiller, twin 12,650 kW CCR direct cooling systems, and multiple process chillers across 10+ production plants, predominantly using R1270 (propylene) as refrigerant — sourced directly from the site’s own propylene production.

Customer	Zhejiang Petroleum & Chemical Co., Ltd. (浙江石油化工有限公司, “浙石化”)
Industry	Integrated refining & petrochemicals — 40 million tons/year refining capacity
Project Location	Yushan Island, Zhoushan, Zhejiang, China
Equipment	Brine chillers, direct cooling systems, refrigeration systems (25+ units total)
Cooling Capacity Range	380 kW to 14,400 kW per unit
Primary Refrigerant	R1270 (propylene) — also R507, R507A
Coolant	Ethylene glycol (brine systems); direct expansion for direct cooling units
Design Institutes	Luoyang Petrochemical Engineering Design, Shanghai Lanke, Huanqiu (various), HQC (Guangdong/Shanghai), CNPC Northeast Refining & Chemical Engineering
Delivery Period	2019–2023 (5 consecutive years)

Customer Background: Zhejiang Petrochemical

Zhejiang Petroleum & Chemical Co., Ltd. operates one of China’s largest private-sector integrated refining and petrochemical complexes, located on Yushan Island in the Zhoushan Archipelago, Zhejiang Province. Part of the Rongsheng Petrochemical group, the complex has a total crude oil refining capacity of 40 million tons per year across two phases, with downstream units producing ethylene, propylene, aromatics, and a full range of petrochemical derivatives including acrylonitrile, styrene, EO/EG (ethylene oxide/ethylene glycol), polypropylene (PP), LDPE/EVA, butadiene, VAC (vinyl acetate), and EC (ethylene carbonate).

The sheer scale of the Zhejiang Petrochemical complex creates refrigeration demands that are proportionally massive. A single acrylonitrile plant requires 14,400 kW of brine cooling. A continuous catalytic reforming (CCR) unit needs 12,650 kW of direct cooling per train. These are not catalog equipment selections — they are custom-engineered refrigeration systems where compressor motor ratings exceed 3,500 kW and heat exchanger surface areas run into thousands of square meters.

A defining characteristic of the Zhejiang Petrochemical refrigeration supply is the predominant use of R1270 (propylene) as refrigerant. As an integrated refining complex with its own propylene production capacity, the site has ready access to high-purity propylene for refrigerant charging and maintenance. This eliminates supply chain dependency on commercial refrigerant distributors and leverages a feedstock that is already managed within the site’s process safety and inventory systems.

Scope of Supply: 5 Years, 10+ Plants, 25+ Units

Year	Plant / Application	Equipment Type	Capacity (kW)	Motor Power	Refrigerant	Coolant	Units	Design Institute
2019	CCR (Continuous Catalytic Reforming)	Direct cooling	12,650	4,500 kW	R1270	—	2	Luoyang Petrochemical Engineering Design
2019	Acrylonitrile	Brine chiller	14,400	3,500 kW	R1270	Ethylene glycol	1	Shanghai Lanke
2019	EO/EG (Ethylene Oxide / Ethylene Glycol)	Brine chiller	380	185 kW	R1270	Ethylene glycol	2	CNPC Northeast Refining & Chemical Engineering
2019	PP (Polypropylene)	Brine chiller	1,760	560 kW	R1270	Ethylene glycol	2	Luoyang Petrochemical Engineering Design
2020	LDPE/EVA	Brine chiller	560	185 kW	R507	Ethylene glycol	8	Huanqiu (Daqing)
2020	Butadiene	Brine chiller	880	560 kW	R1270	Ethylene glycol	1	HQC (Guangdong)
2021	EC (Ethylene Carbonate)	Direct cooling	1,900	630 kW	R507A	Ethylene glycol	3	HQC (Shanghai)
2022	Styrene	Brine chiller	11,950	2,300 kW × 2	R1270	Ethylene glycol	2	Luoyang Petrochemical Engineering Design
2022	VAC (Vinyl Acetate)	Brine chiller	6,252	1,300 kW × 2	R1270	Ethylene glycol	3	Huanqiu
2023	Refrigeration system	Refrigeration system	1,100	500 kW	Propylene	Ethylene glycol	1	Shanghai Lanke

