CO2
Bayer MaterialScience's research into using carbon dioxide to manufacture plastics has made headway.
The company has announced that recent laboratory tests as part of Bayer's Dream Polymers research project have succeeded in reducing the need for petroleum at precursor level through the incorporation of the gas.
Plastics are normally produced using oil, but this new process also extends the range of plastics that carbon dioxide can be used in producing. A technology using the greenhouse gas to make a key component for high-quality foam (polyurethane) is close to appearing on the market. The proportion of petroleum in this chemical is 80 per cent.
Project Manager Dr Christoph Gürtler said: "We have now succeeded in reducing the petroleum content for making other plastics to just 60 per cent."
Twofold use
In this process, carbon dioxide is used twice. The gas is incorporated directly into a new kind of precurso (polyoxymethylene polycarbonate polyol) in the first instance, replacing 20 per cent of the petroleum.
Second, it is used indirectly, producing a chemical that is also incorporated into the precursor for a further 20 per cent saving in petroleum.
"As a result, the proportion of alternative raw materials is already 40 per cent," remarks Gürtler.
In addition, the number of plastics that can be produced using carbon dioxide is increasing.
Gürtler continued: "It is now also possible to manufacture thermoplastic polyurethanes, films and casting elastomers in this way." Such plastics are used in all kinds of applications, including automotive interiors, cable sheathing and sporting goods such as ski boots.
Positive tests
Dream Polymers' researchers have proved the manufacturing process works in principle, with Gürtler confirming initial application tests have been positive, but he noted there is work to be done before the process is viable commercially.
The report is being supported by the German Federal Ministry of Education and Research. External institutions in Germany such as the CAT Catalytic Center, the Leibniz Institute for Catalysis and the Fraunhofer Institute for Chemical Technology are also involved.
Bayer MaterialScience sees itself as a pioneer when it comes to future applications for carbon dioxide. As part of its Dream Production project, which has already been in progress for some time, the company aims to use carbon dioxide as a component for flexible polyurethane foam at the Dormagen site from 2016 onwards. The new material will initially be used to make mattresses.
