Isaburo Fukawa

A novel non-phosgene polycarbonate production process using by-product CO2 as starting materialPresented at The First International Conference on Green & Sustainable Chemistry, Tokyo, Japan, March 13?15, 2003.

Asahi Kasei Corp. has succeeded in the development of a new green process for producing an aromatic polycarbonate based on bisphenol-A (hereafter usually abbreviated as PC) without using phosgene and methylene chloride. The new PC production process is the worlds first to use carbon dioxide (CO2) as a starting material. Until Asahi Kaseis new process was revealed, all of the PC in the world has been produced using carbon monoxide (CO) made from cokes or lower hydrocarbons and oxygen as a starting material. Furthermore, more than about 93% of the PC has been produced by the so-called “phosgene process” which uses phosgene made from CO and chlorine (Cl2) as a monomer. However, the phosgene process inherently involves a number of environmental and economic shortcomings in addition to the high toxicity of phosgene itself and the high carcinogenic probability of methylene chloride itself. Asahi Kaseis new process enables high-yield production of the two important products for our citizens’ lives, high-quality PC and high-purity monoethylene glycol (MEG), starting from ethylene oxide (EO), carbon dioxide (CO2) and bisphenol-A. This new technology not only overcomes the environmental and economic problems existing in the phosgene process, but also achieves resource conservation, and energy conservation. Furthermore, the new process contributes to the earth environment by the reduction of CO2 emissions (173 tons per thousand tons of product PC). Commercial application of the new process was carried out at the 50,000 ton year−1 PC plant of Chimei-Asahi Corporation, a joint venture between Asahi Kasei Corporation and Chi Mei Corporation, which was newly constructed in Taiwan and has been successfully operating since June 2002. In recognition of the outstanding advance in ecological and sustainable performance that this technology represents, Japans Minister of Economy, Trade and Industry conferred the Green and Sustainable Chemistry Award of 2003 on us. Furthermore, the Chairman of Japan Chemical Industry Association also conferred the 35th Japan Chemical Industry Association Award of 2003 on us as an outstanding chemical technology. An outline of this new non-phosgene PC process embodying the spirit of Green and Sustainable Chemistry is given here.

Case Studies on How to Enhance the Chance of Technical Breakthrough and (Pseudo) Serendipity

Technical breakthrough and (pseudo) serendipity (hereinafter TB&S) found in the experiments are the important triggers and promoters for R&D and innovation. It is often said that 2-3 research groups publish similar research results simultaneously in the world. TB&S, especially (pseudo) serendipity can differentiate the research results of one group from those of the other group. By collecting examples of research projects of chemistry and material in a corporation and academia, we examined and classified them using key factors. About 20 common key factors are deduced from the events of TB&S. We postulate from the study that in order to enhance TB&S, the key factor is the combination of unexpected experiment (Amateur experiment) and outstanding scientific acumen and passion of professional. We discussed how to realize the combination of unexpected experiment and professional in laboratories from several view points. We also discussed how to plan unexpected experiments intentionally

Ether synthesis from activated aromatic halides and alkali-metal carbonates

Aromatic halides activated by an electron-withdrawing group at the ortho or para position has been found to react with alkali-metal carbonates or hydrogencarbonates at elevated temperatures to form ethers. The ether yield is markedly enhanced by catalysts such as silica and aluminium silicate. The rate of the etherification is dependent on the kind of activating groups 2Y–Ar–X + M2CO3→ Y–Ar–O–Ar–Y + 2MX + CO2(Y = NO2 > CN > ArSO2 > ArCO), halides (X = F > Cl ≈ Br ≈ I) and alkali metals (M = K > Na > Li). Cuprous and cupric compounds act as cocatalysts with silica and further promote the reaction. The reaction of p-chlorobenzophenone with potassium carbonate or sodium carbonate to bis(4-benzoylphenyl) ether in the presence of silica or silica–cuprous oxide catalyst was investigated in detail and the reaction mechanism is proposed. The silyl ether formed from an aromatic halide and the silanol group on the surface of silica is presumed to be the intermediate of the etherification.