Sustainable preparation of bisphenol-a for the production of polycarbonate

Abstract

The present invention relates to a method for the preparation of bisphenol-A for the synthesis of polycarbonate according to claim 1, and to a method for the preparation of polycarbonate from the bisphenol-A obtained according to the above-mentioned preparation method according to claim 14, and to a multi-component system for the preparation of bisphenol-A according to the above-mentioned preparation method. In this method, the bisphenol-A is prepared from provided acetone and provided phenol, wherein these raw materials have to be method products of a specific preparation method which are based on CO2, methane from a biological source, carbohydrates and / or organic, solid compounds as starting materials.

Description

[0001] Sustainable production of bisphenol-A for the production of polycarbonate

[0002] The present invention relates to a production process of bisphenol-A for the synthesis of polycarbonate, as well as a process for the production of polycarbonate from the bisphenol-A obtained according to the above-mentioned production process and a multicomponent system for the production of bisphenol-A according to the above-mentioned production process.

[0003] To date, the industrial production of bisphenol-A has been primarily based on the use of fossil raw materials, such as synthesis gas from natural gas and petroleum-based aromatic compounds. The consistent use of renewable raw materials and / or valuable waste materials for the production of materials such as bisphenol-A is a goal for the provision of sustainable plastics, such as polycarbonate and materials derived from it.

[0004] Furthermore, the use of energy from renewable energy sources for the industrial production of chemical raw materials, such as bisphenol-A, is being sought.

[0005] The publication US 2010 / 0152406 A1 describes that bisphenol A can be produced from renewable phenol and renewable acetone, i.e., phenol and acetone from renewable raw materials. Accordingly, acetone is to be produced from the renewable raw material sources bioethanol or through fermentation. However, according to the teaching of the said publication, the routes outlined therein for the production of renewable acetone are considered unsuitable for industrial-scale production.

[0006] It was therefore an object of the present invention to provide a more sustainable production process for bisphenol-A on an industrial scale, which enables the use of renewable raw materials. Furthermore, a further object of the invention was to provide a method for producing bisphenol-A with which low-emission bisphenol-A for the production of polycarbonates can be achieved despite possible fluctuations in the availability of renewable energy. The term "renewable energy" is understood by those skilled in the art to mean energy from a non-depletable energy source, such as wind power, hydropower, bioenergy (e.g., electricity generation from biogas or biomass), or solar energy.

[0007] Applying the UN definition of sustainability ("sustainable development") according to the Brundtland Report of the World Commission on Environment and Development, the expert understands the "sustainability" of a process to mean that the implementation of the process in the present makes as little or no contribution as possible to ensuring that future generations of humanity will no longer be able to meet their own needs, in particular needs with regard to the use of resources such as fossil fuels and, in particular, needs with regard to the conservation of habitats, such as the protection of the Earth's atmosphere. The object of the invention is therefore to make the production of bisphenol A and polycarbonate made from it more sustainable than the production methods known from the prior art.The contribution of bisphenol A and polycarbonate production to the declining satisfaction of the needs of future generations should be reduced or even avoided.

[0008] A first subject of the invention is therefore a process for producing bisphenol-A for the production of polycarbonate, comprising at least the steps: a) Providing acetone, which is a process product of a process comprising at least the following steps: i) Providing methanol, which is a process product of a process with at least the following steps: i-1) Conversion of CO to methanol, wherein the CO is a process product of at least one partial reduction of CO2 to CO and / or a process product of at least one partial oxidation of organic material to CO, wherein at least one organic material is selected from at least one organic, solid compound, methane from a biological source or mixtures thereof; ii) Synthesis of acetone from previously provided methanol by at least the following steps:

[0009] Providing propene as a product of a process comprising at least the following steps: ii-1) converting the previously provided methanol to a product mixture containing dimethyl ether, water, and methanol; ii-2) converting starting material containing dimethyl ether, water, and methanol, each from the aforementioned product mixture, at a temperature of more than 200°C by contact with a catalyst, preferably with at least one zeolite compound, to propene; converting the propene by at least ii-3) oxidizing the propene to acetone; b) providing phenol, which is a process product of at least one production process comprising at least the following steps: i) providing at least one organic, aromatic compound according to formula (I),

[0010] R 1 represents a hydrogen atom, a hydroxyl group, methyl, carboxyl, carboxylate or -CHR 3 R 4 where R 3 and R4 independently of one another represent a (C1-C3) alkyl group or together with the remaining molecule form an aliphatic hydrocarbon cycle; and

[0011] R 2 represents a hydrogen atom, methyl, carboxyl or carboxylate, with the proviso that if R 1 for -CHR 3 R 4 stands, R 2 a hydrogen atom and if R 1 represents a hydroxyl group, R 2 represents a hydrogen atom, carboxyl or carboxylate, wherein said organic aromatic compound is a process product of a conversion of at least one starting material selected from at least one compound from the group formed by polymeric organic compounds, carbohydrates and methane from a biological source; and if in said organic aromatic compound from step i) according to formula (I) R 1 does not represent a hydroxyl group and R 2does not represent a hydrogen atom ii) at least one of steps ii-1) and / or ii-2) and / or iii-3) ii-1) reacting the organic aromatic compound from step i) with propene to obtain a propan-2-yl substituted aromatic organic compound as product; ii-2) oxidizing the organic aromatic compound from step i) and / or the product from step ii-1), whereby at least one oxidized aromatic organic compound is obtained; ii-3) cleaving off at least one carbon-containing substituent of the organic aromatic compound from step i) and / or of the oxidized organic aromatic compound from the oxidation according to step ii-2); c) converting a mixture comprising the provided acetone and the provided phenol to bisphenol-A.

[0012] According to the invention, a "catalyzed reaction" or "catalytic conversion" takes place using a catalyst that catalyzes the product formation from at least one reactant (e.g., carbon dioxide or methanol) by reducing the energy required and / or by increasing selectivity while increasing the product yield, compared to the same reaction under the same reaction conditions but in the absence of the catalyst. For example, the conversion according to step a) ii-2) is a catalytic conversion of said starting material to propene.

[0013] In step a) of the process according to the invention, acetone is provided. For the provision of acetone, it is sufficient according to the invention if the acetone provided is an actual process product of at least steps i) and ii) mentioned under a). This means that for the execution of the step of providing acetone, it is sufficient to remove said acetone as a raw material from a storage container or from a feed line in order to feed it at least to step c) of the process according to the invention. In this case, the bisphenol A producer, as the executor of the process according to the invention, does not itself carry out steps i) and ii) mentioned under a) of the process according to the invention for the production of acetone, but only ensures that the acetone provided was produced by applying at least steps i) and ii) mentioned under a) and is thus their process product.

[0014] It is also possible according to the invention if, in order to provide the acetone, the steps i) and ii) mentioned at least under a) for producing the acetone are carried out as integral steps of a process according to the invention for producing bisphenol A by the bisphenol A producer and the acetone obtained thereby, optionally after intermediate storage in a storage container, is fed at least to step c) of the process according to the invention.

[0015] The options for providing, i.e. supplying or producing the specific acetone by the bisphenol A producer also apply to the following embodiments of steps i) and ii) mentioned under a).

[0016] The step i) mentioned under a) in the process according to the invention requires the provision of methanol, which is a process product of a process with at least the following steps: i-1) Conversion of CO to methanol, wherein the CO is a process product of at least one partial reduction of CO2 to CO and / or a process product of at least one partial oxidation of organic material to CO, wherein at least one organic material is selected from at least one organic, solid compound, methane from a biological source or mixtures thereof.

[0017] According to the present invention, a material or chemical compound is organic if the material / chemical compound contains at least one covalent carbon-hydrogen bond.

[0018] A substance or material is defined as solid if the substance exists as a solid at 25°C and 1013 mbar.

[0019] According to the present invention, for the provision of methanol, it is sufficient if the methanol is an actual process product of at least the reaction mentioned under i-1), whereby carbon monoxide (also referred to as CO) is used for this reaction, which in turn is a process product of a specific process. This means that for the implementation of the methanol provision step, it is sufficient to simply withdraw said methanol as a raw material from a storage container or from a supply line.In this case, the bisphenol A producer as the executor of the process according to the invention or the supplier of the acetone provided for the process according to the invention does not carry out the above-mentioned reaction for producing the methanol itself, but only ensures that the methanol provided for providing the acetone has been produced by applying at least the said step i-1) and is thus the product of the process.It is also possible according to the invention if, in order to provide the methanol, at least the aforementioned reaction for producing the methanol is carried out as an integral step of the process according to the invention for producing bisphenol A by the bisphenol A producer or the supplier of the acetone provided, and the methanol obtained thereby, optionally after intermediate storage in a storage container, is fed to the synthesis of acetone provided under step a) of the process according to step ii) by carrying out at least steps ii-1), ii-2) and ii-3).

[0020] The options for providing, i.e. supplying or producing the special methanol by the bisphenol A producer, also apply to the following embodiments of providing the methanol.

[0021] To produce methanol, carbon oxides are typically reacted with hydrogen (the mixture is also known as synthesis gas). This process is exothermic and can be described by the following reaction equations:

[0022] CO + 2H2CH3OH

[0023] CO2 + 3H2CH3OH + H2O

[0024] Both reactions are coupled by the also exothermic water-gas shift reaction, which can be described as follows:

[0025] Traditionally, methanol synthesis uses synthesis gas consisting primarily of CO and H2, which in turn is produced from natural gas (fossil methane) and steam in a steam reforming process. The composition of the synthesis gas has a strong influence on its optimal utilization. The composition can be described by the stoichiometry number (SZ):

[0026] For SZ = 2, the reactants are present in a stoichiometric ratio according to the above-mentioned reaction equations. However, slightly higher values ​​for SZ (2.01-2.1) are actually used, which is achieved by a higher hydrogen content in the synthesis gas (Dittmeyer et al., "Chemische Technik," Volume 4, 5th edition). In the process according to the invention, the carbon monoxide required for the conversion to methanol production is not provided by conventional steam reforming using fossil carbon sources (natural gas), but rather by partial reduction of carbon dioxide and / or by partial oxidation (and, if necessary, gasification) of said organic material to CO.

[0027] In the partial oxidation of organic, solid material (preferably organic, polymeric material), according to the process according to the invention, CO is provided from organic, solid material (preferably from used polymer waste fractions) and oxygen-containing gas by converting said organic, solid material under partial oxidation into a gas containing CO (hereinafter also referred to as gasification).

[0028] By using polymer-containing waste fractions, which can, for example, consist predominantly of PET, PE, PP, polyurethane or polycarbonate-containing waste fractions (hereinafter referred to as polymer waste fraction), to provide CO, these polymer-containing waste fractions are recycled and thus bisphenol A and also polycarbonate from this bisphenol A are produced with improved sustainability.

[0029] A "polymeric compound" is a molecule with a relative molar mass (Mw) of at least 2000 g / mol, whose chemical structure predominantly comprises multiply repeating structural units derived from one or more different molecules of lower relative molar mass. Unless explicitly stated otherwise, the average molar masses stated for polymers or polymeric compounds in this application are always weight-average molar masses Mw, which can generally be determined by gel permeation chromatography using an RI detector, with the measurement conveniently being carried out against an external standard. A "polymeric material" is a material containing at least one polymeric compound.

