How much can carbon emissions be reduced from crude oil to garment per ton of polyester fiber? The answer from Tongkun Group-led team: through PTA-PET direct coupling low-carbon mode and eco-friendly titanium catalyst, achieving full lifecycle green standards. This technology won the first prize in the 2025 National Science and Technology Awards, marking the chemical fiber industry's return to top honor after eight years.
Technical Breakthroughs: Three Dimensions Reshape the Chain
Polyester fiber accounts for over 70% of China's chemical fiber output, known as the 'industrial staple.' The project, led by Donghua University researcher Wang Huaping, involved ten units including Tongkun Group and Zhejiang Sci-Tech University, spending over a decade building an autonomous advanced manufacturing system.
In green manufacturing, the project pioneered PTA-PET direct coupling mode, replacing traditional batch production; eco-friendly titanium catalysts reduced heavy metal pollution; crude oil-based fiber oil and green oiling technology cut chemical consumption. These formed full lifecycle green standards, offering replicable paths for low-carbon transition.
For intelligent manufacturing, the project upgraded full-process automation and achieved large-scale domestic substitution of DCS control systems. This means distributed control systems once reliant on imports now have local solutions. The integrated quality control system reduced defect rates and energy consumption.
Service-oriented manufacturing is the most differentiated value. The 'multi-head multi-tail' series-parallel composite polymerization platform, with 'one head three tails' modular digital linkage, enables factories to produce multiple differentiated polyester fibers simultaneously. For downstream buyers, this means flexible supply for small batches and diverse varieties, not just standard commodities.
Industry Impact: The Logic Behind 200 Billion Sales
To date, project results have been promoted in industrial bases like Zhejiang, Jiangsu, and Xinjiang, with cumulative new sales exceeding 200 billion yuan, profits and taxes over 10 billion yuan, and export earnings of 1.8 billion USD. These numbers reflect the substantive leap from 'following' to 'leading' in the full polyester fiber chain.
For upstream chemical fiber companies, the technology reduces energy and emissions per unit, directly addressing 'dual carbon' compliance pressure. Domestic DCS substitution reduces reliance on overseas suppliers, enhancing supply chain security.
Midstream fabric and yarn mills benefit from differentiated product supply. Previously, polyester fiber was heavily commoditized with price wars; now modular polymerization and spinning allow custom specifications, boosting added value. This is crucial for clusters like Shengze and Keqiao, which need higher-quality raw materials for functional fabrics.
Downstream apparel and home textile brands will see more stable supply and faster delivery. Service-oriented 'agile manufacturing' enables multi-region collaboration, shortening logistics from raw material to finished goods.
University-Industry Synergy: Donghua's Double Award Effect
In this award, Donghua University simultaneously won the first prize and the International Science and Technology Cooperation Award, becoming the only university to receive both national honors. The cooperation award went to Lehigh University professor Elsa Reichmanis, who has long promoted Sino-US fiber materials collaboration, chairing multiple Advanced Fiber and Polymer Materials International Conferences, now the world's largest fiber-themed academic event.
This 'domestic research + international collaboration' model reflects new features of China's textile tech innovation: no longer relying solely on imported digestion, but actively building autonomous systems while maintaining global vision through cooperation. Donghua's State Key Laboratory of Advanced Fiber Materials, as the core platform, integrates materials science, textile tech, and information intelligence, providing talent and experimental foundations.