Engineering Challenges: Mega-Scale Petrochemical Refrigeration

14,400 kW Acrylonitrile Brine Chiller: Among the Largest Single-Unit Deliveries

The acrylonitrile brine chiller is one of the largest single-unit process chillers Lmart has ever delivered. At 14,400 kW cooling capacity with a 3,500 kW compressor motor, this unit presents engineering challenges that go well beyond scaling up a standard chiller design:

• Compressor engineering: A 3,500 kW motor driving a propylene screw compressor requires careful attention to starting current management (typically 5–7× full-load current for across-the-line starting), torsional analysis of the compressor-coupling-motor assembly, and bearing loading under all operating conditions including surge and emergency shutdown.
• Heat exchanger sizing: The evaporator must transfer 14,400 kW from ethylene glycol brine to evaporating propylene. At typical brine approach temperatures of 3–5 °C, this requires shell-and-tube exchanger surface areas exceeding 1,000 m², with careful tube layout to ensure uniform refrigerant distribution across all tube passes.
• Propylene refrigerant charge: A system of this capacity contains several tons of propylene refrigerant — a flammable hydrocarbon (A3 classification per ASHRAE 34). The refrigerant charge quantity drives machinery room classification, ventilation requirements, gas detection system coverage, and emergency depressurization provisions per GB 50160 and GB 50058.
• Transport logistics: A 14,400 kW chiller package exceeds standard road transport dimensional limits. Lmart engineered the unit for modular transport and field assembly, with the compressor skid, evaporator, condenser, and control panel shipped as separate modules with bolted interconnections.

12,650 kW CCR Direct Cooling: Catalytic Reforming Refrigeration

Continuous catalytic reforming (CCR) produces high-octane reformate and hydrogen from heavy naphtha. The process requires refrigeration to condense and recover light hydrocarbons from the reactor effluent gas stream. At 12,650 kW per unit with 4,500 kW compressor motors, the two CCR direct cooling systems for Zhejiang Petrochemical are among the most powerful direct-expansion refrigeration units in Lmart’s reference list.

Direct cooling in CCR service means the propylene refrigerant evaporates directly in process-side heat exchangers — there is no intermediate brine loop. This eliminates the 3–5 °C temperature approach penalty of brine systems but places the refrigerant equipment directly in the process area, requiring full compliance with hazardous area classification for simultaneous presence of process hydrocarbons (naphtha, LPG components) and refrigerant propylene.

The 4,500 kW motor on each CCR unit is the largest single compressor motor in the Zhejiang Petrochemical refrigeration scope. At this power level, motor starting strategy (soft starter, VFD, or auto-transformer starting), power factor correction, and harmonic impact on the site electrical network become significant engineering considerations that must be coordinated with the site’s electrical design institute.

Propylene (R1270) as Primary Refrigerant: Site-Sourced Hydrocarbon Cooling

Eight of the ten Zhejiang Petrochemical line items use propylene (R1270) as refrigerant. This is not a coincidence — it is a deliberate engineering and procurement strategy enabled by the integrated refining complex’s in-house propylene production:

• Thermodynamic properties: Propylene provides excellent performance in the −20 °C to −40 °C evaporating temperature range common in petrochemical process cooling. Its latent heat, specific volume, and pressure-temperature relationship are well-suited to screw compressor operation at the compression ratios typical of these applications.
• Supply logistics: With on-site propylene production, refrigerant procurement is reduced to an internal materials transfer rather than an external purchase-and-delivery cycle. Initial charging and any maintenance top-ups draw from the site’s polymer-grade propylene storage — eliminating lead times, minimum order quantities, and the shelf-life management required for commercial refrigerant cylinders.
• Safety infrastructure reuse: As a refining and petrochemical complex, Zhejiang Petrochemical already maintains comprehensive hydrocarbon safety systems — gas detection networks, emergency shutdown systems, hazardous area electrical classification, and fire suppression infrastructure. Using propylene as refrigerant operates within this existing safety framework rather than introducing a separate refrigerant safety regime.
• Environmental profile: Propylene has zero ODP and a GWP of approximately 2 — effectively negligible compared to HFC refrigerants like R507A (GWP 3,985). For a mega-scale complex with total refrigerant charges measured in tens of tons, this environmental advantage is operationally significant under evolving F-gas regulations.