[0030] Partial oxidation causes organic material (preferably solid organic material, particularly preferably polymeric organic material, most preferably the polymer waste fraction) and oxygen to undergo a partial oxidation reaction, resulting in a product gas mixture containing hydrogen and CO and, if appropriate, by-products. By-products include, in particular, hydrocarbons with 1 to 8 carbon atoms. CO2 and water vapor are also present in the product gas mixture. A further by-product from the gasification process is a residual fraction that cannot be further converted.

[0031] The temperature required for gasification is achieved at least partially by partial combustion (partial oxidation) of the organic, solid material (preferably the polymeric, organic material, particularly preferably the polymer waste fraction) with an oxygen-containing gas. The partial oxidation of the introduced organic, solid material is carried out in the reactor at a temperature of at least 400°C. Preferably, the partial oxidation of the material in the reactor is carried out at a temperature in a temperature range from 600°C to 1500°C, in particular from 850°C to 1400°C, more preferably from 1100°C to 1300°C.

[0032] The carbon monoxide provided as a process product of a partial oxidation can, for example, have been produced by a process for producing carbon monoxide for the provision of methanol, comprising at least the following steps

[0033] 1) Providing an oxygen-containing gas stream containing at least 50 wt.% oxygen gas,

[0034] 2) partial oxidation of organic material (preferably organic material containing at least one polymeric organic compound), wherein said organic material is introduced into a reactor of a device and treated there at least by supplying said oxygen-containing gas stream and heat at at least 400°C to form a product gas, and the resulting product gas, optionally after at least one further partial oxidation step of the product gas, is discharged from the device as a carbon monoxide-containing product gas stream together with particulate solid dispersed therein;

[0035] 3) the carbon monoxide-containing product gas stream is fed to a cleaning process in which at least

[0036] 3-1) the carbon monoxide-containing product gas stream is fed to a washing step for the separation of solids, wherein

[0037] (i) water is brought into contact with the carbon monoxide-containing product gas stream, whereby the particulate solid dispersed in the carbon monoxide-containing product gas stream forms a slag and this slag is removed and discharged, (ii) the carbon monoxide-containing product gas stream purified from particulate solid is discharged;

[0038] 3-2) a carbon monoxide-containing product gas stream purified from particulate solids by means of a washing step is fed to at least one water separation step in a drying step, water is separated off and the resulting carbon monoxide-containing product gas stream is discharged,

[0039] 3-3) a carbon monoxide-containing product gas stream purified by separation of water is fed to at least one carbon dioxide separation, carbon dioxide is separated and the resulting carbon monoxide-containing product gas stream and carbon dioxide are discharged;

[0040] 3-4) a carbon monoxide-containing product gas stream purified by separation of carbon dioxide is fed to at least one separation unit for the separation of carbon monoxide, a separation of carbon monoxide is carried out and the resulting carbon monoxide and a hydrogen gas-containing residual gas are discharged;

[0041] 3-5) optionally, a hydrogen gas-containing residual gas separated by means of said separation unit is fed to a residual gas treatment, hydrogen gas is separated and hydrogen gas and a tail gas are discharged.

[0042] A solid is known to be "particulate" if it exists in the form of a granular mixture of a large number of loose, solid particles of the substance in question, which in turn includes so-called grains. A grain is a term used to describe the particulate components of powders (grains are the loose, solid particles), dusts (grains are the loose, solid particles), granules (loose, solid particles are agglomerates of several grains), and other granular mixtures.

[0043] A "reactor" is a volume in which a chemical transformation, such as the partial oxidation of a polymeric, organic compound of a material, takes place. For partial oxidation, this could be, for example, the volume of a heated vessel containing the material.

[0044] The oxygen gas required for the partial oxidation can be taken, for example, from a water electrolysis plant or an air separation plant. In a preferred embodiment of the partial oxidation, the oxygen-containing gas stream is provided by electrolysis of water to obtain oxygen gas and hydrogen gas, and the oxygen gas from this electrolysis is used to provide the oxygen-containing gas stream.

[0045] Water electrolysis can be carried out using state-of-the-art systems. Well-known and commercially available systems include both alkaline water electrolysis and polymer electrolyte-based electrolysis, known as PEM electrolysis. The principles of water electrolysis are described in Chapter 6.3.4 of Volkmar M. Schmidt's "Electrochemical Process Engineering" (2003, Wiley-VCH-Verlag; ISBN 3-527-29958-0).

[0046] According to the invention, the organic solid material introduced into the reactor for partial oxidation preferably contains at least one polymeric organic compound. The partial oxidation should take place as uniformly and selectively as possible in the reactor. These parameters can be improved if, within the scope of a preferred embodiment, the weight ratio of the oxygen gas contained in the oxygen-containing gas stream to the polymeric organic compound is introduced into the reactor within a weight ratio range of 0.4 to 1.0 to 1.2 to 1.0, preferably 0.6 to 1.0 to 0.9 to 1.0, based on the time before introduction.

[0047] In a preferred embodiment, the partial oxidation of the introduced organic, solid material is carried out at an absolute pressure of more than 1 bar, preferably at an absolute pressure in a range of 2 to 80 bar, particularly preferably at an absolute pressure in a range of 2 to 50 bar.

[0048] The partial oxidation of the organic solid material can be carried out in at least one of the following three reactors: entrained flow gasification reactor, fluidized bed gasification reactor and fixed bed gasification reactor.

[0049] For use in an entrained-flow gasification reactor, the organic solid material must be ground to a particle size with an average particle diameter X50.3 of < 0.1 mm (dust). It is fed into the reactor either pneumatically or as a slurry. The major limitation of this type of partial oxidation for chemical waste recycling is the grindability and pumpability of feedstocks from heterogeneous waste. Thermal treatment of biomass (torrefaction) at 200–300 °C under O2 exclusion is used to produce a "biochar" with grindability similar to that of hard coal. In another variant, upstream pyrolysis can be used to produce a pumpable pyrolysis oil. The oil obtained by waste pyrolysis can be partially oxidized either directly or in the form of a slurry mixed with the solid pyrolysis residue (pyrolysis coke).This process configuration was designed by Noell (Noell conversion process for the recycling and disposal of waste, Jürgen Carl EF-Verl. für Energie- und Umwelttechnik, 1994. ISBN: 3924511829).

[0050] Another variant is the use of a fluidized bed gasification reactor. The gasification of organic, solid material, particularly waste, in fluidized bed reactors is widely known with the technologies EBARA (Showa Denko, Japan), ENERKEM (Enerkem, Edmonton, Canada), and the large-scale demonstration of high-temperature Winkler gas production (HTW) by Rheinbraun AG (now RWE) from 1993 to 1997 in Berrenrath, Germany. Pretreatment for feeding the organic material, or material containing polymers containing organic compounds, into the reactor requires comminution to an average particle diameter X50.3 of 30 - 80 mm. Feeding into the reactor vessel is via screw conveyors, limiting the gasification pressure to a maximum of 10 bar. The technologies of ENERKEM and EBARA enable the gasification of high-calorific waste (plastic waste or plastic-rich refuse-derived fuels).Fluidized bed gasifiers operate at mild temperatures of 700–950 °C, significantly below the ash melting point of the feedstock, to avoid caking and agglomeration in the reactor. Another advantage of this mild reactor temperature is the incomplete carbon conversion in the fluidized bed. Furthermore, the raw gas from fluidized bed gasifier reactors typically contains significant amounts of methane and other hydrocarbons. To compensate for this and ensure a high syngas yield of H2 and CO, the ENERKEM and EBARA processes utilize a second high-temperature partial oxidation stage (approximately 1400 °C), located directly downstream of the fluidized bed, to melt fly ash and convert hydrocarbons in the first-stage product gas into the final carbon monoxide-containing product gas stream. ENERKEM calls this second stage a "thermoreformer," while EBARA refers to it as a "high-temperature gasification furnace."The high temperature of this second partial oxidation stage increases CO2 production.

[0051] The CO for the provision of methanol can also preferably originate as a process product from the conversion of methane from a biological source by means of partial oxidation in a conventional reformer process. In a preferred embodiment of such a provision, the CO is a process product of a conversion of at least methane from a biological source and water vapor (particularly preferably with the addition of CO2), with the addition of thermal energy at a temperature of at least 500°C, to carbon monoxide. A further suitable, sustainable reformer process with the addition of CO2 is described in the PCT patent application with the application number PCT / EP2022 / 052267, to which reference is expressly made in its entirety. This process relates to the production of carbon monoxide from methane from a biological source, water vapor, and CO2, comprising at least the steps

[0052] Synthesis of carbon monoxide in a reformer process in which methane from a biological source and water vapor are converted into carbon monoxide-containing product gas with the addition of at least CO2 and with the addition of heat energy at a temperature of at least 500°C,

[0053] Purification of the carbon monoxide-containing product gas obtained from the aforementioned synthesis, at least by separation of CO2 and optionally additionally by at least one separation selected from the separation of water, the separation of hydrogen or a combination thereof, to obtain carbon monoxide;

[0054] Providing CO2 for said addition to the aforementioned reforming process at least from said separation of CO2 from the aforementioned purification step.

[0055] In this case, it is again preferred if the heat energy supplied to the reformer process for the synthesis of carbon monoxide is provided by at least one method selected from (i) the combustion of fuel containing hydrogen generated by means of renewable energy, (ii) the combustion of fuel containing methane from a biological source, (iii) conversion of electrical energy generated from renewable energy into heat.

[0056] By "methane from biological sources" (also referred to as biomethane), experts in the art define methane, as distinct from fossil methane, as that which is technically obtained through methane fermentation from biomass. Methane fermentation is known to be the anaerobic decomposition of organic matter by microorganisms. Methane from biological sources is produced, for example, in biogas plants, in which both organic waste and renewable raw materials are fermented. By "renewable energy" experts mean energy from a non-depletable energy source, such as wind energy, hydropower, bioenergy (e.g., electricity generation from biogas or biomass), or solar energy. Therefore, wind power, solar energy, hydropower, or mixtures thereof are particularly suitable as renewable energies.

[0057] According to the invention, the methanol provided according to i) of process step a) according to the invention is preferably a process product of a conversion of CO, wherein this CO used in the conversion is a process product of at least a partial reduction of CO2 to CO, in particular selected from a reverse water gas shift reaction using EE provided by electrolysis (preferably by water electrolysis, ie electrolysis of water), from an electrochemical reduction of CO2 to CO or from mixtures thereof.

[0058] In a particularly preferred embodiment of the process according to the invention, the methanol provided is provided as a process product of a reaction of CO, wherein the CO used in the reaction is a process product of at least a partial reduction of a gas stream which contains at least CO X with x = 1 or 2 and optionally hydrogen gas.

[0059] It has also proven highly preferred if, in one embodiment of the process, methanol is obtained by converting CO2 with or without hydrogen and used to produce methanol. In this case, it is particularly preferred if the conversion is an electrochemical reaction, a homogeneously catalyzed reaction, or a heterogeneously catalyzed reaction. In another embodiment, the CO2 used for this purpose also comes from another CCE source, for example, the CO2 emitted during the production of thermal energy or the CO2 from an external CCE source, e.g., an industrial exhaust gas.

