Comparative analysis of CO2-based alternative pathways for diphenyl carbonate production
Journal
Chemical Engineering Journal
Journal Volume
520
Start Page
166354
ISSN
1385-8947
Date Issued
2025-09-15
Author(s)
Wu, Tsai-Wei
Ohno, Hajime
Wang, Anqing
Guzman-Urbina, Alexander
Shinkai, Yousuke
Furuhashi, Hiroki
Umezu, Ryotaro
Fukushima, Yasuhiro
Abstract
CO2 conversion to dialkyl carbonate (DRC) is a promising strategy for mitigating CO2 emissions, particularly when combined with dehydration to remove the H2O byproduct. Although DRC serves an intermediate in various reactions, the broader implications of net CO2 emission reduction via CO2-derived DRC remain underexplored. In this study, we investigated diphenyl carbonate (DPC) production, a key monomer in polycarbonate (PC) synthesis, to evaluate the environmental advantages of integrating greener feedstocks into the PC supply chain. For comparison, inventory data for the conventional phosgene-based DPC production route were collected. The CO2-based route comprises two primary steps: CO2 to DRC and DRC to DPC. The DRCs investigated in this study range from dimethyl carbonate (DMC) to dibutyl carbonate (DBuC). To address gaps in inventory data, three processes, DEC to DPC, DPrC to DPC, and CO2 to DBuC, were initially proposed through rigorous simulations. A systematic approach was adopted for process design, optimization, environmental and economic evaluation of alternative DPC production routes. Cradle-to-gate CO2 emission analysis revealed that the C3 route (CO2 to DPrC to DPC) exhibits the highest emission reduction potential, achieving a 15 % decrease in emissions compared to the phosgene route. However, economic analysis indicated that the minimum required selling price for DPC using the phosgene route is 18 % lower than that of the C3 route. Broader system boundary considerations emphasized the importance of comprehensive environmental assessments. This study offers insights into the trade-offs between environmental and economic performance and proposes concrete strategies for improving the low-carbon non-phosgene DPC manufacturing route.
Subjects
Carbon utilization
Cradle-to-gate CO2 emissions
Diphenyl carbonate
Green production
Publisher
Elsevier BV
Type
journal article