Method for producing synthetic resin and method for fixing carbon dioxide

Abstract

The present disclosure addresses the problem of providing a method which is for producing a synthetic resin (X) and by which the load on the environment can be reduced when producing the synthetic resin (X). A method for producing a synthetic resin (X) according to an aspect of the present disclosure includes reacting a first raw material (A) having carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide and different from the first raw material (A).

Description

[Technical Field]

[0001] The present disclosure relates to a method for producing a synthetic resin and a method for fixing carbon dioxide. [Background technology]

[0002] Patent Document 1 discloses a method for producing a urea resin that is excellent in physical properties such as hardness and heat resistance, and in which the resin itself is biodegradable, and a biodegradable urea resin composition, in which urea resin is produced by reacting 1 mole of urea with 1 mole or more but less than 1.3 moles of formaldehyde, and the urea resin composition is prepared by blending 15 to 80 parts by weight of a cellulose material with 100 parts by weight of the urea resin obtained by this method. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 8-325342 Summary of the Invention

[0004] An object of the present disclosure is to provide a method for producing a synthetic resin that can reduce the environmental load during the production of the synthetic resin, and a method for immobilizing carbon dioxide that includes synthesizing this synthetic resin.

[0005] A method for producing synthetic resin (X) according to one embodiment of the present disclosure includes reacting a first raw material (A) having carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide and different from the first raw material (A).

[0006] A method for immobilizing carbon dioxide according to one embodiment of the present disclosure includes reacting a first raw material (A) having carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide and different from the first raw material (A). [Brief explanation of the drawings]

[0007] [Figure 1] 1A and 1B are flow diagrams showing specific examples of a synthetic resin manufacturing process according to an embodiment of the present disclosure. DETAILED DESCRIPTION OF THE INVENTION

[0008] It is generally difficult to reuse synthetic resins such as urea resins, and disposing of such resins places a heavy burden on the environment.

[0009] The technology described in Patent Document 1 (JP Patent Publication No. 8-325342 A) aims to impart biodegradability to products made from the urea resin composition by blending a cellulose material with a urea resin, thereby reducing the environmental burden when the urea resin is disposed of.

[0010] In response to this, the inventors have attempted to reduce the overall environmental burden from the time synthetic resins are produced until they are disposed of. The inventors then conducted research to develop a method for producing a synthetic resin that can reduce the environmental impact of its production, and a method for immobilizing carbon dioxide that includes synthesizing this synthetic resin, and have completed the present disclosure. However, the present disclosure should not be construed as being limited by the details of this development.

[0011] Hereinafter, embodiments of the present disclosure will be described with reference to FIGS. 1A and 1B as appropriate. Note that the present disclosure is not limited to the following embodiments. The following embodiments are merely a portion of various embodiments of the present disclosure, and various modifications are possible depending on the design as long as the object of the present disclosure can be achieved. That is, although each of FIGS. 1A and 1B is a flow chart conceptually illustrating an example of a manufacturing process for synthetic resin (X), the manufacturing process for synthetic resin (X) is not limited to the manufacturing process shown in FIGS. 1A and 1B.

[0012] The method for producing synthetic resin (X) according to this embodiment involves reacting a first raw material (A) containing carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide, which is different from the first raw material (A). Therefore, biomass and carbon dioxide can be used as carbon sources for synthetic resin (X). Biomass contains carbon from various sources, including carbon derived from atmospheric carbon dioxide. Therefore, synthesizing synthetic resin (X) using biomass can be considered equivalent to synthesizing synthetic resin (X) using atmospheric carbon dioxide. This eliminates the use of fossil fuel-derived substances, such as petroleum, as carbon sources for synthetic resin (X), or reduces the amount of fossil fuel-derived substances used. This reduces the consumption of valuable fossil fuels and the release of fossil fuel-derived carbon dioxide into the environment, thereby contributing to the prevention of global warming. This reduces the environmental impact of producing synthetic resin (X).

[0013] Furthermore, the production of this synthetic resin (X) can be used to fix carbon dioxide. The method for fixing carbon dioxide according to this embodiment involves reacting a first raw material (A) containing carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide and different from the first raw material (A). This makes it possible to reduce the amount of carbon dioxide released into the environment, thereby contributing to the suppression of global warming.

[0014] The method for producing the synthetic resin (X) will now be described in more detail.

