PHENOL • ACETONE & DERIVATIVES

Phenol is primarily produced from cumene, although it can also be made from benzoic acid or chlorobenzene. Phenol’s main uses are in the manufacture of phenolic resins, for plywood and moulding powders, and in bisphenol A (BPA) an intermediate for the manufacture of epoxy and polycarbonate resins. Phenol can also be used to produce caprolactam.

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Acetone is primarily used as a chemical intermediate and as a solvent. As a chemical intermediate acetone is used to produce bisphenol A, methyl methacrylate (MMA) and MIBK, as well as diacetone alcohol (DAA) and hexylene glycol. As a solvent, acetone is used for acetylene storage, varnishes, lacquers, printing inks, adhesives and cellulose resins.

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Cumene is manufactured from benzene and propylene and is used almost exclusively to produce phenol and its co-product acetone. There is also some small, residual consumption into acetophenone and alpha-methyl-styrene (for ABS).

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Cyclohexanone is the main raw material for the production of caprolactam. This is the dominant end use, which means that almost all production is in the hands of caprolactam producers. It can be made either from cyclohexane or from phenol. When it is made from cyclohexane also cyclohexanol is co-produced, from which it is separated by distillation. When phenol is the starting material, cyclohexanol is the sole product, which is then de-hyrogenated to cyclohexanone. The other main use is as a solvent, for example for wood varnishes and polyurethane systems.

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MMA is used in polymers (PMMA) in various forms such as cast sheets, latices and moulding and extrusion polymers. Applications include advertising signs, aircraft windows, desk tops, lighting fixtures, building panels and plumbing/bathroom fixtures, as well as LED TV screen panels and light guide plates for LED TV. MMA is also used as a co-monomer in paints and coatings applications. Most MMA plants use the ACH route to produce MMA but Mitsubishi also has an Alpha process, based on ethylene, methanol and carbon monoxide.

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Bisphenol A (BPA) is made from acetone and phenol and is an intermediate in the manufacture of epoxy resins and of polycarbonate resins. The ratio of BPA use is approximately 40:60 as between epoxy and polycarbonate resins. The rapid growth of polycarbonate resins in recent years has seen an increase in the number of BPA manufacturing sites world-wide.

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Polycarbonate resins are made from phosgene and bisphenol A (BPA) though a newer, greener process now employs dimethyl carbonate and BPA. The principal use is in the electronics sector for components and housings where its good electrical insulation, heat resistance and flame retardant properties are at a premium. Other uses include extruded sheets in construction, glazing in the automotive sector and medical use. Optical media applications such as CDs, DVDs and Blu-ray discs has declined. Polycarbonate resin production is predominantly in Asia where most volume applications are located.

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