Search

JP-2026514399-A - Sustainable preparation of bisphenol A for the production of polycarbonates

JP2026514399AJP 2026514399 AJP2026514399 AJP 2026514399AJP-2026514399-A

Abstract

The present invention relates to a method for preparing bisphenol A for synthesizing the polycarbonate described in claim 1, a method for preparing polycarbonate from bisphenol A obtained by the above-described preparation method described in claim 14, and a multicomponent system for preparing bisphenol A by the above-described preparation method. In this method, bisphenol A is prepared from provided acetone and provided phenol, where these raw materials must be method products of a specific preparation method based on CO2 , methane of biological origin, carbohydrates and/or organic solid compounds as starting materials.

Inventors

  • ブラン アンドレアス
  • ヴェーバー ライナー

Assignees

  • コベストロ、ドイチュラント、アクチエンゲゼルシャフト

Dates

Publication Date
20260511
Application Date
20240328
Priority Date
20230330

Claims (16)

  1. A process for producing bisphenol A(F) for the manufacture of polycarbonate, comprising at least the following steps: a) A step (4) of providing acetone, which is a process product of a process including at least the following steps: i) At least the following steps: i-1) A step of obtaining methanol by conversion of CO (2), wherein the CO is a process product of at least partial reduction (1) of CO2 to CO, and/or a process product of at least partial oxidation (1) of an organic material to CO, wherein at least one organic material (A) is selected from at least one organic solid compound, methane of biological origin, or a mixture thereof. (3) A step of providing methanol, which is a process product of a process including, ii) From the previously provided methanol (3), at least the following steps: A step (4) of providing propene as a product of a process including at least the following steps, ii-1) A step of converting the previously provided methanol (3) to obtain a product mixture containing dimethyl ether, water, and methanol, ii-2) A step of converting a starting material containing dimethyl ether, water, and methanol from the product mixture into propene (E) by contacting it with a catalyst and preferably at least one zeolite compound as a catalyst at a temperature exceeding 200°C, ii-3) A step of converting the propene (E) by oxidation (5) of the propene (E) to acetone, The process of synthesizing acetone by, Processes including, b) A step (8) providing phenol which is a process product of at least one manufacturing method comprising at least the following steps: i) At least one organic aromatic compound according to formula (I) (In the formula, R1 represents a hydrogen atom, a hydroxyl group, methyl, carboxyl, carboxylate, or -CHR3R4 , where R3 and R4 independently represent a ( C1 - C3 )-alkyl group or form an aliphatic hydrocarbon ring together with the residual molecule. R2 represents a hydrogen atom, methyl, carboxyl, or carboxylate; however, if R1 represents -CHR3R4 , R2 represents a hydrogen atom, and if R1 represents a hydroxyl group, R2 represents a hydrogen atom, carboxyl , or carboxylate. Here, the process provides an organic aromatic compound which is a process product of the transformation (9) of at least one starting material selected from the group consisting of polymeric organic compounds, carbohydrates, and methane of biological origin. In the organic aromatic compound from step i) according to formula (I), when R1 does not represent a hydroxyl group and R2 does not represent a hydrogen atom, ii) Steps ii-1) and/or ii-2) and/or iii-3) ii-1) A step of reacting the organic aromatic compound (H) from step i) with propene to obtain a propane-2-yl substituted aromatic organic compound as a product; ii-2) A step of oxidizing the organic aromatic compound (H) from step i) and/or the product from step ii-1) to obtain at least one oxidized aromatic organic compound; ii-3) A step of removing at least one carbon-containing substituent from the organic aromatic compound (H) from step i) and/or from the oxidation by step ii-2); At least one of the following steps, Processes including, c) A step of carrying out a reaction (7) of a mixture containing the provided acetone and the provided phenol to obtain bisphenol A(F), A process that includes this.
  2. The process according to claim 1, characterized in that the CO used in reaction (2) by step a) i-1) is a process product of at least partial reduction of a gas stream containing at least CO x (wherein x = 1 or 2) and optionally hydrogen gas (B).
  3. The process according to claim 1 or 2, characterized in that the CO in step a) i-1) is a process product of at least partial reduction from CO2 to CO, selected from, in particular, a reverse water-gas shift reaction using H2 (B) provided by electrolysis, an electrochemical reduction from CO2 to CO, or a combination thereof.