[0060] According to the invention, an “electrochemical reaction” takes place by applying an electric current in the reaction medium (e.g. via at least one electrode immersed in the reaction medium) in the presence of at least one reactant (e.g. carbon dioxide).

[0061] A "catalyzed reaction" or "catalytic conversion" is defined as above (vide supra). According to the invention, a "homogeneously catalyzed reaction" takes place using a homogeneous catalyst, and a "heterogeneously catalyzed reaction" takes place using a heterogeneous catalyst.

[0062] A preferred CCh source is at least one "external CCE source" that contributes CO2 that is not emitted by the process according to the invention. An external CO2 source would be, for example, the CO2 that arises during cement production, during FF production for ammonia synthesis, during fermentation, in the exhaust gas during combustion of fuels (e.g., waste incineration), or CO2 that is extracted from the air.

[0063] In a particularly preferred embodiment of the process according to the invention, the carbon monoxide for methanol synthesis is produced from CO2 in a reverse water-gas shift (RWGS) reaction zone by at least one conversion of hydrogen and CO2 to carbon monoxide. Such an embodiment of carbon monoxide production is described, for example, in document WO 2021 / 089737 A, which is expressly incorporated herein by reference.

[0064] A "reaction zone" is the part of a reaction space in which a chemical reaction, e.g., a reverse water gas shift reaction, takes place. A "reaction space" is a volume in which the reactants involved in a chemical reaction are brought together and in which the chemical reaction takes place. For a chemical reaction, this could, for example, be the volume of a vessel in which a reactant, e.g., carbon dioxide in the case of a reverse water gas shift reaction, and its reactant, hydrogen in the case of a reverse water gas shift reaction, are present together and are reacted in the reaction zone. This volume could, for example, be located in a reactor.

[0065] The hydrogen gas used for the RWGS reaction is preferably provided by electrolysis, in particular by chlor-alkali electrolysis or water electrolysis, particularly preferably by water electrolysis. In this case, electrical energy preferably generated from renewable energy (in particular from hydropower, solar energy, or wind power) is used. In the particularly preferred process, the carbon monoxide provided for the provision of the methanol is a product of a process comprising at least the following steps:

[0066] Providing a CCL gas stream,

[0067] Cleaning the CO2 gas stream from secondary components, in particular nitrogen oxides, sulphur compounds, dust, water, oxygen and HCl, optionally by means of adsorption, gas scrubbing or catalytic treatment to obtain purified carbon dioxide,

[0068] Feeding of hydrogen gas together with the purified CO2 gas stream into a RWGS reaction zone and conversion of the reactants according to the principle of the RWGS reaction to a product gas mixture of water vapor, CO and optionally by-products, in particular lower hydrocarbons, particularly preferably methane,

[0069] Separation of unreacted carbon dioxide from the gas mixture obtained from the separation of the RWGS reaction, in particular by means of amine scrubbing, and recycling of the unreacted carbon dioxide to the RWGS reaction,

[0070] Separation of the hydrogen not converted in the RWGS reaction from the gas mixture of carbon monoxide and hydrogen obtained after the separation, in particular using a cold box, and optionally recycling the hydrogen to the RWGS reaction,

[0071] Removal of the remaining carbon monoxide from the separation.

[0072] The CCE source for providing the CCL gas stream can be, for example, the CO2 emitted during the provision of heat energy for the process according to the invention (e.g. for the RWGS reaction), the CO2 obtained during air separation or CO2 from another external CCL source.

[0073] An "external CCL source" contributes CO2 that is not emitted by the process according to the invention or its embodiments. An external CO2 source would be, for example, the CO2 that is produced in the exhaust gas during cement production or during the combustion of fuels (e.g., waste incineration), or CO2 that is extracted from the air. This CO2 from an external CCL source is produced, within the scope of a preferred embodiment of the process according to the invention, by absorbing a CO2 portion from (i) process gases or exhaust gases selected from at least one process selected from cement production, H2 production, or combustion, and / or (ii) from air by introducing it into alkali metal hydroxide solution, for example, potassium hydroxide solution. This forms potassium bicarbonate, which can subsequently be thermally decomposed back into CO2 and potassium hydroxide solution. The CO2 released in this process is then fed to the process according to the invention for the synthesis of carbon monoxide.

[0074] The RWGS reaction is preferably carried out in the reaction zone at a temperature > 650°C, particularly preferably > 700°C, most preferably > 750°C.

[0075] The RWGS reaction is preferably carried out in the presence of at least one catalyst. This is particularly preferably selected from at least one compound from the group:

[0076] (I) Mixed metal oxides of the formula A(iwx)A' w A"xB(iyz)B'yB"zO3-deita where:

[0077] A, A' and A" are independently selected from the group: Mg, Ca, Sr, Ba, Li, Na, K, Rb, Cs, Sn, Sc, Y, La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Ti, Lu, Ni, Co, Pb, Bi and / or Cd; and

[0078] B, B' and B" are independently selected from the group: Cr, Mn, Fe, Bi, Cd, Co, Cu, Ni, Sn, Al, Ga, Sc, Ti, V, Nb, Ta, Mo, Pb, Hf, Zr, Tb, W, Gd, Yb, Mg, Li, Na, K, Ce and / or Zn; and

[0079] 0 < w < 0.5; 0 < x < 0.5; 0 < y < 0.5; 0 < z < 0.5 and - 1 < delta < I ;

[0080] (II) Mixed metal oxides of the formula A(iwx)A' w A"xB(iyz)B'yB"zO3-deita where:

[0081] A, A' and A" are independently selected from the group: Mg, Ca, Sr, Ba, Li, Na, K, Rb, Cs, Sn, Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, Ti, Lu, Ni, Co, Pb and / or Cd; and

[0082] B is selected from the group: Cr, Mn, Fe, Bi, Cd, Co, Cu, Ni, Sn, Al, Ga, Sc, Ti, V, Nb, Ta, Mo, Pb, Hf, Zr, Tb, W, Gd, Yb, Mg, Cd, Zn, Re, Ru, Rh, Pd, Os, Ir and / or Pt; and B' is selected from the group: Re, Ru, Rh, Pd, Os, Ir and / or Pt; and B" is selected from the group: Cr, Mn, Fe, Bi, Cd, Co, Cu, Ni, Sn, Al, Ga, Sc, Ti, V, Nb, Ta, Mo, Pb, Hf, Zr, Tb, W, Gd, Yb, Mg, Cd and / or Zn; and

[0083] 0 < w < 0.5; 0 < x < 0.5; 0 < y < 0.5; 0 < z < 0.5 and - 1 < delta < 1 ;

[0084] (III) mixtures of at least two different metals M1 and M2 on a support comprising an oxide of Al, Ce and / or Zr doped with a metal M3; where: M1 and M2 are independently selected from the group: Re, Ru, Rh, Ir, Os, Pd and / or Pt; and

[0085] M3 is selected from the group: Sc, Y, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and / or Lu;

[0086] (IV) Mixed metal oxides of the formula LOx(M( y / Z )Al(2-y / z)O3)z; where:

[0087] L is selected from the group: Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Sc, Y, Sn, Pb, Pd, Mn, In, Ti, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and / or Lu; and

[0088] M is selected from the group: Ti, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Re, Fe, Ru, Os, Co, Rh, Ir, Ni, Pd, Pt, Zn, Cu, Ag and / or Au; and

[0089] 1 < x < 2; 0 < y < 12; and 4 < z < 9;

[0090] (V) Mixed metal oxides of the formula LO(A12O3) Z ; where:

[0091] L is selected from the group: Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Sc, Y, Sn, Pb, Mn, In, Ti, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and / or Lu; and

[0092] 4 < z < 9;

[0093] (VI) oxide catalyst comprising Ni and Ru.

[0094] (VII) metal M1 and / or at least two different metals M1 and M2 on and / or in a support, wherein the support is a carbide, oxycarbide, carbonitride, nitride, boride, silicide, germanide and / or selenide of the metals A and / or B; where:

[0095] Ml and M2 are independently selected from the group: Cr, Mn, Fe, Co, Ni, Re, Ru, Rh, Ir, Os, Pd, Pt, Zn, Cu, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and / or Lu; and A and B are independently selected from the group: Be, Mg, Ca, Sc, Ii, V, Cr, Mn, Fe, Co, Ni, Y, Zr, Nb, Mo, Hf, Ta, W, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and / or Lu; and / or

[0096] Reaction products of (I), (II), (III), (IV), (V), (VI) and / or (VII) in the presence of carbon dioxide, hydrogen, carbon monoxide and / or water at a temperature of > 700 °C.

[0097] In an equally preferred embodiment of the process, the methanol provided for the preparation of acetone in the process according to the invention is provided from carbon monoxide, the carbon monoxide being a product of an electrochemical partial reduction of carbon dioxide to carbon monoxide. In this embodiment, to provide CO, a CO2 gas stream is introduced into an electrolysis device and reduced to carbon monoxide at an electrode, preferably at a gas diffusion electrode (particularly preferably using electrical energy generated from renewable energy). This electrochemical partial reduction is also referred to below as CO2 electrolysis.

[0098] CO2 electrolysis, for example, can be a high-temperature electrolysis process, which operates at temperatures exceeding 600°C, possibly with the addition of water to produce synthesis gas. High-temperature electrolysis processes are generally well-known and commercially available, for example, from Haldor Topsoe, eCOs®. During high-temperature electrolysis, oxygen is produced at the anode.

[0099] If the CCL electrolysis is operated as low-temperature electrolysis, the electrolysis takes place at a temperature below 150°C.

[0100] In all CCL electrolysis processes, the CO2 gas is fed into the cathode chamber.

[0101] In the case of low-temperature electrolysis, CO2 is converted, in particular, at a gas diffusion electrode to carbon monoxide and optionally hydrogen. Those skilled in the art are familiar with electrodes and a method for carrying out the electrochemical reduction of CO2, for example, from WO 2021 / 069470 A. The electrochemical reduction of CO2 is preferably carried out according to a process described in WO 2021 / 069470 A. This document is expressly incorporated herein by reference in its entirety. In this preferred electrolytic process for producing carbon monoxide, carbon monoxide, optionally hydrogen, and chlorine are obtained by the electrochemical conversion of carbon dioxide and alkali metal chloride solution.This preferred electrolysis process is characterized in that the carbon dioxide is electrochemically reduced at a gas diffusion electrode as cathode in an aqueous alkali chloride-containing solution as catholyte and at the same time chlorine is anodically generated from an aqueous alkali chloride-containing solution as anolyte, wherein the alkali salt of carbonic acid formed in the catholyte, selected from alkali carbonate, alkali hydrogen carbonate or mixtures thereof, is then reacted with hydrogen chloride to form carbon dioxide and alkali chloride and the carbon dioxide released in this process is returned to the cathode compartment to the gas diffusion electrode and the alkali chloride produced is returned optionally to the anode compartment and / or to the cathode compartment.

[0102] Following the established principles, a MEA (membrane electrode assembly) concept can also be used in low-temperature electrolysis. A catalyst is applied to the membrane. A gas diffusion layer placed in front of it regulates gas and liquid transport. This can occur on both the anode and cathode sides. It is also possible to place a gas diffusion electrode in direct contact with the membrane.

