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New Phosgene-Free Route to Polycarbonates

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New Phosgene-Free Route to Polycarbonates University of Pennsylvania ScholarlyCommons Department of Chemical & Biomolecular Senior Design Reports (CBE) Engineering 4-2013 New Phosgene-Free Route to Polycarbonates Federico Castro University of Pennsylvania Abigail Jablansky University of Pennsylvania Heui Beom Lee University of Pennsylvania Imran MacMillan University of Pennsylvania Follow this and additional works at: https://repository.upenn.edu/cbe_sdr Part of the Biochemical and Biomolecular Engineering Commons Castro, Federico; Jablansky, Abigail; Lee, Heui Beom; and MacMillan, Imran, "New Phosgene-Free Route to Polycarbonates" (2013). Senior Design Reports (CBE). 54. https://repository.upenn.edu/cbe_sdr/54 This paper is posted at ScholarlyCommons. https://repository.upenn.edu/cbe_sdr/54 For more information, please contact [email protected]. New Phosgene-Free Route to Polycarbonates Abstract A process to produce 100 million pounds per year of diphenyl carbonate (DPC) based on the phosgene- free oxidative carbonylation of phenol in US Patent 8,212,066 has been designed. In this reaction, phenol reacts directly with carbon monoxide in the presence of a palladium catalyst, an organic co-catalyst or ligand, a redox catalyst, and a base catalyst. The proposed design features a single-reactor system followed by a separation train that includes a vacuum distillation tower, and it produces only water and carbon monoxide as byproducts. Detailed process and unit descriptions, an in- depth economic analysis, and environmental concerns and other considerations are also included. The net present value of this project was determined to be $51,560,200 with a return on investment of 37.69% and an internal rate of return of 36.1%. 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