Since the outbreak of the new crown pneumonia epidemic, masks have become a necessary medical material for epidemic prevention and control. In response to the needs of the current situation, the chemical company affiliated to the National Energy Group quickly organized and implemented the key project of "conversion of polypropylene spinning material S2040", and successfully converted production in a short period of time, producing raw materials for medical protective products such as masks and protective clothing - Poly Propylene S2040 high melt finger spinning material. As of March 10, nearly 12,000 tons of high-melt-index fiber polypropylene S2040 series products that can be used in masks, surgical gowns and other medical protective products have been produced, and the product quality rate has reached 100%!
High solubility refers to the processing of fiber polypropylene into non-woven fabrics, which can become the raw material for downstream mask companies to manufacture masks. According to the calculation that about 900,000-1,000,000 disposable surgical masks and 200,000-250,000 N95 medical masks can be made per ton of high-melting-finger fiber, this batch of polypropylene S2040 high-melting finger spinning materials produced from coal , which can meet the material supply of about 10.8-12 billion surgical masks and 2.4-3 billion N95 medical masks!
At present, these high melting finger fiber polypropylene S2040 are being sent to Hubei, Shandong, Tianjin, Zhejiang, Jiangsu, Guangdong and other provinces by railway.
Bright and unique skills, the transfer of fire line to production shows the responsibility of central enterprises
Coal can be processed into the upstream raw material required by the mask industry - high melting index polypropylene fiber material (a semi-crystalline thermoplastic). After melting and shaping the high melting index polypropylene fiber material, it can be manufactured Become medical non-woven fabrics and finally make into masks.
Baotou Chemical, a national energy group chemical company located in Baotou City, Inner Mongolia Autonomous Region, is responsible for the production and operation of the world's first national-level coal-to-olefins demonstration project. For the first time, it adopts the DMTO process technology with China's independent intellectual property rights to realize the conversion of methanol into low-carbon olefins. The industrialization demonstration of important petrochemical basic raw materials has opened up a new coal chemical technology route for producing olefins and polyolefins with coal as raw materials.
Baotou Chemical mainly produces 17 grades of polyethylene and 121 grades of polypropylene products that can be used in films, tube sheets, etc. The polypropylene plant can produce 300,000 tons of polypropylene resin per year, and can produce homopolymers and random copolymers. And a full range of polypropylene uncolored pellets for impact copolymers. The L5E89 grade general-purpose wire drawing material before the conversion is mainly used for woven bags, daily necessities and packaging films.
The S2040 grade polypropylene used for medical protective products produced in the "S2040 conversion of polypropylene device spinning material" project" is a high melting index spinning material with a melting index of 40g/10min. Under the condition of not changing the main catalyst , through the degradation method, the comprehensive molecular regulator is gradually added in the granulation section to gradually increase the melting of the product, and the amount of solid additives such as main antioxidant 3114, auxiliary antioxidant 168, acid scavenger calcium stearate, etc. Industrial production standards for spinning materials for medical protective products such as masks.
Dare to innovate to unlock the technical problem of "stuck neck"
Industrial production of high-melting non-woven fabrics generally adopts liquid degradation method. In this method, it is difficult for molecular regulators to mix uniformly with polypropylene powder and antioxidants in the granulation section. The product has an odor.
If you have no experience to learn from, you can innovate yourself! The project research team tried to adjust the mixing time, change the outlet temperature of the purification fan, try to maximize the volatilization of other gases, and try to adjust the ratio of the hydrogen adjustment method and the degradation method to find a balance point, so that the melting index of the product can meet the standard while ensuring that the product has no peculiar smell… …It is not hard to know, but hard to do.
The conversion of polypropylene plant from drawing material L5E89 to spinning material S2040 needs to go through the transition of multiple grades. What if there is no experience in the production of similar products? The project team brainstormed ideas, drew lessons from domestic devices of the same type, repeatedly calculated and demonstrated, and prepared a production conversion plan! Time is tight and the task is heavy, what should I do? Break down the production tasks into specific dates and times, and the installation supervisor takes the lead in "white and black" working overtime to catch up with the progress! How to debug key equipment such as resin ultra-high melting index extrusion granulator? Then adjust the temperature of the cylinder, the template, and the dicing water step by step, and switch the speed of the cutter and the feed pressure step by step... Facts have proved that as long as you face difficulties and dare to innovate, all "stuck neck" problems will be solved. Solved!
Keep improving and interpret the "speed of central enterprises"
Baotou Chemical: At 11:22 on March 1st, the polypropylene production grade was switched from L5E89 to V30G; at 16:00 on March 1, the polypropylene production grade was switched from V30G to S2024; at 22:28 on March 1, polypropylene production was The grade was cut from S-2024 to H30S; at 6:00 on March 2, the grade of polypropylene production was cut from H30S to S2040...
As of March 8, Baotou Chemical has produced 197 tons of V30G, 223 tons of S2024, 277 tons of H30S, and 5,429 tons of S2040. Among them, V30G grades, S2024 grades and H30S grades all meet the standard of qualified products! In particular, the S2040 brand products used for medical protective products have achieved a 100% premium rate.
During production, by adjusting the ratio of hydrogen conditioning method and degradation method, the amount of molecular regulator added was reduced from the original plan of 5500-7000PPM to 4500PPM, which not only reduced the unit consumption of the additive, but also eliminated the risk of peculiar smell in the product. The polypropylene unit was stably maintained at 98% load, the unit consumption of main catalyst, propylene, and ethylene were all lower than the designed unit consumption, and the unit consumption of public works was also lower than the expected value.
The S2040 series spinning material produced by Baotou Chemical has the advantages of zero transition material conversion, lowest unit consumption of molecular regulator, stable and uniform melt index, low yellow index and no odor. These data all show that the chemical company Baotou Chemical Co., Ltd. Baotou Chemical Co., Ltd. has successfully completed the conversion and development project of polypropylene spinning material for medical protective products. It took 19 hours to switch production, and the results were outstanding.
At the same time, Yulin Chemical, a subsidiary of the National Energy Group Chemical Company, located in Qingshui Industrial Park, Yushen Industrial Zone, Yulin City, Shaanxi Province, has also begun the task of converting 6,000 tons of production to ensure medical masks and protective clothing during the prevention and control of the new crown pneumonia epidemic. goods supply.
The methanol downstream deep processing project in charge of the operation and management of Yulin Chemical is a major project involving the national energy strategic planning in northern Shaanxi, and a major practice project of the “New Coal Chemical Industry Leader” strategy of the National Energy Group Chemical Company. Propylene, by-products include mixed C4, mixed C5+, propane, liquid nitrogen and by-product ammonium sulfate, etc. The S1003 grade before this transition is an ordinary wire drawing material, which is generally used for the production of woven bags and other products.
On September 17, 2019, in order to enrich the variety of products and enhance the added value of products, Yulin Chemical completed the preparation and approval of the production S2040 work plan, and the trial production was successful on October 24 of the same year.
On February 26th, the optimized work plan for production conversion S2040 was approved; on March 3rd, the transfer and commissioning of the additive scale of the extruder was started; on March 4th, the compounding agents and degradants required for the production of products arrived at the factory; in March At 13:00 on the 4th, qualified products were produced, and the polypropylene product grade was successfully converted from S1003 to S2040 at one time; at 14:40 on March 10, the cumulative production of S2040 products was more than 6,030 tons, successfully completed the production task, and switched back to S1003 .
The conversion of National Energy Group Chemical Company realized the first production of polypropylene S2040 high-melt finger spinning material for medical protective equipment in the field of Unipol polypropylene process equipment.