[0103] The gas diffusion electrode used can be installed in the electrolysis cell in either a zero-gap or a finite-gap configuration. A preferred configuration for low-temperature electrolysis of CO2 is described in WO 2020 / 057998 A1, which is expressly incorporated by reference.

[0104] An excess of CO2 can be fed into the cathode chamber, or rather the gas diffusion electrode installed therein. Excess means introducing more CO2 than is necessary for stoichiometric conversion due to the flowing electric current. Thus, a gas mixture consisting of unreacted CO2, CO, and H2 emerges from the cathode chamber.

[0105] In a further embodiment of CO2 electrolysis, it is preferred if the electrical energy used is electrical energy produced from renewable energy, in particular electrical energy produced from wind power, solar energy, or hydropower. If the carbon monoxide used to produce the methanol is a product of at least one of the aforementioned processes, at least one of the processes known to those skilled in the art for this purpose, starting from CO2-containing synthesis gas, can be used to convert the CO to methanol.

[0106] If CO is not already produced directly as synthesis gas in a mixture with sufficient hydrogen from step ii-1), hydrogen gas is added to the CO before conversion to methanol to obtain synthesis gas if a sufficient amount of hydrogen gas is insufficient. This hydrogen gas, which is additionally added to the CO as part of the preparation of methanol, is preferably provided by electrolysis, in particular by chlor-alkali electrolysis or water electrolysis. Water electrolysis can be carried out using state-of-the-art systems. Technical systems for alkaline water electrolysis as well as for polymer electrolyte-based electrolysis, so-called PEM electrolysis, are well known and commercially available. The principles of water electrolysis are described as an example in Chapter 6.3.4 in Volkmar M. Schmidt's "Elektrochemische Verfahrenstechnik" (2003 Wiley-VCH-Verlag; ISBN 3-527-29958-0).In a further embodiment, it is preferred if the electrical energy used for the electrolysis to produce hydrogen is electrical energy produced from renewable energy, in particular electrical energy produced from wind power, solar energy or hydropower.

[0107] Particularly preferred is an embodiment in which the methanol to be provided for the process according to the invention was produced as a process product using renewable energy, preferably at a geographical location with good availability of renewable energy, in order to subsequently provide this methanol for the process according to the invention either by delivery via transport in containers or via methanol stream as part of a continuous process. For provision as part of a continuous process, the methanol production is preferably in fluid communication with the production of acetone, e.g., via a pipeline.

[0108] Methanol production plants can be licensed on the market, for example, from Air Liquide, Johnson Matthey, and other companies. An overview of conventional methanol production from synthesis gas is published, for example, in Ott et al., Methanol in: Ullmann's Encyclopedia of Industrial Chemistry, 2012, Wiley-VCH Verlag, Weinheim (doi 10.1002 / 14356007. al6_465.pub3), which is expressly incorporated by reference.

[0109] The methanol provided as described above in step a) i) is converted to acetone in step a) ii) of the process according to the invention for providing the acetone by a process comprising at least the following steps:

[0110] Providing propene as a product of a process comprising at least the following steps: ii-1) converting the previously provided methanol to a product mixture containing dimethyl ether, water, and methanol; ii-2) converting starting material containing dimethyl ether, water, and methanol, each from the aforementioned product mixture, at a temperature of more than 200°C by contact with a catalyst, preferably with at least one zeolite compound, to propene;

[0111] Conversion of the propene by at least ii-3) oxidation of the propene to acetone.

[0112] Steps ii-1) and ii-2) are part of the methanol-to-propylene process (also called the MTP process). The MTP process was first developed by Lurgi.

[0113] In an MTP process, for example, gaseous methanol is converted over a catalyst in a reactor to form a product mixture containing dimethyl ether, water, and methanol as defined in step ii-1) of the process according to the invention. Suitable reactors for this purpose include, for example, a fixed-bed reactor or a fluidized-bed reactor.

[0114] In a preferred embodiment of the process according to the invention, the conversion of the methanol provided according to step a) ii-1) is carried out by contacting the methanol, preferably the methanol in the gas phase, with a catalyst.

[0115] A particularly preferred catalyst for converting the methanol in step ii-1) is, for example, AhCh granules, as described in the publications EP 0 448 000 B1 or DE 197 23 363 A1. Before converting the methanol in step a) ii-1), the methanol provided is preferably brought to a temperature in the range of 200°C to 350°C, and the conversion is carried out using this appropriately tempered methanol. The product mixture comprising dimethyl ether, methanol, and water preferably has a temperature of 350°C to 450°C after the conversion.

[0116] The product mixture from step ii-1), in particular in the form of a gas stream, is introduced, optionally after carrying out optional purification steps, as starting material for step ii-2), for example, into a further reactor and converted there to propene over a catalyst. A suitable catalyst is, for example, the catalyst marketed by Clariant under the trade name MTPROP®, or a zeolite compound as a catalyst, as described, for example, in US Pat. No. 7,015,369 B2 in column 1, lines 43-52, and in Examples 1 and 2 thereof. Preferably, in a further embodiment of the process according to the invention, the starting material is converted to propene by contact with a zeolite compound as a catalyst.

[0117] It is preferred if in step ii-2) the starting material is reacted at a temperature of 350°C to 600°C, in particular at a temperature of 380°C to 550°C.

[0118] The propene provided by step ii-2) of the process according to the invention is oxidized to acetone according to step ii-3), optionally after the removal of secondary constituents. Furthermore, in one embodiment of step b) of the process according to the invention, as explained further below, it may be preferred to use propene provided by step ii-2) in the provision of phenol according to step b) via a cumene intermediate in a cumene oxidation to obtain phenol and acetone (vide infra).

[0119] The oxidation step ii-3) of the propene according to the process of the invention can be carried out, for example, by at least one of the following methods:

[0120] 1) according to the Wacker-Hoechst process by reacting propene and water on a catalyst system of palladium(II) chloride and copper(II) chloride to form acetone;

[0121] 2) Hydroxylation of propene with water to 2-propanol and subsequent catalytic dehydrogenation of 2-propanol to acetone;

[0122] 3) Conversion of propene to cumene and carrying out the cumene hydroperoxide process (Hock process) or conversion of propene to diisopropylbenzene and carrying out the cumene hydroperoxide process with diisopropylbenzene hydroperoxide instead of cumene hydroperoxide, in each case to obtain acetone.

[0123] These methods and their implementation are familiar to the person skilled in the art, as described, for example, in the publication Weber et al., Acetone in: Ullmann's Encyclopedia of industrial chemistry, 2013, Wiley-VCH Verlag, Weinheim (doi 10.1002 / 14356007. a01_079.pub4), to which reference is expressly made in full.

[0124] In addition, in the context of the process according to the invention, in addition to the provision of said acetone, phenol is provided in a step b), wherein the phenol provided is a process product of at least one production process which comprises at least the following steps: i) Provision of at least one organic, aromatic compound according to formula

[0125] (I), wherein

[0126] R 1 represents a hydrogen atom, a hydroxyl group, methyl, carboxyl, carboxylate or - CHR 3 R 4 where R 3 and R 4 independently of one another represent a (Ci-Csj-alkyl group or together with the remaining molecule form an aliphatic hydrocarbon cycle; and R 2 represents a hydrogen atom, methyl, carboxyl or carboxylate, with the proviso that if R 1 for -CHR 3 R 4 stands, R 2 a hydrogen atom and if R 1represents a hydroxyl group, R 2 represents a hydrogen atom, carboxyl or carboxylate, wherein said organic aromatic compound is a process product of a conversion of at least one starting material selected from at least one compound from the group formed by polymeric organic compounds, carbohydrates and methane from a biological source; and if in said organic aromatic compound from step i) according to formula (I) R 1 does not represent a hydroxyl group and R 2does not represent a hydrogen atom ii) at least one of steps ii-1) and / or ii-2) and / or iii-3) ii-1) reacting the organic, aromatic compound from step i) with propene to obtain a propan-2-yl substituted aromatic, organic compound as product; ii-2) oxidation of the organic, aromatic compound from step i) and / or the product from step ii-1), whereby at least one oxidized, aromatic, organic compound is obtained; ii-3) cleaving off at least one carbon-containing substituent of the organic, aromatic compound from step i) and / or of the oxidized, organic, aromatic compound from the oxidation according to step ii-2).

[0127] For the purposes of the invention, “phenol” is understood to mean the compound monohydroxybenzene.

[0128] In step b) of the process according to the invention, phenol is provided. According to the invention, for the provision of the phenol, it is sufficient if the provided phenol is an actual process product of at least steps i) and ii) mentioned under b). This means that for the execution of the step of providing the phenol, it is sufficient to simply remove the said phenol as a raw material from a storage container or from a feed line as part of a delivery in order to feed it at least to step c) of the process according to the invention. In this case, the bisphenol A producer, as the executor of the process according to the invention, does not itself carry out the steps i) and ii) mentioned under b) of the process according to the invention for the production of the phenol, but only ensures that the provided phenol was produced by applying at least steps i) and ii) mentioned under b) and is thus their process product.It is also possible according to the invention if, in order to provide the phenol, the steps i) and ii) mentioned at least under b) for producing the phenol are carried out as integral steps of a process according to the invention for producing bisphenol A by the bisphenol A producer and the phenol obtained thereby, optionally after intermediate storage in a storage container, is fed at least to step c) of the process according to the invention.

[0129] The options for providing, i.e. supplying or producing the specific phenol by the bisphenol A producer also apply to the following embodiments of steps i) and ii) mentioned under b).

[0130] The said organic, aromatic compound process product of formula (I) according to step b) i) is provided by converting at least one starting material selected from at least one compound from the group formed by polymeric organic compounds, carbohydrates and methane from biological sources. As a starting material, preferably at least one polymeric, organic compound is suitable, which is selected from at least one homopolymeric or copolymeric compound from the group lignin, polyester, polyamide, polyurethane (PUR), polyurea, polyisocyanurate (PIR), polycarbonate, preferably from at least one homopolymeric or copolymeric compound from the group polyurethane (PUR), polyisocyanurate (PIR). As a starting material, preferably at least one carbohydrate is suitable, selected from polysaccharide (such as particularly preferably starch or cellulose), trisaccharide (e.g.Kestose), as well as C-6 monosaccharide (such as particularly preferably glucose, setose or mannose), C-5 monosaccharide (such as particularly preferably xylose or arabinose).

[0131] In one embodiment of step b), in step b) i) at least one compound of formula (I) is provided in which R 1 and R 2independently of one another represent a hydrogen atom or a methyl group, preferably toluene and / or benzene for this embodiment. This at least one compound (in particular benzene and / or toluene) is obtained in a preferred embodiment by pyrolysis of the starting material at a temperature of 400 to 1000°C. The person skilled in the art understands pyrolysis to be thermal decomposition under low-oxygen conditions, the absence of oxygen being sought so that combustion of the organic material is avoided as far as possible. It is preferred if the gas phase contains less than 2 vol.% oxygen, in particular less than 1 vol.% oxygen, when carrying out the pyrolysis. Correspondingly suitable pyrolysis processes for obtaining xylene, toluene and benzene are known to the person skilled in the art, for example from the documents WO 2020 / 204707 A1 and US 9,328,297 B1.

