Mitsubishi Chemical Bisphenol-A Technology

Bisphenol-A: (BPA) 4,4’-bisphenol A (BPA) is an important industrial chemical, which is mainly used as a raw material of polycarbonate and epoxy resin. BPA is produced by acid catalyzed condensation reaction of two moles of phenol and one mole of acetone. Traditionally, commercial scale BPA production has been based on a strong mineral acid catalyst such as hydrochloric acid. Hydrochloric acid is highly corrosive, so the BPA plant requires expensive corrosion-proof materials. In addition, complicated waste water treatment facility is needed for the mineral acid catalyzed process. Since waste water from the process contains some amount of hydrochloric acid, it must be treated by neutralization with lime, precipitation of the calcium, and further biotreatment. An alternative catalyst now widely used is cation exchange resin. This type of catalyst mitigates equipment corrosion. Some components, which contain thiol groups, can improve BPA production rate and its yield. Introduction of Mitsubishi BPA Technology MCC has been improving BPA process to realize lower raw material consumption and the stable operation. Even now, MCC continues to exert effort to achieve effective BPA process. MCC's BPA process (PROCESS) employs an improved ion exchange resin catalyst that exhibits higher activity and longer life compared to other resin catalysts. Impurities are significantly reduced, leading to improved raw material efficiency and finished product color. Feature of Mitsubishi BPA process The characteristic and superiority of MCC BPA process are as follows. (1) Superior Product Quality (2) High Catalyst Performance (3) Low Construction Cost (4) MCC’s rich experience Chemistry of this process Main Reaction

2 + → + H2O

OH

HO OHC

CH3

CH3

H3C

C

H3C

O

Phenol Acetone Bisphenol-A

Copyright © 2011 Mitsubishi Chemical Corporation. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical including by photocopy, recording or information storage and retrieval system, without permission in writing from Mitsubishi Chemical Corporation.

Besides Bisphenol-A, small amounts of following major impurities are produced. 2,4-BPA isomer Methyl BPA Trisphenol Chromans p-Isopropenylphenol cyclic dimer p-Isopropenylphenol linear dimer

Simplified block flow

Copyright © 2011 Mitsubishi Chemical Corporation. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical including by photocopy, recording or information storage and retrieval system, without permission in writing from Mitsubishi Chemical Corporation.

Copyright © 2011 Mitsubishi Chemical Corporation. All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical including by photocopy, recording or information storage and retrieval system, without permission in writing from Mitsubishi Chemical Corporation.

World BPA Plant Capacity In 2010, world BPA production capacity is 5,826 kt/year. Each BPA supplier’s capacity in the world is as shown below;.

BPA World Capacity LIST (2010)

1,185

941

679

310

405

430

220

323

85

110

110

240

270

245

0 200 400 600 800 1,000 1,200 1,400

Others

Idemitsu

Sunoco

Nippon Steel

LG

Chang chun

Kumho

Mitsubishi

Nanya

Momentive

Dow

Mitsui

Sabic

Bayer

(KT/Y)

World Total 5,553