R507/R507A for Non-Propylene Applications

Two Zhejiang Petrochemical applications use R507 or R507A instead of propylene: the LDPE/EVA brine chillers (560 kW × 8, R507) and the EC direct cooling systems (1,900 kW × 3, R507A). In both cases, the selection reflects process-specific constraints:

• The LDPE/EVA units are distributed across the polyethylene production area where the small individual unit capacity (560 kW) and distributed installation pattern make propylene gas detection coverage impractical compared to using a non-flammable HFC.
• The EC (ethylene carbonate) direct cooling units operate at evaporating temperatures where R507A’s operating pressures provide better compressor volumetric efficiency than propylene, offsetting the logistic advantage of site-sourced propylene.

Why Zhejiang Petrochemical Selected Lmart

Mega-scale propylene refrigeration experience. The 14,400 kW acrylonitrile chiller and the 12,650 kW CCR direct cooling systems are flagship-scale refrigeration equipment. Zhejiang Petrochemical’s EPC contractors required a manufacturer with demonstrated capability in propylene refrigeration systems at capacities above 10,000 kW — a threshold that eliminates most domestic refrigeration packagers whose experience is concentrated in smaller commercial and light industrial systems.

Multi-application coverage from a single source. Across 5 years, Lmart supplied refrigeration for CCR, acrylonitrile, EO/EG, PP, LDPE/EVA, butadiene, styrene, VAC, EC, and general refrigeration — 10 distinct production applications. Single-source supply across this range simplifies spare parts management (common compressor platforms, common control architectures), reduces the number of vendor qualification files the site must maintain, and provides a single point of contact for technical support across the refrigeration fleet.

Design institute familiarity. Zhejiang Petrochemical’s production plants were designed by Luoyang Petrochemical Engineering Design, Shanghai Lanke, Huanqiu (multiple offices), HQC, and CNPC Northeast. Lmart has established working relationships with all five institutes, reducing design review cycle times and minimizing engineering clarification requests that delay procurement.

Propylene system safety competence. Propylene refrigeration systems require ATEX/IECEx-equivalent hazardous area electrical design, propylene-compatible sealing materials, steel piping systems (no copper), and relief/depressurization systems sized for flammable gas discharge. Lmart’s propylene system design and fabrication capability — proven across dozens of units for multiple petrochemical clients — provides the safety engineering credibility that Zhejiang Petrochemical’s HSE teams require.

Engineering and Manufacturing Highlights

Propylene Screw Compressor Systems

Propylene’s thermodynamic properties — moderate molecular weight (42 g/mol), favorable pressure-temperature curve, and reasonable discharge temperatures at typical petrochemical compression ratios — make it well-suited to oil-injected screw compressor technology. However, propylene screw systems differ from HFC systems in several critical respects:

• Shaft seal design: Propylene is a gas at atmospheric conditions, so any seal leakage results in direct hydrocarbon emission. Double mechanical seals with buffer gas or oil barrier systems are standard, with seal leakage monitoring integrated into the safety PLC.
• Oil compatibility: Propylene is miscible with mineral and PAO lubricating oils at typical operating temperatures, but oil viscosity must be maintained at discharge temperatures that can exceed 80 °C in single-stage compression at high ratios. Oil separator efficiency is critical — propylene carry-over in the oil reduces compressor displacement, while oil carry-over into the refrigerant circuit fouls heat exchanger surfaces.
• Electrical classification: All electrical components on and near the compressor package must be rated for Zone 1 or Zone 2 hazardous area classification (IEC 60079), including the main motor, control instrumentation, solenoid valves, and lighting.