[0132] In a particularly preferred embodiment of the pyrolysis, this at least one compound is provided as a process product of a process comprising at least the following steps:

[0133] Pyrolysis of organic material at a temperature of 600 to 1000°C to obtain gaseous pyrolysate and pyrolysis residue;

[0134] Contacting the gaseous pyrolysate with a heterogeneous catalyst to obtain a conversion product containing at least one aromatic organic compound having a molecular weight of less than 300 g / mol;

[0135] Processing of the conversion product to obtain the said compound of formula (I), in particular toluene or benzene.

[0136] A corresponding pyrolysis process for providing this product is described, for example, in WO 2020 / 204707 A1, which is expressly incorporated by reference in this application. Heterogeneous catalysts suitable for the process for producing the conversion product are also described therein. Suitable organic materials for pyrolysis include, for example, polysaccharides, lignin, wood, plastic waste, or at least one homopolymer or copolymer compound from the group consisting of polyester, polyamide, polyurethane (PUR), polyurea, polyisocyanurate (PIR), and polycarbonate.

[0137] In a further embodiment of step b), in step b) i) at least one compound of the above formula (I) is provided, in which R 1 and R 2independently of one another represent a hydrogen atom or a methyl group, particularly preferably toluene and / or benzene, wherein methane from a biological source is used as the starting material. The conversion of methane to aromatic hydrocarbons such as benzene is familiar to the person skilled in the art. Aromatic hydrocarbon, in particular benzene, is provided, for example, in a fluidized bed reactor or a fixed bed reactor by contact of methane with a catalyst with the addition of heat, wherein the catalyst was obtained by impregnating ZSM-5 (an open-pore zeolite) as a support with 4 wt. % molybdenum compound (B. Cook et al., Applied Catalysis A: General 365 (2009), 34-41). Likewise, an optimized process was described in the document WO2006 / 068814, in which the temperature required for the reaction is supplied to the process stream in intermediate heating sections.In this embodiment, the methane from biological sources can be used in the prior art processes analogously to the provision of aromatic hydrocarbons, in particular benzene.

[0138] The compound of the above formula (I) provided in the context of the embodiments of step b), in which R 1 and R 2 independently of one another represent a hydrogen atom or a methyl group, serves, for example, as a starting material for providing oxidized, aromatic, organic compound as a process product of step b) ii-2).

[0139] If at least one of the groups R 1 or R 2represent a methyl group, the methyl groups present in the compound of formula (I) are oxidized to carboxyl groups in step b) ii-2). This is carried out, for example, at 100-150°C in the presence of cobalt naphthalate and atmospheric oxygen. The oxidized, aromatic, organic compound obtained is decarboxylated according to step b) ii-3) with elimination of carbon dioxide, whereby phenol is obtained as a process product. An oxidative decarboxylation is carried out, for example, in molten reactant (at, for example, 230-240°C in the presence of atmospheric oxygen and steam and copper(II) benzoate as catalyst). The carbon dioxide obtained in the decarboxylation in step b) ii-3) can, for example, preferably be used in step a) of the process according to the invention as a carbon dioxide source to provide methanol.

[0140] If both groups R 1 and R 2according to formula (I) above, an oxidation can be carried out according to step b) ii-2) with introduction of a ring-bound hydroxyl group to obtain phenol. This can be done, for example, with oxygen, hydrogen peroxide, or N2O. This oxidation is preferably carried out with the addition of heat (e.g., at 600-800°C) using catalysts such as zeolite (e.g., of the ZSM-5 type) or titanium silicate (TS-1). This direct oxidation of benzene represents a possible, but not preferred, embodiment of step b) ii-2).

[0141] In a further, particularly preferred embodiment of step b), in step b) i) at least one compound of formula (I) as described above is provided, in which R 1 and R 2represent hydrogen (benzene), wherein the benzene provided in this preferred embodiment is introduced as an organic, aromatic compound in step b) ii-1), wherein steps a) and b) converge here, so that steps b) ii-1) and b) ii-3) are part of the oxidation step ii-3) from step a) of the process, in which the propene provided in step a) ii-2) is reacted with benzene from step b) i) to form cumene and then the cumene hydroperoxide process (Hock process) is carried out as oxidation to obtain acetone and phenol as the provided process product. Therefore, a process is preferred in which, to carry out step b) ii-1), the benzene provided in step b) i) is introduced into the oxidation of propene in step a) ii-3) and is reacted there with the propene provided from step a) ii-2) to form cumene and then the cumene formed is oxidized to provide phenol and acetone.

[0142] The implementation of the cumene hydroperoxide process is known and familiar to the expert from various textbooks.

[0143] The entire process according to the embodiment with convergent steps b) ii-1) and b) ii-3) with the oxidation step ii-3) from step a) can thus be formulated as a process for the production of bisphenol-A for the production of polycarbonate, comprising at least the steps: a) providing propene, which is a process product of a process comprising at least the following steps: i) providing methanol, which is a process product of a process with at least the following steps: i-1) converting CO to methanol, wherein the CO is a process product of at least one partial reduction of CO2 to CO and / or a process product of at least one partial oxidation of organic material to CO, wherein at least one organic material is selected from at least one organic, solid compound, methane from a biological source or mixtures thereof;ii) Synthesis of propene from previously provided methanol by at least the following steps: ii-1) Conversion of the previously provided methanol to a product mixture containing dimethyl ether, water and methanol; ii-2) Conversion of starting material containing dimethyl ether, water and methanol, each from the aforementioned product mixture, at a temperature of more than 200°C by contact with a catalyst, preferably with at least one zeolite compound as catalyst, to propene; b) Provision of acetone and phenol, which is a process product of at least one production process which comprises at least the following steps: i) Provision of benzene as at least one organic, aromatic compound according to formula (I); wherein

[0144] R 1 and R 2represent a hydrogen atom, wherein the benzene is a process product of a conversion of at least one starting material selected from at least one compound from the group formed by polymeric organic compounds, carbohydrates and methane from a biological source; ii) carrying out steps ii-1), ii-2) and iii-3) ii-1) reacting the benzene provided in step i) with propene provided in step a) ii) to obtain a propan-2-yl-substituted aromatic organic compound, in particular cumene, as product; ii-2) oxidizing the propan-2-yl-substituted aromatic organic compound, in particular cumene, from step ii-1), to obtain at least one aromatic organic hydroperoxide compound, in particular cumene hydroperoxide;ii-3) Eliminating acetone as at least one carbon-containing substituent of the aromatic, organic hydroperoxide compound from the oxidation according to step ii-2) to provide acetone and phenol; c) converting a mixture containing the provided acetone and the provided phenol to bisphenol-A;

[0145] Likewise, without convergence of steps a) and b), in carrying out a step b) ii-3), organic aromatic compounds of the formula (I) provided in step b) i) can be converted to phenol via an oxidation analogous to the cumene hydroperoxide process, in which R 1 for a group CHR 3 R 4 where R 3 and R 4 independently of one another represent a (Ci-C3)-alkyl group or together with the remaining molecule form an aliphatic hydrocarbon cycle and independently of this R 2are hydrogen. In such an embodiment, in step b) i) of the process, those corresponding organic aromatic compounds according to formula (I) are provided in which in R 1 the residues R 3 and R 4 are independently selected from methyl, ethyl, propyl or together with the remaining molecule form a 6-membered aliphatic hydrocarbon ring, in particular cyclohexyl. Process according to one of the preceding claims, characterized in that according to formula (I) R 1 as remainder -CHR 3 R 4 is selected from propan-2-yl, sec-butyl or cyclohexyl.

[0146] In a further embodiment of step b), in step b) i) at least one compound of formula (I) is provided in which R 1 for a hydroxyl group and R 2represents hydrogen (phenol). This includes, in particular, the preferred provision of phenol according to the invention as a product of a microbiological process. In this case, the provided phenol is particularly preferably obtained as a product of a process for phenol production in a recombinant host comprising the steps

[0147] Providing a recombinant host strain produced by methods according to WO 2014 / 076113 A1, to which reference is expressly made in its entirety,

[0148] Incubation of the recombinant host strain under fermentation conditions in the presence of at least one saccharide as starting material.

[0149] Preferred saccharides for this purpose are polysaccharides such as disaccharides (e.g. sucrose) or trisaccharides (e.g. kestose), as well as C-6 monosaccharides (such as glucose, setose or mannose) and C-5 monosaccharides (such as xylose or arabinose). Suitable host strains include, for example, those selected from a representative of the group consisting of bacteria, yeasts or fungi. Bacteria of the Escherichia coli strain are preferred, with E. coli BW25113, E. coli DHIOb, and E. coli LJ110 being particularly preferred. Likewise preferred are bacteria of the Pseudomonas putida strain, in particular Pseudomonas putida S12.

[0150] The recombinant host strains contain the necessary nucleic acid sequences specified in WO 2014 / 076113 A1.

[0151] For example, glucose can be converted into phenol by incubating the saccharide with the recombinant host.

[0152] In addition to the microbiological conversion of the starting material, the phenol can be provided according to a further embodiment of step b) i) from the conversion of the polymeric, organic compound lignin. This can be achieved by depolymerizing the lignin at, for example, 400°C and up to 300 bar pressure in the presence of nitrogen or CO2 (cf. Zurbel et al., Chem. Ing. Tech., 2019, 4, 484-493) and subsequent conversion of the resulting alkylmethoxyphenols, e.g., by the method described in Huang et al., ACS Catal. 2018, 8, 11184-11190.

[0153] In a further embodiment of step b), in step b) i) at least one compound of formula (I) is provided in which R 1 represents a carboxyl group or carboxylate and R 2represents a hydroxyl group (salicylic acid / salicylate) or hydrogen (benzoic acid / benzoate). Phenol is provided according to this embodiment as a process product of a decarboxylation according to step b) ii-3). This decarboxylation can be carried out, for example, as described above (vide supra).

[0154] The acetone prepared in step a) and the phenol prepared in step b) are mixed. A mixture containing this acetone and this phenol is converted to bisphenol A in step c) of the process according to the invention.

[0155] The conversion to bisphenol A is carried out by a process known to those skilled in the art, for example as described in WO 00 / 35847, EP 1 728 777 A1, or US Pat. No. 2,775,620. The conversion is preferably carried out using at least one catalyst (in particular selected from hydrogen chloride, polystyrenesulfonate, or crosslinked polystyrenesulfonate) at a temperature of 45°C to 110°C, in particular 50°C to 80°C.

[0156] When reacting the mixture, it is again preferred if the mixture used contains phenol and acetone in a molar ratio of phenol to acetone in a range from 2.1 to 1 to 15 to 1, in particular from 5 to 1 to 12 to 1.

[0157] Particularly preferably, the catalyst (in particular at least one polystyrenesulfonate compound) is located in the reaction zone of a reactor on a fixed bed which is contacted with the said mixture for reaction.

