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Zhuhai Biyang Chemical Co (BP Zhuhai Company), China




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During the final quarter of 2005 BP announced it was planning to build a second world-scale purified terephthalic acid (PTA) plant at its joint venture Zhuhai Biyang Chemical (BP Zhuhai Company) site in Guangdong Province, China. Construction work began during the mid-2006.

"In August 2011, plans to build a new PTA plant at the Zhuhai site were unveiled by BP."

The plant became operational at the start of 2008 and has a capacity of 900,000tpa of PTA. Total investment was around $400m.

The company is a joint venture between BP, which owns 85%, and Zhuhai Port (formerly known as Fuhua Group), which owns 15%.

In February 2011, BP announced an expansion plan to increase capacity of the plant by 200,000tpa. Engineering design for the project has been completed. The expansion is expected to be completed by the first quarter of 2012.

Third PTA plant at the Zhuhai Biyang Chemical (BP Zhuhai Company) site

In August 2011, plans to build a new PTA plant at the Zhuhai site were unveiled by BP. The third plant will be built with an investment of $600m and have a capacity of 1.25mtpa.

It will increase the total capacity of the Zhuhai site to 2.95mtpa. The facility is currently in the pre-engineering stage and is expected to be completed by 2014.

Technology incorporated into the purified terephthalic acid facility

The PTA plant is said to be the first to use BP's latest generation PTA process technology. BP said the technology enabled scale and cost efficiencies which significantly reduced capital and conversion costs.

The technology helps in reducing 65% of greenhouse gas emissions, 75% wastewater and 40% solid wastes. In addition, it achieves 25% less operational costs compared to other processes.

Design and building of the Chinese complex

During May 2006, France's Technip announced BP Zhuhai had awarded it a services contract for the development of the PTA project. The contract covered management of the project.

Technip's operations and engineering centre in Italy was responsible for executing the contract. This agreement followed on from the front-end engineering and design contract that Technip completed during 2005 for the same PTA plant.

Plant automation

During July 2007 Emerson Process Management announced it had been awarded a contract to digitally automate the 900,000tpa PTA plant.

Emerson engineered and managed the automation project using its PlantWeb digital architecture with FOUNDATION field bus technology for process control and data management. Emerson was also responsible for the detailed design, including the engineering design and implementation of the digital architecture.

Training simulator

Invensys Process Systems China was responsible for delivering a fully engineered operator training system (OTS) for the PTA production plant.

"During the final quarter of 2005 BP announced it was planning to build a second world-scale purified terephthalic acid (PTA) plant."

The OTS was built using DYNSIM dynamic simulation technology from SimSci-Esscor and was delivered to the plant in September 2007. Invensys said the OTS project was the first cooperative effort of its kind between BP Zhuhai and Invensys.

PTA is used in the manufacturing of plastic bottles, textiles polyesters, films and fibres. China is one of the leading textile producers in the world and accounts for about half of the chemical demand in the world.

The company, established during 1997, already operates a 500,000tpa PTA facility which was completed in 2003.

Completion of the second plant had increased the production capacity at BP Zhuhai to 1.5mtpa, confirming Zhuhai as one of the major PTA production centres in China.

BP is the world's largest producer of PTA (purified terephthalic acid).
John Berra, president of Emerson Process Management, said: "We are encouraged by BP's confidence in our ability to provide system design, configuration, staging, acceptance testing, commissioning and start-up support."