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Polyalphaolefins Technology

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CPChem’s PAO history dates back to December 1980, when the continuous PAO unit in Baytown, Texas, started up. Since then, the company pioneered the production of 1-dodecene-based PAOs in 1995, which have grown steadily in popularity. CPChem has continuously expanded its production of PAOs through multiple expansions in Baytown, the 2011 acquisition of PAO assets in Beringen, Belgium, and mPAO production in Texas. Our most recent expansion in 2017 in Baytown expanded our production capacity to 58 KTA, and our 2025 expansion in Beringen doubles our capacity to 120 KTA.  

With more than 40 years’ experience manufacturing PAOs, CPChem continues to invest in the future, growing our production capacity to help meet the increasing demand for PAOs worldwide.  


How Polyalphaolefins Are Manufactured

PAOs are manufactured through a synthetic chemical process that originates from ethylene. Ethylene is produced by cracking either crude oil or natural gas. The direct feedstock (normal alpha olefin – NAO) is produced through the chain growth and displacement process for producing petrochemically pure alpha olefins. The PAOs are produced through synthesizing oligomers of 1-octene, 1-decene or 1-dodecene. These oligomers are distilled and hydrogenated to yield specific molecular weight ranges that meet the viscosity grades that are desired. For example, the fraction that has predominantly the 1-decene trimer (C30 oligomer) has a 100°C viscosity of 4 cSt and is known as PAO 4.

Polyalphaolefins (PAO) process diagram

Polyalphaolefin Chemical Structure

Through careful control of reaction conditions and fractionation, we can precisely control the properties of our PAO products. The actual structure of PAOs is very complex since an isomerization reaction occurs during oligomerization which yields a myriad of isomers. These isomers are what give PAOs their excellent low temperature properties.

The controlled production process ensures that Synfluid® PAOs are essentially devoid of undesirable species found in mineral oil like sulfur, cyclic compounds and aromatic content.

Comparison of PAOs vs Mineral Oil

PropertyGroup III Mineral OilsGroup IV PAOs
FeedstockDerived from various crude oil feedstocksSynthesized from pure alpha olefins
ProcessingMultiple refining technologies (e.g., hydrocracking, isodewaxing)Uniform chemical synthesis process
Viscosity Index (VI)Can approach PAO levelsNaturally high and consistent
Low-Temperature PerformanceImproved but variableExcellent and predictable
Purity & ConsistencyVaries due to feedstock and processHigh purity and consistent molecular structure
Application ReliabilityMay vary between batchesReliable across applications