[0158] The reaction of phenol and acetone in step c) is most preferably carried out in the presence of at least one sulfonic acid ion exchanger and at least one sulfur-containing cocatalyst to form a product mixture containing bisphenol A, which is optionally subsequently processed to obtain purified bisphenol A. Gel-like (microporous) or macroporous, sulfonated crosslinked polystyrene resins (acidic ion exchangers) are used as acidic catalysts, which can be either monodisperse or heterodisperse. Divinylbenzene is normally used as the crosslinker, but other crosslinkers such as divinylbiphenyl can also be used. In addition to the catalyst, a cocatalyst is used. This is usually a thiol that bears at least one SH function and positively influences both the selectivity and the reactivity of the reaction.The cocatalyst can be either homogeneously dissolved in the reaction solution or fixed to the catalyst itself. Homogeneous cocatalysts include mercaptopropionic acid, hydrogen sulfide, alkyl sulfides, or alkylsilylthiols, such as ethyl sulfide or silylmethanethiol, and similar compounds. Fixed cocatalysts include aminoalkylthiols and pyridylalkylthiols, which are ionically bound to the catalyst. The SH function can be protected and released only during or after fixation to the catalyst, as is the case with dimethylthiazolidine and alkylcarbamoylalkylthioesters. Likewise, the cocatalyst can be covalently bound to the catalyst as an alkyl or arylthiol or be a component of the catalyst. Two or more of the described cocatalysts can also be used together.The purification of the bisphenol A obtained after the reaction is carried out, for example, as described in the document EP 1 728 777 A1.

[0159] The method according to the invention is illustrated by way of example in Fig. 1. The reference numerals have the following meaning:

[0160] A = organic material (as organic solid compound and / or methane from biological source) or CO2

[0161] B = Oxidizing agent (such as oxygen gas) or reducing agent (such as hydrogen gas or electric current)

[0162] C = product gas mixture containing CO

[0163] D = Synthesis gas

[0164] E = Propen

[0165] F = Bisphenol A

[0166] G = starting material consisting of at least a polymeric, organic compound or carbohydrate or bio-methane

[0167] H = precursor according to formula (I), if not R 1= hydroxyl group and R 2 = Hydrogen atom I = Phenol

[0168] 1 = CO provision by partial reduction of CO2 or partial oxidation of the organic material

[0169] 2 = Conversion of CO to methanol

[0170] 3 = Provision of methanol from 2

[0171] 4 = Conversion of methanol to propene E using the MTP process

[0172] 5 = Oxidation of propene E to acetone

[0173] 6 = Provision of acetone

[0174] 7 = Synthesis of bisphenol-A using provided acetone and provided

[0175] phenol

[0176] 8 = Provision of phenol

[0177] 9 = Conversion of the starting material G to phenol or a precursor thereof according to

[0178] Formula (I)

[0179] 10 = Conversion of the precursor H from 9 to phenol

[0180] Arrows in Figures 1, 2, and 3 symbolize the flow of materials, energy, or heat between process steps or device components in which the corresponding process steps take place. Process features drawn with dashed lines symbolize process steps of a process whose product is the materials provided in steps 6 and 8. A solid dot represents a process gas conditioning system, including an optional mixing device.

[0181] Fig.l shows a process for the production of bisphenol-AF for the production of polycarbonate, comprising at least the steps: a) Provision of acetone, which is a process product of a process comprising at least the following steps: i) Provision 3 of methanol, which is a process product of a process with at least the following steps: i-1) Conversion 2 of CO, for example in a mixture with hydrogen gas as

[0182] Synthesis gas D, to methanol, wherein the CO 3 provided for this purpose is a process product of at least one partial reduction 1 of CO 2 A with reducing agent B to CO and / or a process product of at least one partial oxidation 1 of organic material with oxidizing agent B to CO, wherein at least one organic material A is selected from at least one organic, solid compound, methane from a biological source or mixtures thereof; ii) Synthesis of acetone from previously provided methanol 3 by at least the following steps:

[0183] Providing 4 propene as a product of a process comprising at least the following steps: ii-1) converting the previously provided methanol 3 into a

[0184] Product mixture containing dimethyl ether, water and methanol; ii-2) converting starting material containing dimethyl ether, water and methanol, each from the aforementioned product mixture, at a temperature of more than 200°C by contact with a catalyst, preferably with at least one zeolite compound as catalyst, to propene E; and

[0185] Conversion of propene E by at least ii-3) oxidation 5 of the propene E to acetone; b) provision 8 of phenol, which is a process product of at least one production process which comprises at least the following steps: i) provision of at least one organic aromatic compound according to formula (I), wherein

[0186] R 1 represents a hydrogen atom, a hydroxyl group, methyl, carboxyl, carboxylate or -CHR 3 R 4 where R 3 and R 4independently of one another represent a (Ci-C3)-alkyl group or together with the remaining molecule form an aliphatic hydrocarbon cycle; and

[0187] R 2 represents a hydrogen atom, methyl, carboxyl or carboxylate, with the proviso that if R 1 for -CHR 3 R 4 stands, R 2 represents a hydrogen atom and if R 1 represents a hydroxyl group, R 2 represents a hydrogen atom, carboxyl or carboxylate, wherein said organic aromatic compound is a process product of a conversion of at least one starting material G selected from at least one compound from the group formed by polymeric organic compounds, carbohydrates and methane from a biological source; and if said organic aromatic compound from step i) according to formula (I) is a precursor H, in which R 1 does not represent a hydroxyl group and R 2does not represent a hydrogen atom ii) at least one of steps ii-1) and / or ii-2) and / or iii-3) for converting the precursor 10 ii-1) reacting the precursor H from step i) with propene to obtain a propan-2-yl substituted aromatic organic compound as product; ii-2) oxidizing the precursor H from step i) and / or the product from step ii-1), whereby at least one oxidized aromatic organic compound is obtained; ii-3) cleaving off at least one carbon-containing substituent of the precursor H from step i) and / or the oxidized organic aromatic compound from the oxidation according to step ii-2); c) converting a mixture containing the provided acetone and the provided phenol to bisphenol-AF.

[0188] The bisphenol A obtained from step c) of the bisphenol A production process according to the first aspect of the invention or its embodiments, and optionally processed, is suitable for the production of polycarbonate. Therefore, a second aspect of the invention is a process for the production of polycarbonate, comprising at least the following steps:

[0189] Production of bisphenol-A according to the process for producing bisphenol-A of the first subject matter of the invention;

[0190] Preparation of at least one carbonic acid derivative selected from phosgene, carbonic acid diesters or mixtures thereof;

[0191] Reaction of said carbonic acid derivative with at least one diphenol, with the proviso that at least the previously prepared bisphenol A is used as diphenol.

[0192] The production of bisphenol A is described in the first aspect of the invention. All embodiments of the first aspect can be used analogously for the process of the second aspect of the invention, in accordance with the preference given to individual process steps described therein.

[0193] The production of the carbonic acid derivative phosgene from at least carbon monoxide and chlorine is known, for example from EP 0 881 986 A1, EP 1 640 341 A2, DE 332 72 74 A1, GB 583 477 A, WO 97 / 30932 A1, WO 96 / 16898 A1, or US 6,713,035 B1. It has proven preferable according to the invention to provide the carbon monoxide (CO) for phosgene production by a process in which the carbon monoxide is a process product of at least one partial reduction of CO2 to CO and / or a process product of at least one partial oxidation of organic material to CO, wherein at least one organic material is selected from at least one organic, solid compound, methane from a biological source or mixtures thereof. Correspondingly suitable and preferred embodiments of this provision of CO are analogous to those described for step a) i-1) of the first aspect of the invention (vide supra).

[0194] The carbonic acid derivative carbonic acid diester is produced, for example, by producing phosgene and subsequently reacting the phosgene with an organic monohydroxy compound, such as phenol, or by a catalytic reaction of phenol and carbon monoxide, as well as oxygen, as described in the publication DE 10 2009 011874 A1. The use of carbonic acid diphenyl ester (also: diphenyl carbonate) as the carbonic acid diester is preferred according to the invention.

[0195] The polycarbonate is produced in a known manner from at least one diphenol, with at least bisphenol A produced by said process being used as such a diphenol (diphenol is also referred to below as a dihydroxyaryl compound), said carbonic acid derivative, optionally chain terminators, and optionally branching agents. To produce polyestercarbonate, a portion of said carbonic acid derivative is replaced by aromatic dicarboxylic acids or derivatives of dicarboxylic acids, specifically by aromatic dicarboxylic acid ester structural units, depending on the carbonate structural units to be replaced in the aromatic polycarbonates.

[0196] In the case of homopolycarbonates, only said bisphenol A is used as the diphenol in the process according to the invention of the second aspect; in the case of the production of copolycarbonates, said bisphenol A is used together with at least one additional diphenol. Preferably usable additional diphenols are selected from at least one diphenol from the group consisting of 4,4'-dihydroxydiphenyl, 1,1-bis-(4-hydroxyphenyl)-phenylethane, 2,2-bis(3,5-dimethyl-4-hydroxyphenyl)-propane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, and 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane (bisphenol TMC (BPTMC)).

[0197] Aromatic dicarboxylic acids suitable for the production of polyester carbonate are, for example, orthophthalic acid, terephthalic acid, isophthalic acid, tert-butylisophthalic acid, 3,3'-diphenyldicarboxylic acid, 4,4'-diphenyldicarboxylic acid, 4,4-benzophenonedicarboxylic acid, 3,4'-benzophenonedicarboxylic acid, 4,4'-diphenyl ether dicarboxylic acid, 4,4'-diphenylsulfonedicarboxylic acid, 2,2-bis-(4-carboxyphenyl)-propane, trimethyl-3-phenylindane-4,5'-dicarboxylic acid.

[0198] Of the aromatic dicarboxylic acids, terephthalic acid and / or isophthalic acid are particularly preferred.

[0199] Derivatives of dicarboxylic acids are the dicarboxylic acid dihalides and the dicarboxylic acid dialkyl esters, in particular the dicarboxylic acid dichlorides and the dicarboxylic acid dimethyl esters.

[0200] The replacement of the carbonate groups by the aromatic dicarboxylic acid ester groups occurs essentially stoichiometrically and quantitatively, so that the molar ratio of the reactants is also reflected in the finished polyester carbonate. The incorporation of the aromatic dicarboxylic acid ester groups can occur both randomly and blockwise.

[0201] Processes for reacting diphenol and said carbonic acid derivative are known to the person skilled in the art.

[0202] Polycarbonate can be produced, for example, in a stirred reactor or screw extruder by transesterification of diphenyl carbonate with bisphenol A in the melt at approximately 200–350°C under slightly reduced pressure (e.g., 0.1 to 20 kPa). Phenol is distilled off, and polycarbonate is obtained in the form of strands, which are then pelletized or granulated (V. Serini, "Polycarbonates," in: Ullmann's Encyclopedia of Industrial Chemistry, Wiley-VCH, Weinheim, 2000).

