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

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Abstract

This paper focuses on the world’s first non-phosgene process using CO2 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 CO2 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 CO2 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 CO2 emissions (0.173t/PC 1t) is also achieved, because CO2 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.

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Acknowledgements

The success of this work in the R&D owes to lots of endeavors of many persons in Asahi Kasei Group, and the success in industrialization owes to the many members of Asahi Kasei Group and Chi Mei Group. We express our grateful acknowledgement to the all members who put their hearts into the development and industrialization of our new process and led to success.

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Authors and Affiliations

  1. New Business Development, Asahi Kasei Corporation, 1-105 Kanda Jinbocho, Chiyoda-ku, Tokyo, 101-8101, Japan

    Shinsuke Fukuoka

  2. Asahi Kasei Corporation, 1-105 Kanda Jinbocho, Chiyoda-ku, Tokyo, 101-8101, Japan

    Isaburo Fukawa

  3. Chemistry & Chemical Process Laboratory, Asahi Kasei Chemicals Corporation, Kojima-Shionasu, Kurashiki, Okayama, 711-8510, Japan

    Masahiro Tojo & Kazuhiro Oonishi

  4. Technology Licensing Department, Asahi Kasei Chemicals Corporation, Kojima-Shionasu, Kurashiki, Okayama, 711-8510, Japan

    Hiroshi Hachiya, Muneaki Aminaka & Kazumi Hasegawa

  5. Asahi Kasei Chemicals Corporation, 1-105 Kanda Jinbocho, Chiyoda-ku, Tokyo, 101-8101, Japan

    Kyosuke Komiya

Authors
  1. Shinsuke Fukuoka
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  2. Isaburo Fukawa
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  3. Masahiro Tojo
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  4. Kazuhiro Oonishi
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  5. Hiroshi Hachiya
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  6. Muneaki Aminaka
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  7. Kazumi Hasegawa
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  8. Kyosuke Komiya
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Correspondence to Shinsuke Fukuoka.

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Fukuoka, S., Fukawa, I., Tojo, M. et al. A Novel Non-Phosgene Process for Polycarbonate Production from CO2: Green and Sustainable Chemistry in Practice. Catal Surv Asia 14, 146–163 (2010). https://doi.org/10.1007/s10563-010-9093-5

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