With the successful development of the national "863" project, titled "The Cleaner Production Catalyst and Process for the Synthesis of Dimethyl Carbonate and Phenol Transesterification of Diphenyl Carbonate," China is now on track to achieve non-phosgene production of polycarbonate in the future. According to a report from the technology research and development unit of the Chengdu Institute of Organic Chemistry, Chinese Academy of Sciences, this proprietary technology has secured 11 patents and offers a comprehensive software package for designing a 10,000-ton industrial-scale test facility. Currently, China's polycarbonate industry relies heavily on imports. Last year alone, the country imported 730,000 tons. Over the next five to ten years, demand is expected to rise by 10% to 15%. Many domestic companies are eager to tap into this growing market and are planning large-scale production facilities. It is anticipated that by 2010, China’s polycarbonate production capacity will reach 300,000 tons, with a corresponding demand for diphenyl carbonate reaching between 26 million and 30,000 tons. The transesterification process for producing diphenyl carbonate not only stimulates demand for products like methanol and dimethyl carbonate but also enhances the downstream industrial chain of coal and natural gas in China, boosting product value. More importantly, it helps break foreign intellectual property barriers, ensuring a reliable supply of raw materials for clean polycarbonate production. Diphenyl carbonate is primarily used in polycarbonate manufacturing and finds applications in solvents, plasticizers, pharmaceuticals, and pesticides. Traditionally, it has been produced using phosgene, a toxic and highly corrosive substance that poses risks to safety and the environment. As economic and technological progress continues, replacing phosgene with non-toxic dimethyl carbonate to synthesize phenyl carbonate esters has become an attractive alternative. This process is considered a clean production method, first developed and commercialized by GE in the 1990s. Researchers at Chengdu Organic Chemistry Co., Ltd. have designed advanced catalysts and high-performance reactors, optimized reaction conditions, and improved product separation and purification techniques. They have mastered the core technology of the transesterification method. Further optimization was conducted at a 1,000-ton pilot plant in Tangshan, Hebei Province. Key challenges such as catalyst lifespan, reactive distillation, and separation were addressed, ensuring the reliability of the industrial test program. Operational data from the pilot plant show a phenol conversion rate of over 46% per pass, a diphenyl carbonate selectivity of over 99%, a catalyst lifespan of more than 1,080 hours, and product quality meeting polycarbonate standards. This marks a significant step forward in China’s efforts to develop sustainable and environmentally friendly chemical production technologies.

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