[0203] Polycarbonate, for example, can also be produced by reacting phosgene with at least bisphenol A as at least one diphenol. This method is preferred according to the invention. According to a continuous interfacial process for producing polycarbonates known from EP 0 304 691 A2, an aqueous phase comprising diphenol(s) and the exact amount of alkali hydroxide is combined with an organic phase containing phosgene as the said carbonic acid derivative in a tube using a static mixer. The phosgene excess is very high at 20 to 100 mol%, and the residence time in the reaction tube for the first reaction step is 10 to 75 s. This process can only produce prepolymers with a molecular weight of 4000 to 12000 g / mol. This is followed by a further condensation using at least one catalyst to achieve the desired molecular weight.Suitable catalysts are tertiary amines and onium salts. Tributylamine, triethylamine, and N-ethylpiperidine are preferred.

[0204] The amine catalyst used can be open-chain or cyclic; triethylamine and N-ethylpiperidine are particularly preferred. The catalyst is preferably used as a 1 to 55 wt.% solution.

[0205] Onium salts are understood here to be compounds such as NR4X, where R can be an alkyl and / or aryl radical and / or H and X is an anion, for example a chloride ion, a hydroxide ion or a phenolate ion.

[0206] The fully reacted, at least two-phase reaction mixture, containing at most traces (< 2 ppm) of aryl chlorocarbonic acid esters, is allowed to settle for phase separation. The aqueous alkaline phase (reaction wastewater) is separated, and the organic phase is extracted with dilute hydrochloric acid and water. The combined aqueous phases are fed to wastewater treatment, where solvent and catalyst components are separated by stripping or extraction and recycled. Subsequently, after adjustment to a specific pH value of, for example, 6 to 8, e.g., by adding hydrochloric acid, any remaining organic impurities such as monophenol and / or unreacted diphenol(s) are removed by treatment with activated carbon, and the aqueous phase is fed to chlor-alkali electrolysis.

[0207] In another variant of the processing, the reaction waste water is not combined with the washing phases, but after stripping or extraction to separate solvents and catalyst residues, it is adjusted to a certain pH value of e.g. 6 to 8, e.g. by adding hydrochloric acid and, after separation of the remaining organic impurities such as monophenol and / or unreacted diphenol or unreacted diphenols by treatment with activated carbon, it is fed to the chlor-alkali electrolysis.

[0208] The washing phases can, if necessary, be returned to the synthesis after removal of the solvent and catalyst components by stripping or extraction.

[0209] Phosgene can be used in liquid, gaseous or dissolved form in an organic solvent.

[0210] After adding the phosgene, it may be advantageous to mix the organic phase and the aqueous phase for a certain time before adding any branching agent (provided this is not added together with the diphenolate), chain terminator, and catalyst. Such a post-reaction time can be advantageous after each addition. These post-stirring times, if used, are between 10 seconds and 60 minutes, preferably between 30 seconds and 40 minutes, and particularly preferably between 1 and 15 minutes.

[0211] The organic phase containing the polycarbonate must now be cleaned of all alkaline, ionic or catalytic contamination.

[0212] Even after one or more settling processes, optionally supported by passages through settling tanks, stirred tanks, coalescers or separators or combinations of these measures - where water may be added in each or some separation steps, possibly using active or passive mixing devices - the organic phase still contains portions of the aqueous alkaline phase in fine droplets as well as the catalyst, usually a tertiary amine.

[0213] After this rough separation of the alkaline, aqueous phase, the organic phase is washed one or more times with dilute acids, mineral, carboxylic, hydroxycarboxylic, and / or sulfonic acids. Aqueous mineral acids are preferred, especially hydrochloric acid, phosphorous acid, and phosphoric acid, or mixtures of these acids. The concentration of these acids should be in the range of 0.001 to 50 wt.%, preferably 0.01 to 5 wt.%.

[0214] The organic phase is then repeatedly washed with demineralized or distilled water. The organic phase, which may be dispersed with parts of the aqueous phase, is separated after the individual washing steps using settling tanks, stirred tanks, coalescers, separators, or combinations of these measures. The wash water can be added between the washing steps, if necessary, using active or passive mixing devices.

[0215] Between these washing steps or after washing, acids, preferably dissolved in the solvent underlying the polycarbonate solution, can optionally be added. Hydrogen chloride gas and phosphoric acid or phosphorous acid are preferred here, which can optionally also be used as mixtures. The purified polycarbonate solution thus obtained should contain no more than 5 wt.%, preferably less than 1 wt.%, and most preferably less than 0.5 wt.% water after the final separation step.

[0216] To isolate the polycarbonate, the first step involves exchanging the low-boiling solvent, such as methylene chloride, for a high-boiling solvent, such as chlorobenzene. This is done using an exchange column.

[0217] The isolation of the polycarbonate from the solution containing the high-boiling solvent, for example chlorobenzene, can be achieved by evaporating the solvent using temperature, vacuum or a heated carrier gas.

[0218] If the concentration of the polycarbonate solution and possibly also the isolation of the polycarbonate takes place by distilling off the solvent, if necessary by superheating and depressurization, this is referred to as a ‘flash process’, see also ‘Thermal separation processes’, VCH Verlagsanstalt 1988, p. 114; if instead a heated carrier gas is sprayed together with the solution to be evaporated, this is referred to as ‘spray evaporation / spray drying’, as described by way of example in Vauck, “Grundoperationenchemischer Verfahrenstechnik”, Deutscher Verlag für Grundstoffindustrie 2000, 11th edition, p. 690. All of these processes are described in the patent literature and textbooks and are familiar to the person skilled in the art.

[0219] Highly concentrated polycarbonate melts are obtained by removing the solvent through heat (distillation) or by the technically more effective flash process. In the well-known flash process, a polycarbonate solution is repeatedly heated under slight excess pressure to temperatures above the boiling point at atmospheric pressure. These solutions, which are superheated relative to atmospheric pressure, are then released into a vessel with a lower pressure, e.g., at atmospheric pressure. It may be advantageous not to allow the concentration stages, or in other words the temperature stages of the superheating, to become too large, but rather to choose a two- to four-stage process.

[0220] From the highly concentrated polycarbonate melt thus obtained, the solvent residues can be removed either directly from the melt by evaporation extrusion (BE-A 866 991, EP-A 0 411 510, US-A 4 980 105, DE-A 33 32 065), thin-film evaporators (EP-A-0 267 025), falling-film evaporators, strand evaporators or by friction compaction (EP-A-0 460 450), optionally with the addition of an entraining agent such as nitrogen or carbon dioxide or using a vacuum (EP-A 0 039 96, EP-A 0 256 003, US-A 4 423 207), or alternatively by subsequent crystallization (DE-A 34 29 960) and heating of the solvent residues in the solid phase ( US-A 3 986 269, DE-A 20 53 876).

[0221] Granules are obtained, if possible, by direct spinning of the melt followed by granulation, or by using discharge extruders from which the material is spun in air or under liquid, usually water. If extruders are used, additives can be added to the melt upstream of the extruder, if necessary using static mixers or by means of side extruders within the extruder.

[0222] The addition of additives to polycarbonate or to polycarbonate compounds serves to extend the service life or the color (stabilizers), to simplify processing (e.g. demolding agents, flow aids, antistatic agents) or to adapt the properties of the resulting polycarbonate material to specific loads (impact modifiers, such as rubbers; flame retardants, colorants, glass fibers).

[0223] A third subject matter of the invention is a multi-component system for producing bisphenol-A according to the aforementioned production process of the first subject matter of the invention, comprising i) a volume filled with acetone, which is a process product of step a) of the process of the first subject matter of the invention; ii) a volume filled with phenol, which is a process product of step b) of the process of the first subject matter of the invention; iii) at least one reactor for producing bisphenol-A, which contains at least one inlet for said acetone and at least one inlet for said phenol, wherein the inlet for said acetone is in fluid communication with the volume of said acetone and the inlet for said phenol is in fluid communication with the volume of said phenol.

[0224] A "fluid connection" is a part of a multi-component system that connects other parts of the system and through which a substance, which can exist in any state of aggregation, can be transported as a material flow from one part to the next, for example, a supply line in the form of a pipe. The term "fluidly connected" means that named parts of the multi-component system are connected to one another via a fluid connection.

[0225] The "volume filled with acetone" of the multicomponent system can, for example, be the volume of a storage container or the volume of a pipeline. If said volume is a storage container, it is preferred in a further embodiment if the multicomponent system additionally provides at least one unloading device for movable, sealed transport containers, which is in fluid communication with the inlet for said acetone of the reactor for producing bisphenol A.

[0226] In the case of delivery, the acetone is preferably provided as a process product within the meaning of said step a) of the process according to the invention in a mobile, enclosed transport container and, if necessary, transferred therefrom to storage containers for intermediate storage. Said mobile, enclosed transport container can, for example, be the tank of a tank car, a tanker, or a tank truck. "Enclosed" means that said transport container is closed at its device for filling or discharging the transported goods during transport.

[0227] For the purposes of the invention, a storage container is defined as a container that is tied to a fixed location, such as a tank farm. Storage containers are considered to be part of immovable fixed assets or are part of them.

[0228] In the case of delivery, the phenol is preferably provided as a process product within the meaning of said step b) of the process according to the invention in a mobile, enclosed transport container and, if necessary, transferred from it to storage containers for intermediate storage. Said mobile, enclosed transport container can, for example, be the tank of a tank car, a tanker, or a tank truck. "Enclosed" means that said transport container is closed at its device for filling or discharging the transported goods during transport.

[0229] All embodiments of step a) of the process according to the invention for producing bisphenol A are also valid for the multicomponent system mutatis mutandis.

[0230] All embodiments of step b) of the process according to the invention for producing bisphenol A are also valid for the multicomponent system, mutatis mutandis. A further subject matter is the use of a mixture containing acetone as a product of a process comprising at least steps a) i) and a) ii) described in the first subject matter of the invention, and phenol as a product of a process comprising at least steps b) i) and b) ii) described in the first subject matter of the invention, for producing bisphenol A.

[0231] All embodiments of step a) of the process according to the invention for producing bisphenol A are also valid for this use mutatis mutandis.

[0232] All embodiments of step b) of the process according to the invention for producing bisphenol A are also valid for this use mutatis mutandis.

[0233] The following examples are given by way of example to illustrate the invention, without limiting the invention to the disclosure content of the examples.

[0234] Examples

[0235] In Figs. 2 and 3 exemplary embodiments of the inventive

[0236] procedure is presented.