  4. The process according to any one of claims 1 to 3, wherein the CO in step a) i-1) is a process product of at least one reverse water-gas shift reaction using H2 (B) provided by electrolysis, or is provided by electrochemical reduction from CO2 to CO, or a combination thereof, wherein electrical energy generated from renewable energy is used.
  5. The process according to any one of claims 1 to 4, characterized in that the conversion of methanol in step a) ii-1) is carried out by contacting methanol, preferably methanol in the gas phase, with a catalyst.
  6. The process according to any one of claims 1 to 5, characterized in that, in step a) ii-1), the methanol provided has a temperature in the range of 200°C to 350°C.
  7. The process according to any one of claims 1 to 6, characterized in that the conversion of the starting material in step a) ii-2) is carried out at a temperature of 350°C to 600°C, particularly 380°C to 550°C.
  8. In step a) ii-3), the oxidation (5) of propene (E) is carried out by the following method: 1) A method of producing acetone by the reaction of propene(E) with water using a catalyst system composed of palladium(II) chloride and copper(II) chloride, according to the Wacker-Hoechst process; 2) A method of hydroxylating propene(E) with water to obtain 2-propanol, followed by catalytic dehydrogenation of 2-propanol to obtain acetone; 3) A method of obtaining acetone in each case by converting propene(E) to cumene and carrying out the cumene hydroperoxide method, or by converting propene(E) to diisopropylbenzene and carrying out the cumene hydroperoxide method using diisopropylbenzene hydroperoxide instead of cumene hydroperoxide; The process according to any one of claims 1 to 7, characterized in that it is carried out according to at least one of the following.
  9. The process according to any one of claims 1 to 8, characterized in that in formula (I), residues R3 and R4 are independently selected from methyl, ethyl, and propyl, or together with the residual molecule, form a six-membered aliphatic hydrocarbon ring, particularly a cyclohexyl.
  10. The process according to any one of claims 1 to 9, characterized in that in formula (I), the residue -CHR3R4 is selected from propan-2-yl, sec-butyl, or cyclohexyl .
  11. The process according to any one of claims 1 to 10, characterized in that the starting material in step b)i) is at least one compound selected from the group consisting of polysaccharides, trisaccharides, C-6 monosaccharides, C-5 monosaccharides, methane of biological origin, and homopolymer and copolymer compounds from the group consisting of cellulose, lignin, polyester, polyamide, polyurethane (PUR), polyurea, polyisocyanurate (PIR), and polycarbonate.
  12. The process according to any one of claims 1 to 11, characterized in that step b)i) includes providing benzene as the organic aromatic compound, introducing the benzene into the oxidation (5) of propene (E) in step a)iii-3), where it reacts with the propene (E) provided from step a)iii-2) to yield cumene, and then oxidizing the formed cumene to yield phenol and acetone.
  13. The process according to any one of claims 1 to 12, characterized in that step b)i) includes providing the organic aromatic compound, particularly toluene and/or benzene, by thermal decomposition of the starting material at a temperature of 400°C to 1000°C.
  14. At least the following steps: A step of producing bisphenol A, which is a process product of the process described in any one of claims 1 to 13, A step of producing at least one carbonate derivative selected from phosgene, diester carbonate, or a mixture thereof, A step of reacting the carbon dioxide derivative with at least one diphenol, wherein at least a pre-prepared bisphenol A is used as the diphenol. The manufacturing process for polycarbonate, including [the specified component].
  15. The process according to claim 14, characterized in that the production of the carbon dioxide derivative is carried out by providing carbon monoxide as a starting material, which is at least one process product selected from processes such as RWGS using H2 as a process product of water electrolysis, gasification, electrochemical reduction from CO2 to CO, or a combination thereof.
  16. i) a volume filled with acetone which is the process product of step a) of the process according to any one of claims 1 to 13, ii) A volume filled with phenol, which is the process product of step b) of the process according to any one of claims 1 to 13, iii) At least one reactor for the production of bisphenol A, comprising at least one inlet for acetone and at least one inlet for phenol, wherein the inlet for acetone is fluid-connected to the volume of acetone and the inlet for phenol is fluid-connected to the volume of phenol, A multi-component system for producing bisphenol A by the manufacturing process described in claims 1 to 13, comprising the above.

