A Novel Non-Phosgene Process for Polycarbonate Production from CO2: Green and Sustainable Chemistry in Practice

Abstract

This paper focuses on the world's first nonphosgene process using CO 2 as starting material succeeded in development and industrialization by Asahi Kasei Corp. The Asahi Kasei Process enables high-yield production of high-quality PC having excellent properties and high-purity monoethylene glycol (MEG), starting from ethylene oxide (EO), by-produced CO 2 and bisphenol-A without waste and waste water. The innovative reactive distillation technologies in the monomer production and the innovative gravity-utilized, non-agitation polymerization reactor in the melt polymerization, led the new process to success. The monomer process consists of 3 production steps, ethylene carbonate (EC) from CO 2 and EO, dimethyl carbonate (DMC) and MEG from EC and MeOH, and diphenyl carbonate (DPC) and MeOH from DMC and PhOH. All intermediates are recycled. The new type polymerization reactor perfectly overcomes the difficulty based on the extremely high viscosity in the melt polymerization of DPC with Bis-A. The by-produced PhOH is recycled to the monomer process. The reduction of CO 2 emissions (0.173t/ PC 1t) is also achieved, because CO 2 used as raw material is utilized as the main chain components of the products. Four commercial plants (Taiwan: 150,000 t/y, Korea: 2 plants of 65,000 t/y, Russia: 65,000 t/y) using the Asahi Kasei Process are now successfully operating, and the plant of 260,000 t/y in Saudi Arabia will start in 2010.

Carbon Dioxide Recycling: Emerging Large‐Scale Technologies with Industrial Potential

“…An industrial phosgene-free process to aromatic polycarbonates (APCs) from, inter alia, an epoxide reaction with CO 2 to yield ethylene carbonates [73] was developed by Asahi Kasei. Until the Asahi Kasei process, all of APC's carbonate groups were derived from CO and > 90 % involved phosgene.…”

“…Fukuoka et al discussed recent progresses in the APC process. [73] The production volume at the Chimei Asai plant in Taiwan (resulting from a ). [73] The process was licensed in 2009 to Saudi Kayan Petrochemical Co, in Jubail, Saudi Arabia for a 260 kt a À1 polycarbonate production plant that was due to commence in March 2011.…”

CO2utilization: an enabling element to move to a resource- and energy-efficient chemical and fuel production

“…There are various industrial initiatives in this sector, among which are the above-mentioned Bayer initiative (focused especially at producing polyoils for polyurethane), BASF initiative (for polypropylene carbonate) and Novomer Inc. initiative (for a polypropylene carbonate) [8]. Although it is already commercial, the Asahi Kasei's process for phosgene-free production of aromatic polycarbonate starts from ethylene epoxide, bisphenol-A and CO 2 [48].…”

Perspectives and State of the Art in Producing Solar Fuels and Chemicals from CO2

“…For the production of CO 2 -based polymers, correct LCA assessments also do not exist, and the GIV value depends on specific process characteristics that have not yet been developed on a commercial scale, apart from Asahi Kasei's phosgene-free process to produce aromatic polycarbonate starting from ethylene epoxide, bisphenol-A, and CO 2 [31]. Polypropylene and polyethylene carbonate as well as polyhydroxyalkanoate (PHA) from CO 2 and linear epoxides are currently developed by Novomer on a pilot-plant scale [32], while Bayer is developing on a pilot scale a process for producing polyurethane from polyether polycarbonate polyols, as already cited [16].…”