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DREAM PRODUCTION FUNDED PROJECTS Prior to the start of the ‘Dream Production’ project, separating carbon di- oxide from power plant flue gas streams (‘carbon capture’) was still only at the pilot-plant stage of development. At that time, the work was focused predominantly on establishing energy-efficient scrubbing processes and on identifying stable CO2 solvents to provide the most cost-effective means of reducing the CO2 burden produced by power plants. However, the quality of the captured CO2 had to be sufficiently high for it to be utilisable in potential downstream chemical conversion processes. The CO2-based polyether carbonate target products are proposed as an al- ternative to the conventional polyether polyols that are formed entirely from fossil-based chemical building blocks. The first lab-scale quantities of these polyether carbonates were produced in the preceding ‘Dream Reac- tions’ project. Because of the high pressures involved, scaling up the reac- tion required finding new chemical engineering solutions. It was also un- clear what effect impurities in the CO2 captured from power plant flue gas streams would have on catalyst behaviour. The reaction of CO2 with amines to carbamino acids in the production of isocynanates has been the subject of a number of previous studies. Areas in which improvements were required included catalyst development, evalu- ating the range of potential synthetic applications and process engineering concepts for removing water during the dehydration step. 1.4.2 Project description Goal The goal of the ‘Dream Production’ project was to develop processes that would enable the utilisation of CO2 as a synthetic building block for the in- dustrial synthesis of polymers. This involved capturing CO2 from the flue gas stream of a coal-fired power plant and supplying it at a level of purity compatible with use in industrial synthetic chemistry. The focus of the work examining the utilisation of CO2 as a C1 building block was on the produc- tion of polyether polycarbonate polyols. Over the course of the project these polyols were processed further to yield samples of polyurethane whose ma- terial properties were then studied. To broaden understanding of the field, the principle of catalytically activat- ing CO2 was applied to the production of isocyanates from the reaction of amines and CO2. The objective was to identify an improved, preferentially catalytic process that would, over the long-term, enable polyurethanes to be produced from CO2-based polyether carbonates and CO2-based isocyanates. 45PDF Image | Chemical Processes and Use of CO2
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