Large-Format Shell-and-Tube Exchangers

The 14,400 kW and 11,950 kW units require evaporators and condensers at the upper end of shell-and-tube heat exchanger manufacturing capability. These vessels are designed to ASME VIII or GB/T 150, with tube counts exceeding 1,000 tubes per exchanger, tube sheet thicknesses above 100 mm, and total weights requiring multi-axle transport and crane lifts above 50 tons. Tube-to-tubesheet joint integrity is verified by helium leak testing on every joint — a single leaking tube in a propylene evaporator creates a direct path for flammable refrigerant to enter the brine circuit.

Batch Production: LDPE/EVA — 8 Identical Units

The 2020 LDPE/EVA order — eight identical 560 kW brine chillers — represents the other end of the manufacturing spectrum from the mega-scale CCR and acrylonitrile units. Batch production of eight units enables manufacturing efficiencies: common cutting lists, welding procedure qualification applied across all units, sequential assembly line flow, and standardized test procedures. For Zhejiang Petrochemical, identical units across the LDPE/EVA plant provide full interchangeability of spare parts, consistent control system integration, and simplified maintenance training.

Quality Assurance and Project Execution

Zhejiang Petrochemical and its EPC contractors maintain rigorous vendor inspection requirements proportional to the equipment criticality and the flammable refrigerant service. Lmart’s QA execution for each project includes:

• Pre-manufacturing design review with the specifying design institute, including P&ID verification, instrument specification review, and hazardous area classification confirmation
• Material certification and PMI (Positive Material Identification) for all pressure-containing components
• Pressure vessel fabrication per GB/T 150 or ASME VIII with full NDE (radiographic or ultrasonic examination of butt welds, magnetic particle or dye penetrant inspection of fillet welds)
• Hydrostatic pressure test per code requirements, witnessed by the client’s third-party inspection agency
• Complete package assembly including refrigerant piping, instrumentation, control panel, motor wiring, and safety system integration
• Propylene-specific testing: nitrogen pressure test and helium leak test of the complete refrigerant circuit, evacuation and dehydration verification, and refrigerant charging procedure documentation
• Factory acceptance test (FAT) with client and design institute representatives: control sequence simulation, safety interlock verification, vibration measurement, and documentation review
• Delivery to Yushan Island via combination of road and sea transport, with custom rigging and lifting procedures for oversized units
• On-site commissioning support including refrigerant charging, system startup, performance verification, and operator training

For the 14,400 kW acrylonitrile chiller and the 12,650 kW CCR units, the FAT included extended compressor run-in testing and vibration spectrum analysis to verify bearing condition and rotor balance before shipment — correcting any issues at the factory is orders of magnitude less costly than addressing them after installation on Yushan Island.

Results and Strategic Significance

The Zhejiang Petrochemical account demonstrates Lmart’s capability at the top end of the domestic industrial refrigeration market. The combination of 14,400 kW single-unit capacity, propylene hydrocarbon refrigerant, and mega-scale petrochemical site requirements places this work in a category that few Chinese refrigeration packagers can credibly address.

Key metrics from the 5-year supply relationship:

• Total installed cooling capacity: Exceeding 100,000 kW across all delivered units
• Largest single unit: 14,400 kW acrylonitrile brine chiller — among the largest process chillers manufactured in China
• Largest compressor motor: 4,500 kW on CCR direct cooling units
• Production applications covered: 10 distinct petrochemical processes
• Design institutes served: 5 major Chinese engineering design firms

For prospective customers evaluating industrial refrigeration suppliers for large-scale petrochemical applications, the Zhejiang Petrochemical reference provides evidence of demonstrated capability in propylene refrigeration system design, manufacturing, and commissioning at capacities that are rarely matched in the domestic market.

Customer Voice

The scale and duration of the Zhejiang Petrochemical supply relationship — 25+ units across 5 years, including single units above 10,000 kW — represents a level of vendor commitment that reflects sustained confidence in manufacturing quality and on-site performance. Each subsequent order was awarded after the previous delivery had been commissioned and validated in operation.

“At these capacities, equipment failure is not a maintenance inconvenience — it is a production loss measured in millions of RMB per day. The vendor selection process is correspondingly rigorous.”

— Industry observation on mega-scale petrochemical refrigeration procurement (paraphrased)

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