HollySys Supports Successful Trial Production at CNPC Blue Ocean New Materials (Tongzhou Bay) Pilot Plant

Recently, HollySys supported the Blue Ocean New Materials (Tongzhou Bay) Pilot Plant in completing its first batch trial production, achieving an output of 79.7 kg of metallocene catalyst with a product yield of 94.88%. This milestone sets a new benchmark among similar facilities in China and represents a significant advancement in the R&D and industrial application of high-end catalytic materials.

Located in Nantong, China, the Blue Ocean New Materials (Tongzhou Bay) Pilot Plant serves as a critical platform for the green and low-carbon transformation of China National Petroleum Corporation (CNPC)'s refining and petrochemical operations, as well as the development of its advanced materials innovation capabilities. With a total investment of approximately USD 156.5 million, the facility features CNPC’s first 60-ton-per-year single-site catalyst pilot production unit and a 2 KTA pilot unit for high-purity electronic chemicals (G4/G5 grade), dedicated to advancing key technologies in areas such as single-site catalysts and advanced electronic chemicals.

Unlike mature production facilities, pilot plants involve continuous process validation and frequent design iterations, placing high demands on automation flexibility and engineering execution. In this project, The project presented two key challenges. Frequent design changes required rapid adjustments to control points and logic strategies. With an operating flexibility range of 30% to 110%, the pilot plant demanded highly adaptable control systems, online configuration capabilities, and rapid on-site response. Meanwhile, integrating multiple control systems added significant complexity, as 16 independent PLC systems from different suppliers required extensive data mapping, logic reconstruction, and joint commissioning.

HollySys deployed its HOLLiAS® MACS DCS as the core control platform for the project. The system's key components, including controllers, modules, power supplies, computers, switches, and software, were all independently developed by HollySys. By replacing 16 PLC systems from 7 suppliers, the integrated platform enabled centralized operation and maintenance across the pilot plant. It now manages nearly 4,000 I/Os and supports key functions such as equipment-level control, process sequence control, and safety interlock control, providing a unified and reliable automation foundation for the facility.

To ensure smooth project execution, HollySys adopted a dual-track approach combining front-loaded Factory Acceptance Testing (FAT) with agile on-site support. During the FAT stage, the project team conducted joint verification and simulation testing with multiple PLC suppliers to optimize control strategies in advance. After deployment, HollySys engineers provided continuous on-site support for nearly 180 days, completing system integration, logic optimization, and commissioning to ensure the successful completion of the first batch trial production.

HollySys remains dedicated to advancing industrial automation technologies and providing end-to-end solutions for key industries including petrochemicals, advanced materials, and new energy, supporting both new project development and the digital transformation and upgrading of existing industrial facilities.