[0237] Example 1:

[0238] Figure 2 illustrates an embodiment of the method according to the invention. The reference numerals have the following meanings:

[0239] Al = CO2

[0240] Bl = hydrogen gas as a product of water electrolysis

[0241] C = product gas mixture containing CO

[0242] D = Synthesis gas

[0243] E = Propen

[0244] F = Bisphenol A

[0245] Gl = Plastic waste as polymeric, organic compounds

[0246] Hl = benzene as precursor according to formula (I), if not R 1 = hydroxyl group and R 2 = hydrogen atom

[0247] H2 = Cumene hydroperoxide as oxidized aromatic compound

[0248] 1 = Phenol

[0249] J = gaseous pyrolysate la = CO provided by RWGS

[0250] 2 = Conversion of CO and hydrogen gas Bl to methanol

[0251] 3 = Provision of methanol from 2

[0252] 4 = Conversion of methanol to propene using the MTP process

[0253] 5 = Oxidation of propene E to acetone

[0254] 6 = Provision of acetone

[0255] 7 = Synthesis of bisphenol-A using provided acetone and provided

[0256] phenol

[0257] 8 = Provision of phenol

[0258] 9 = Conversion of the starting material Gl to benzene as a precursor Hl

[0259] 9a = Pyrolysis to convert the starting material Gl into gaseous pyrolysate

[0260] 9b = catalytic conversion of the gaseous pyrolysate to

[0261] 10a = Conversion of the precursor from 9a to cumene hydroperoxide

[0262] 10b = Conversion of cumene hydroperoxide into acetone and phenol

[0263] 11 = Electrolysis of water using electrical current from renewable energy The synthesis 7 of bisphenol-A F is carried out after the provision of acetone 6. The provided acetone is necessarily a product of a process in which the acetone is produced via provided methanol 3 as an intermediate. In this case, at least carbon monoxide is obtained in a carbon monoxide-containing product gas stream C in a reverse-water-gas-shift reaction 1a (RWGS) by reducing carbon dioxide Al with hydrogen gas Bl obtained from a water electrolysis 11 and which, after passing through a process gas treatment (point in Fig.2) purification of the carbon monoxide from the product gas stream C and addition of hydrogen gas Bl, the synthesis gas D obtained is converted to methanol and this methanol is further converted in an MTP process 4 to propene E, wherein the propene E is first converted to cumene with benzene as precursor H1 for the oxidation 5 of the propene and the resulting propan-2-yl radical of the cumene is converted after oxidation in the 2-position to a 2-hydroperoxy-propan-2-yl radical of the cumene hydroperoxide H2 10a and then converted to acetone by means of oxidative cleavage 10b.

[0264] The synthesis 7 of bisphenol-A F is also carried out after the provision of phenol 8. The provided phenol is necessarily a product of a process in which the phenol is produced from benzene as precursor H1, where the benzene in turn is a product of a catalytic conversion 9b of gaseous pyrolysate J from a pyrolysis 9a of polymeric, organic compound Gl in the form of plastic waste. For the provided phenol, the benzene is first converted to cumene hydroperoxide 10a in an oxidation 5 of propene as described above, and then converted to phenol in the oxidative cleavage 10b.

[0265] Example 2:

[0266] Figure 3 illustrates an embodiment of the method according to the invention. The reference numerals have the same meaning as in Example 1, unless otherwise specified below:

[0267] Al = plastic waste as an organic, solid compound

[0268] B2 = Oxygen-containing gas (e.g. O2 as a product of water electrolysis 11) 1b = CO provision by partial oxidation

[0269] The synthesis 7 of bisphenol-A F is carried out after the provision of acetone 6. The provided acetone is necessarily a product of a process in which the acetone is produced via provided methanol 3 as an intermediate. In this process, at least carbon monoxide is necessarily generated in a carbon monoxide-containing product gas stream C by a partial oxidation 1b of plastic waste A1 with oxygen gas B2 obtained from a water electrolysis 11, and this after passing through a process gas treatment (point in Fig.2) purification of the carbon monoxide of the product gas stream C and addition of hydrogen gas Bl, the synthesis gas D obtained is converted to methanol and this methanol is further converted to propene E in an MTP process 4, wherein the propene E is first converted to cumene with benzene as precursor H1 for the oxidation 5 of the propene and the resulting propan-2-yl radical of the cumene is converted after oxidation in the 2-position to a 2-hydroperoxy-propan-2-yl radical of the cumene hydroperoxide H2 10a and then converted to acetone by means of oxidative cleavage 10b.

[0270] The synthesis 7 of bisphenol-A F is also carried out after the provision of phenol 8. The provided phenol is necessarily a product of a process in which the phenol is produced from benzene as precursor H1, where the benzene in turn is a product of a catalytic conversion 9b of gaseous pyrolysate J from a pyrolysis 9a of polymeric, organic compound Gl in the form of plastic waste. For the provided phenol, the benzene is first converted to cumene hydroperoxide 10a in an oxidation 5 of propene as described above, and then converted to phenol in the oxidative cleavage 10b.

Claims

Patent claims 1. A process for the preparation of bisphenol-A (F) for the production of polycarbonate, comprising at least the steps: a) providing (4) acetone, which is a process product of a process comprising at least the following steps: i) providing (3) methanol, which is a process product of a process with at least the following steps: i-1) converting (2) CO to methanol, wherein the CO is a Process product of at least one partial reduction (1) of CO2 to CO and / or a process product of at least one partial oxidation (1) of organic material to CO, wherein at least one organic material (A) is selected from at least one organic, solid compound, methane from a biological source, or mixtures thereof; ii) synthesis of acetone from previously provided methanol (3) by at least the following steps: Providing (4) propene as a product of a process comprising at least the following steps: ii-1) converting the previously provided methanol (3) into a Product mixture containing dimethyl ether, water, and methanol; ii-2) converting starting material containing dimethyl ether, water, and methanol, each from the aforementioned product mixture, at a temperature of more than 200°C by contact with a catalyst, preferably with at least one zeolite compound as catalyst, to propene (E); Conversion of the propene (E) by at least ii-3) oxidation (5) of the propene (E) to acetone; b) provision (8) of phenol, which is a process product of at least one production process comprising at least the following steps: i) providing at least one organic aromatic compound according to formula (I), wherein R 1represents a hydrogen atom, a hydroxyl group, methyl, carboxyl, carboxylate or -CHR 3 R 4 where R 3 and R 4 independently of one another represent a (Ci-C3)-alkyl group or together with the remaining molecule form an aliphatic hydrocarbon cycle; and R 2 represents a hydrogen atom, methyl, carboxyl or carboxylate, with the proviso that if R 1 for -CHR 3 R 4 stands, R 2 a hydrogen atom and if R 1 represents a hydroxyl group, R 2represents a hydrogen atom, carboxyl or carboxylate, wherein said organic aromatic compound is a process product of a conversion (9) of at least one starting material selected from at least one compound from the group formed by polymeric organic compounds, carbohydrates and methane from a biological source; and if in said organic aromatic compound from step i) according to formula (I) R 1 does not represent a hydroxyl group and R 2does not represent a hydrogen atom ii) at least one of steps ii-1) and / or ii-2) and / or iii-3) ii-1) reacting the organic, aromatic compound (H) from step i) with propene to obtain a propan-2-yl-substituted aromatic, organic compound as product; ii-2) oxidizing the organic, aromatic compound (H) from step i) and / or the product from step ii-1), to obtain at least one oxidized, aromatic, organic compound; ii-3) cleavage of at least one carbon-containing substituent of the organic aromatic compound (H) from step i) and / or of the oxidized organic aromatic compound from the oxidation according to step ii-2); c) conversion (7) of a mixture containing the provided acetone and the provided phenol to bisphenol A (F).

2. Process according to claim 1, characterized in that the CO used in the reaction (2) according to step a) i-1) is a process product of at least a partial reduction of a gas stream which contains at least CO X with x = 1 or 2 and optionally hydrogen gas (B).

3. Process according to one of claims 1 or 2, characterized in that the CO in step a) i-1) is a process product of at least a partial reduction of CO2 to CO, in particular selected from a reverse water gas shift reaction using EE (B) provided by electrolysis, from an electrochemical reduction of CO2 to CO or from mixtures thereof.

4. Process according to one of the preceding claims, characterized in that the CO in step a) i-1) is a process product of at least one reverse water gas shift reaction using EE (B) provided by electrolysis or is provided from an electrochemical reduction of CO2 to CO or from mixtures thereof, with the proviso that electrical energy produced from renewable energy is used here.

5. Process according to one of the preceding claims, characterized in that the conversion of the methanol according to step a) ii-1) is carried out by contacting the methanol, preferably the methanol in the gas phase, with a catalyst.

6. Process according to one of the preceding claims, characterized in that for the conversion of the methanol in step a) ii-1), said methanol provided has a temperature in a range from 200°C to 350°C.

7. Process according to one of the preceding claims, characterized in that the conversion of the starting material according to step a) ii-2) takes place at a temperature of 350°C to 600°C, in particular of 380°C to 550°C.

8. Process according to one of the preceding claims, characterized in that in step a) ii-3) the oxidation (5) of the propene (E) is carried out by at least one of the following methods: 1) according to the Wacker-Hoechst process by reacting propene (E) and water over a catalyst system of palladium(II) chloride and copper(II) chloride to form acetone; 2) Hydroxylation of propene (E) with water to 2-propanol and subsequent catalytic dehydrogenation of 2-propanol to acetone; 3) Conversion of the propene (E) to cumene and carrying out the cumene hydroperoxide process or conversion of the propene (E) to diisopropylbenzene and carrying out the cumene hydroperoxide process with diisopropylbenzene hydroperoxide instead of cumene hydroperoxide, in each case to obtain acetone.

9. Process according to one of the preceding claims, characterized in that according to formula (I) the radicals R 3 and R 4 are independently selected from methyl, ethyl, propyl or together with the remaining molecule form a 6-membered aliphatic hydrocarbon ring, in particular cyclohexyl.

10. Process according to one of the preceding claims, characterized in that according to formula (I) the radical -CHR 3 R 4 is selected from propan-2-yl, sec-butyl or cyclohexyl.

11. Process according to one of the preceding claims, characterized in that as starting material of step b) i) at least one compound is selected from the group formed by polysaccharides, trisaccharides, C-6 monosaccharides, C-5 monosaccharides, methane from biological sources and homopolymeric and copolymeric compounds from the group cellulose, lignin, polyester, polyamide, polyurethane (PUR), polyurea, polyisocyanurate (PIR), polycarbonate.

12. The process according to any one of the preceding claims, characterized in that in step b) i) benzene is provided as an organic aromatic compound and the benzene is introduced into the oxidation (5) of propene (E) in step a) ii-3) and is reacted there with the propene (E) provided from step a) ii-2) to form cumene and the cumene formed is then oxidized to produce phenol and acetone.

13. Process according to one of the preceding claims, characterized in that in step b) i) the organic aromatic compound, in particular toluene and / or benzene, is provided by pyrolysis of the starting material at a temperature of 400 to 1000°C.

14. A process for producing polycarbonate, comprising at least the following steps: Production of bisphenol A, which is a process product of the process according to any one of claims 1 to 13; Preparation of at least one carbonic acid derivative selected from phosgene, carbonic acid diesters or mixtures thereof; Reaction of said carbonic acid derivative with at least one diphenol, with the proviso that at least the previously prepared bisphenol A is used as diphenol.

15. Process according to claim 14, characterized in that for the production of the carbonic acid derivative, carbon monoxide is provided as a starting material, which is a process product of at least one of the following processes, selected from a RWGS using H2 as a process product of water electrolysis, from a gasification, from an electrochemical reduction of CO2 to CO or from mixtures thereof.

16. Multi-component system for bisphenol-A production according to a production process of claims 1 to 13, comprising i) a volume filled with acetone, which is a process product of step a) of the process according to any one of claims 1 to 13; ii) a volume filled with phenol, which is a process product of step b) of the process according to any one of claims 1 to 13; iii) at least one reactor for producing bisphenol-A, which contains at least one inlet for said acetone and at least one inlet for said phenol, wherein the inlet for said acetone is in fluid communication with the volume of said acetone and the inlet for said phenol is in fluid communication with the volume of said phenol.

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