Description

This invention relates to a process for producing bisphenol A for the synthesis of polycarbonate, a process for producing polycarbonate from bisphenol A obtained by the aforementioned process, and a multi-component system for producing bisphenol A by the aforementioned process. The industrial production of bisphenol A has historically relied primarily on fossil fuels, such as synthesis gas derived from natural gas and petroleum-based aromatic compounds. Systematically utilizing renewable raw materials and/or by-products from waste in the production of materials like bisphenol A is a goal for providing sustainable plastics such as polycarbonate and its derivatives. It is also desirable to utilize energy from renewable energy sources for the industrial production of chemical raw materials, such as bisphenol A. Patent Document 1 describes the possibility of producing bisphenol A from renewable phenol and renewable acetone, that is, from phenol and acetone derived from renewable raw materials. Therefore, acetone is produced from bioethanol, a renewable raw material source, or through fermentation. However, according to the teachings in the above document, the route for producing renewable acetone outlined therein is considered unsuitable for industrial-scale production. U.S. Patent Application Publication No. 2010/0152406 Therefore, an object of the present invention was to provide a more sustainable manufacturing process for bisphenol A on an industrial scale that enables the use of renewable raw materials. Furthermore, a further object of the present invention was to provide a method for producing bisphenol A that enables the achievement of low-emission bisphenol A for the production of polycarbonates, even if fluctuations in the availability of renewable energy may occur. "Renewable energy" will be understood by those skilled in the art to mean energy from inexhaustible energy sources, such as wind, hydro, bioenergy (e.g., the conversion of biogas or biomass into electricity), or solar power. The "sustainability" of a process is understood by those skilled in the art in accordance with the definition of sustainability (sustainable development) proposed in the Brundtland Report of the United Nations World Commission on Environment and Development, which means that the current implementation of a process contributes as little as possible, or no contribution at all, to the ability of future generations to meet their needs, particularly those related to the use of resources such as fossil fuels, and especially to the preservation of living spaces, such as the protection of the Earth's atmosphere. Therefore, the object of the present invention is to make the production of bisphenol A and polycarbonates produced therefrom more sustainable than known production methods from the prior art. The contribution of the production of bisphenol A and polycarbonates to the satisfaction of future generations' needs should be reduced, if not avoided. First, the present invention provides a process for producing bisphenol A for producing polycarbonate, comprising at least the following steps: a) A step of providing acetone, which is a process product of a process including at least the following steps: i) At least the following steps: i-1) A step of obtaining methanol by conversion of CO, wherein CO is a process product of at least partial reduction from CO2 to CO, and/or a process product of at least partial oxidation from an organic material to CO, wherein at least one organic material is selected from at least one organic solid compound, methane of biological origin, or a mixture thereof. A step of providing methanol, which is a process product of a process including, ii) From the methanol provided in advance, at least the following steps: A process that provides propene as a product of a process including at least the following steps, ii-1) A step of converting a pre-provided methanol to obtain a product mixture containing dimethyl ether, water, and methanol, ii-2) A step of converting a starting material containing dimethyl ether, water, and methanol from the aforementioned product mixture into propene by contacting it with a catalyst and preferably at least one zeolite compound at a temperature exceeding 200°C, ii-3) A step of converting propene by oxidation of at least propene to acetone, The process of synthesizing acetone by, Processes including, b) A step of providing phenol which is a process product of at least one manufacturing process comprising at least the following steps: i) At least one organic aromatic compound according to formula (I) (In the formula, R1 represents a hydrogen atom, a hydroxyl group, methyl, carboxyl, carboxylate, or -CHR3R4 , where R3 and R4 independently represent a ( C1 - C3 )-alkyl group or form an aliphatic hydrocarbon ring together with the residual molecule. R2 represents a hydrogen atom, methyl, carboxyl, or carboxylate; however, if R1 represents -CHR3R4 , R2 represents a hydrogen at