[0015] In this embodiment, as described above, a first raw material (A) containing carbon derived from biomass is used. That is, the first raw material (A) contains a compound having a carbon atom derived from biomass in its molecule. The first raw material (A) may be synthesized by any method as long as it contains carbon derived from biomass. Biomass refers to industrial resources originating from components of living organisms. Article 2, paragraph 1 of the Basic Act on the Promotion of Biomass Utilization of Japan defines "biomass" as "organic resources derived from plants and animals (excluding crude oil, petroleum gas, combustible natural gas, and coal (hereinafter referred to as "fossil resources")"). In this disclosure, plants and animals refer to all living organisms, including microorganisms. Biomass can contain at least one material selected from the group consisting of plant-based resources such as wood, weeds, rice straw, wheat straw, corn stalks, and sugarcane stalks, animal-based resources such as livestock manure, and household waste. The first raw material (A) may be a product produced directly from biomass, or may be a compound synthesized from a raw material containing a product produced from biomass. That is, the first raw material (A) includes, for example, a compound synthesized from a raw material containing at least one of biomass and a product produced by processing biomass.

[0016] The first raw material (A) contains a compound (A1) synthesized from a raw material containing carbon monoxide and hydrogen, for example, produced by gasifying biomass. In this case, for example, pulverized biomass can be gasified by heating it with steam and oxygen to obtain a gas containing carbon monoxide and hydrogen. This gas can be purified as needed and then contacted with a catalyst under heat and pressure to react the carbon monoxide and hydrogen in the gas, thereby synthesizing methanol (see Figures 1A and 1B). Alternatively, formaldehyde can be produced by heating this methanol in air in the presence of a suitable catalyst. At least one of the above-mentioned methanol and formaldehyde can be contained in the first raw material (A). That is, the compound (A1) can contain at least one of methanol and formaldehyde produced by the above-mentioned method. Note that compounds other than formaldehyde synthesized from methanol may also be contained in the first raw material (A). That is, the compound (A1) may contain a compound other than formaldehyde that is synthesized from methanol.

[0017] The first raw material (A) may contain a compound (A2) synthesized from a raw material containing carbon dioxide produced from biomass. The carbon dioxide produced from biomass may contain, for example, at least one of carbon dioxide produced by combustion of biomass and carbon dioxide produced by steam reforming of biomass.

[0018] When compound (A2) synthesized from a raw material containing carbon dioxide produced from biomass is used, this raw material containing carbon dioxide may further contain hydrogen. In this case, for example, methanol can be synthesized by reacting carbon dioxide and hydrogen in the presence of an appropriate catalyst, optionally with heating (see Figures 1A and 1B). Furthermore, formaldehyde can be synthesized by heating this methanol in air in the presence of an appropriate catalyst. Thus, at least one of methanol synthesized from carbon dioxide and hydrogen and formaldehyde synthesized from this methanol can be contained in the first raw material (A). That is, compound (A2) can contain at least one of methanol and formaldehyde produced by the above-mentioned method. Note that compounds other than formaldehyde synthesized from methanol may also be contained in the first raw material (A). That is, compound (A2) may contain compounds other than formaldehyde synthesized from methanol.

[0019] When the raw material containing carbon dioxide further contains hydrogen, the hydrogen preferably includes at least one of hydrogen produced by water decomposition using a renewable energy source and hydrogen produced by steam reforming of an organic substance. In this case, the consumption of electricity fueled by fossil resources, which generates carbon dioxide, can be reduced in the process of producing synthetic resin (X), thereby further reducing the environmental impact of producing synthetic resin (X).

[0020] A renewable energy source is an energy source that can be used continuously, and is defined in Article 2, Paragraph 3 of the Japanese Act on the Promotion of the Use of Non-Fossil Energy Sources and the Effective Use of Fossil Energy Materials by Energy Suppliers as "solar power, wind power, and other non-fossil energy sources that are recognized as being capable of being used continuously as energy sources." Renewable energy sources include, for example, at least one selected from the group consisting of solar power, wind power, hydropower, geothermal power, solar heat, atmospheric heat and other heat present in nature, and biomass. Examples of water splitting using renewable energy sources include water electrolysis using electricity generated using renewable energy sources and water splitting using sunlight and photocatalysis. When the renewable energy source includes biomass, the biomass can be used more effectively in the synthesis of synthetic resin (X).

[0021] Furthermore, when hydrogen generated by steam reforming of organic matter is used, the organic matter contains at least one selected from the group consisting of biomass, resin materials such as waste plastics, and fossil resources. When the organic matter contains biomass, the compound (A2) can be synthesized using carbon dioxide and hydrogen generated from the biomass, thereby enabling more effective use of the biomass to synthesize the synthetic resin (X). It is also preferable that the carbon dioxide and hydrogen used to synthesize the compound (A2) contain carbon dioxide and hydrogen generated by steam reforming of biomass, respectively. Furthermore, when the organic matter contains a resin material, the resin material may contain at least one of the synthetic resin (X) produced by the production method according to this embodiment and a product made from this synthetic resin (X) (see FIG. 1B). In this case, the hydrogen constituting the synthetic resin (X) according to this embodiment can be reused to synthesize a new synthetic resin (X).

