A GREENER" PROCESS FOR FLUOROPOLYMER PRODUCTION

The fluoropolymer industry faces critical challenges to maintain an environmentally and economically sustainable production. Based on SRI Consulting's analyses, new processes to produce fluoropolymer in a carbon dioxide medium are not only environmentally friendly but also will reduce capital investment and production costs.

MENLO PARK, Calif. (PRWEB) May 4, 2003 --- World consumption of fluoropolymers reached a record level of 246 million pounds per year in 2001. They are expected to maintain a growth rate above the US GNP. In addition to perfluoropolymers, partially fluorinated polymers will continue to impact a wide range of technologies as better control of their unique optical, electronic, processing, and surface properties are achieved. However, the fluoropolymer industry faces new challenges to maintain an environmentally and economically sustainable production.

Recently, a process to produce fluoropolymers using supercritical or dense-phase carbon dioxide as the reaction medium was developed by scientists at the University of North Carolina -- Chapel Hill and DuPont. A $40 million pilot plant facility was built in 2000 to produce fluoropolymer using this process technology. The pilot plant is capable of producing 1,100 metric tons per year of fluoropolymer. Several grades of melt-processible fluoropolymer produced from this process, which they called Process G, are commercially available. There are preliminary plans to build a $235 million world-scale fluoropolymer and monomer plant for startup in 2006.

The use of supercritical or dense-phase CO2 to eliminate conventional chlorofluorocarbon solvent and reduce waste generation is gaining momentum. Conventional chlorofluorocarbon medium are environmentally unfriendly and are restricted due to their high ozone-depletion potential. Processes using aqueous medium are energy inefficient and generate a huge amount of wastewater. Fluoropolymer production in a CO2 medium is not only environmentally friendly but also reduces capital investment and production costs. High purity grades of fluoropolymer can potentially be produced by this process.

SRI Consulting has completed a report on the new development in fluoropolymer production. It principally focused on the production of melt-processible fluoropolymer by the conventional aqueous polymerization process and by the new CO2 process. Technical and process economic comparison of the conventional aqueous polymerization process and by the new CO2 process is discussed in the report. Relative advantages and pitfalls of both processes are disclosed. This report will be of particular interest to producers of fluoropolymers and in general, to polymer resin producers considering environmentally and economically sustainable production.

For further information about PEP Report 166B, Fluoropolymers, please contact the report author, Susan L. Bell, at (281) 876-6926. Fluoropolymers is one of a series of reports prepared by PEP that give detailed analysis of current and emerging chemical and petroleum refining technology. For purchase of this report or for information on subscription to the entire PEP, contact Angela Faterkowski, (281) 876-6919, or visit the PEP website at http://process-economics.com.

About SRI Consulting
SRI Consulting, (www.sriconsulting.com) a wholly owned subsidiary of Silicon Valley-based SRI International, works with companies worldwide to identify market opportunities and develop strategies for competing in today's technology-driven marketplace. SRI Consulting combines strategic business consulting with technology expertise to help companies develop and commercialize new products and leverage new technologies into competitive advantages. These consulting services are backed by SRI International's 50-year heritage as a pioneer in developing new products and markets.