Shell Chemicals has said it is "very close" to commercialising a less costly process of producing diphenyl carbonate (DPC) which avoids using the highly toxic chemical compound phosgene.
In the new process, seen as a potential game-changer for the polycarbonate industry, carbon dioxide, phenol and propylene oxide react to form propylene glycol and DPC.
Ethylene oxide can replace propylene to give ethylene glycol instead of propylene glycol.
Speaking at Shell's media open day, chief scientists for Chemistry and Catalysis Carl Mesters said: "Although the use of DPC eliminates phosgene from the polymer step, several companies use phosgene in the commercial synthesis of DPC.
"Non-phosgene DPC synthesis technology exists but such routes are cumbersome and energy-intensive," added Mesters.
Shell's new process makes DPC without the use of solvents and no salt is required to wash out the polymer.
Shell executive vice president for Chemistry Ben van Beurden added: "The technical part of the process is mature enough to go to the next stage and we are very close to commercialising it. It could be a game-change for the polycarbonate industry."