[0022] Although it is preferable that all carbon in the first raw material (A) is derived from biomass, the carbon in the first raw material (A) may also contain carbon not derived from biomass. That is, at least one compound contained in the first raw material (A) may have carbon not derived from biomass in its molecule. For example, when the first raw material (A) is synthesized from a raw material containing carbon dioxide produced from biomass, the raw material used to synthesize the first raw material (A) may further contain carbon dioxide other than that produced from biomass. In this case, the carbon dioxide other than that produced from biomass may include at least one selected from the group consisting of carbon dioxide produced by combustion of organic matter other than biomass, carbon dioxide produced by steam reforming of organic matter other than biomass, and carbon dioxide extracted from volcanic gas during geothermal power generation. In this case, carbon dioxide that would otherwise be released into the environment can be used to synthesize the synthetic resin (X), thereby reducing the amount of carbon dioxide released into the environment. This further contributes to the prevention of global warming. The organic matter may include at least one selected from the group consisting of resin materials such as waste plastics and fossil resources. The resin material may contain at least one of the synthetic resin (X) produced by the production method according to this embodiment and a product made from this synthetic resin (X). In this case, the generation of carbon dioxide when the synthetic resin (X) is disposed of can be suppressed, and the carbon that constitutes the synthetic resin (X) can be recycled without being released into the environment, thereby significantly reducing the burden on the environment.

[0023] Note that biomass may be used in various ways other than those described above to synthesize the first raw material (A) having carbon derived from biomass. For example, methane may be produced by anaerobic fermentation of biomass, and this methane may be reacted with oxygen to produce methanol. At least one of this methanol and formaldehyde produced by heating this methanol in air in the presence of a suitable catalyst may be contained in the first raw material (A).

[0024] On the other hand, the second raw material (B) is synthesized, for example, by a process including reacting carbon dioxide with ammonia (see FIGS. 1A and 1B). In this case, a synthetic resin (X) containing nitrogen atoms, such as an amino resin, can be synthesized using the second raw material (B).

[0025] The second raw material (B) contains, for example, at least one of urea (see FIGS. 1A and 1B) and melamine. Urea is synthesized, for example, by reacting carbon dioxide and ammonia under a heated and pressurized atmosphere (see FIGS. 1A and 1B). Melamine is synthesized from urea synthesized from carbon dioxide, for example, by a low-pressure urea process or a high-pressure urea process. However, the compounds contained in the second raw material (B) are not limited to those mentioned above.

[0026] The carbon dioxide used to synthesize the second raw material (B) includes at least one selected from the group consisting of carbon dioxide produced by the combustion of organic matter (see FIGS. 1A and 1B), carbon dioxide produced by the steam reforming of organic matter (see FIGS. 1A and 1B), and carbon dioxide extracted from volcanic gas during geothermal power generation. In this case, carbon dioxide that would otherwise be released into the environment can be used to synthesize the synthetic resin (X), thereby reducing the amount of carbon dioxide released into the environment.

[0027] The organic matter contains at least one selected from the group consisting of, for example, biomass, resin materials such as waste plastics, and fossil resources. When the organic matter contains biomass, the biomass can be used more effectively in synthesizing the synthetic resin (X). When the organic matter contains a resin material, the resin material may contain at least one of the synthetic resin (X) produced by the production method according to this embodiment and a product made from this synthetic resin (X) (see FIGS. 1A and 1B). In this case, the carbon constituting the synthetic resin (X) can be recycled without being released into the environment, thereby significantly reducing the burden on the environment.

[0028] The carbon dioxide used to synthesize the second raw material (B) may contain carbon dioxide obtained by a method other than the above.

[0029] When ammonia is used to synthesize the second raw material (B), the ammonia includes, for example, ammonia synthesized from nitrogen and hydrogen (see Figures 1A and 1B). The Haber-Bosch process or the like can be used to synthesize ammonia. In this case, the hydrogen preferably includes at least one of hydrogen generated by water decomposition using a renewable energy source and hydrogen generated by steam reforming of organic matter (see Figure 1B). The nitrogen preferably includes nitrogen in the air. In these cases, the environmental impact of ammonia production can be reduced, and therefore the environmental impact of synthetic resin (X) production can be further reduced.

[0030] The organic matter in the steam reforming of organic matter has already been described. When the organic matter contains a resin material, the resin material may contain at least one of the synthetic resin (X) produced by the production method according to this embodiment and a product made from this synthetic resin (X) (see FIG. 1B). In this case, the hydrogen constituting the synthetic resin (X) according to this embodiment can be reused to synthesize a new synthetic resin (X).

[0031] The ammonia used to synthesize the second raw material (B) may contain ammonia obtained by a method other than the above.

