The expanded polypropylene beads with microcellular structure were prepared by an autoclave-based batch foaming process using non-supercritical CO2 as the foaming agent. Herein, smaller polypropylene micropellets (~0.6 mm) were obtained from three kinds of polypropylene resin by underwater micro-pelletizer system. The results from differential scanning calorimetry indicated that the double melting peaks of beads moved to higher temperature with increasing saturation temperature and pressure. The kind of comonomer did not exert noticeable influence on the double melting behaviors. The X-ray diffraction of expanded polypropylene bead revealed that characteristic peaks of a-type crystal did not change compared with that of original polypropylene micropellets. The relationship between cell morphology and saturation temperature/pressure of expanded polypropylene beads are discussed preliminarily by scanning electron microscope.