Phosgene free route to methyl diphenyl diisocynate (MDI): A technical and economical evaluation

Henderikus van den Berg, Aloysius G.J. van der Ham, H. Gutierrez, Samuel Obarinu Odu, T. Roelofs, J. de Weerdt

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Abstract

The objective is to design an alternative production process for Methyl Diphenyl Diisocyanate (MDI) in which no toxic phosgene is used. The plant should use 4,4′-Methylenedianiline (MDA) as a raw material. Seven routes found in the open literature were investigated and compared on process conditions (yield, conversion, and thermodynamics), technical and economical feasibility, and safety. Three routes remained which all involved the reaction of MDA to a carbamate intermediate and the successive thermal decomposition of this intermediate to MDI and side-products. For these routes, a systematic design procedure was applied. The design for the promising route using urea and 3-methyl-1-butanol was completed to mass and heat balances, heat integration and a preliminary design of the reactors. Uncertainties in the design were indicated. In the process design it was demonstrated that a non-phosgene route for MDI is technically feasible and economical attractive for the design of a new plant (ROI 33%, estimated margin from 20% to 50%).
Original languageEnglish
Pages (from-to)254-257
Number of pages4
JournalChemical Engineering Journal
Volume207-208
DOIs
Publication statusPublished - 2012

Fingerprint

Phosgene
Carbamates
Poisons
carbamate (ester)
Butenes
heat balance
thermal decomposition
Urea
diphenyl
evaluation
Process design
Raw materials
Pyrolysis
urea
mass balance
Thermodynamics
thermodynamics
safety

Keywords

  • METIS-288371
  • Industrial technology (see also 5311)Duurzame energiebronnen
  • IR-81750

Cite this

van den Berg, Henderikus ; van der Ham, Aloysius G.J. ; Gutierrez, H. ; Odu, Samuel Obarinu ; Roelofs, T. ; de Weerdt, J. / Phosgene free route to methyl diphenyl diisocynate (MDI): A technical and economical evaluation. In: Chemical Engineering Journal. 2012 ; Vol. 207-208. pp. 254-257.
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abstract = "The objective is to design an alternative production process for Methyl Diphenyl Diisocyanate (MDI) in which no toxic phosgene is used. The plant should use 4,4′-Methylenedianiline (MDA) as a raw material. Seven routes found in the open literature were investigated and compared on process conditions (yield, conversion, and thermodynamics), technical and economical feasibility, and safety. Three routes remained which all involved the reaction of MDA to a carbamate intermediate and the successive thermal decomposition of this intermediate to MDI and side-products. For these routes, a systematic design procedure was applied. The design for the promising route using urea and 3-methyl-1-butanol was completed to mass and heat balances, heat integration and a preliminary design of the reactors. Uncertainties in the design were indicated. In the process design it was demonstrated that a non-phosgene route for MDI is technically feasible and economical attractive for the design of a new plant (ROI 33{\%}, estimated margin from 20{\%} to 50{\%}).",
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Phosgene free route to methyl diphenyl diisocynate (MDI): A technical and economical evaluation. / van den Berg, Henderikus; van der Ham, Aloysius G.J.; Gutierrez, H.; Odu, Samuel Obarinu; Roelofs, T.; de Weerdt, J.

In: Chemical Engineering Journal, Vol. 207-208, 2012, p. 254-257.

Research output: Contribution to journalArticleAcademicpeer-review

TY - JOUR

T1 - Phosgene free route to methyl diphenyl diisocynate (MDI): A technical and economical evaluation

AU - van den Berg, Henderikus

AU - van der Ham, Aloysius G.J.

AU - Gutierrez, H.

AU - Odu, Samuel Obarinu

AU - Roelofs, T.

AU - de Weerdt, J.

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AB - The objective is to design an alternative production process for Methyl Diphenyl Diisocyanate (MDI) in which no toxic phosgene is used. The plant should use 4,4′-Methylenedianiline (MDA) as a raw material. Seven routes found in the open literature were investigated and compared on process conditions (yield, conversion, and thermodynamics), technical and economical feasibility, and safety. Three routes remained which all involved the reaction of MDA to a carbamate intermediate and the successive thermal decomposition of this intermediate to MDI and side-products. For these routes, a systematic design procedure was applied. The design for the promising route using urea and 3-methyl-1-butanol was completed to mass and heat balances, heat integration and a preliminary design of the reactors. Uncertainties in the design were indicated. In the process design it was demonstrated that a non-phosgene route for MDI is technically feasible and economical attractive for the design of a new plant (ROI 33%, estimated margin from 20% to 50%).

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