[0032] In this embodiment, only the first raw material (A) and the second raw material (B) may be used as raw materials for the synthetic resin (X). In addition to the first raw material (A) and the second raw material (B), one or more raw materials different from both the first raw material (A) and the second raw material (B) may also be used as raw materials for the synthetic resin (X). Furthermore, the synthetic resin (X) may be synthesized in a single reaction using raw materials including the first raw material (A) and the second raw material (B), or in a multi-stage reaction. That is, for example, the synthetic resin (X) may be synthesized in a single reaction from the first raw material (A) and the second raw material (B), or the synthetic resin (X) may be synthesized by further reacting the product synthesized by reacting the first raw material (A) and the second raw material (B).

[0033] There is no limitation on the type of synthetic resin (X) synthesized in this embodiment, as long as it is synthesized using the first raw material (A) and the second raw material (B).

[0034] The synthetic resin (X) is, for example, at least one selected from the group consisting of urea resin (see FIGS. 1A and 1B) and melamine resin.

[0035] When the synthetic resin (X) is a urea resin, for example, the first raw material (A) is formaldehyde and the second raw material (B) is urea (see FIGS. 1A and 1B). In this case, the urea resin can be synthesized, for example, by a dehydration condensation reaction between formaldehyde and urea. In this case, a cured (i.e., C-stage) urea resin can be synthesized by allowing the reaction between formaldehyde and urea to proceed completely, or a urea resin in a prepolymer state (urea resin prepolymer) can be synthesized by not allowing the reaction between formaldehyde and urea to proceed completely. The C-stage urea resin can also be synthesized by further reacting and curing the urea resin prepolymer.

[0036] Urea resins can be widely used in applications such as parts such as casings for electrical devices such as wiring devices, other electrical components, molded products such as tableware, buttons, and lacquerware products, and adhesives. However, recycling of urea resins is difficult. Therefore, if urea resins are produced by the production method according to this embodiment, the burden on the environment can be significantly reduced.

[0037] When the synthetic resin (X) is a melamine resin, for example, the first raw material (A) is formaldehyde and the second raw material (B) is melamine. In this case, the melamine resin can be synthesized by, for example, reacting formaldehyde and melamine under alkaline conditions to synthesize methylolmelamine, and then heating the methylolmelamine to polycondense it. In this case, the reaction of the methylolmelamine may be allowed to proceed completely to synthesize a cured (i.e., C-stage) melamine resin, or the reaction of the methylolmelamine may not be allowed to proceed completely to synthesize a melamine resin in a prepolymer state (melamine resin prepolymer). The melamine resin prepolymer may be further reacted and cured to synthesize a C-stage melamine resin.

[0038] Melamine resins are widely used in applications such as building materials, parts such as casings for electrical devices such as wiring devices, other electrical components, molded products such as tableware, and adhesives. However, recycling of melamine resins is difficult. Therefore, if melamine resins are produced by the production method according to the present embodiment, the burden on the environment can be significantly reduced.

[0039] In the carbon dioxide immobilization method according to this embodiment, carbon dioxide can be immobilized by synthesizing a synthetic resin (X) using, for example, the method for producing a synthetic resin (X) described above. In this embodiment, carbon dioxide can be immobilized more easily than carbon dioxide capture and storage (CCS), which immobilizes carbon dioxide by storing it underground, and can be immobilized more stably than when carbon dioxide is immobilized as a liquid such as methanol. Furthermore, it is possible for all or most of the carbon contained in the synthetic resin (X) to be carbon derived from carbon dioxide, and in this case, carbon dioxide can be immobilized at a high concentration in the synthetic resin (X). Furthermore, particularly when the synthetic resin (X) is a thermosetting resin, carbon dioxide can be stably immobilized for a long period of time.

[0040] As is clear from the above embodiment, the method for producing synthetic resin (X) according to the first aspect of the present disclosure includes reacting a first raw material (A) having carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide and different from the first raw material (A).

[0041] According to the first aspect, by using biomass, it is possible to reduce the burden on the environment during the production of synthetic resin (X).

[0042] In the second aspect of the present disclosure, in the first aspect, the first raw material (A) contains a compound (A1) synthesized from a raw material containing carbon monoxide and hydrogen produced by gasification of biomass.

[0043] According to the second embodiment, the synthetic resin (X) can be synthesized by effectively utilizing biomass.

[0044] In a third aspect of the present disclosure, in the first aspect, the first raw material (A) contains a compound (A2) synthesized from a raw material containing carbon dioxide produced from biomass.

[0045] According to the third aspect, biomass can be effectively utilized, and the amount of carbon dioxide released into the environment can be reduced, further reducing the burden on the environment during the production of synthetic resin (X).

[0046] In the fourth aspect of the present disclosure, the raw material for synthesizing compound (A2) in the third aspect further contains hydrogen.

[0047] In a fifth aspect of the present disclosure, the hydrogen used to synthesize compound (A2) in the fourth aspect includes at least one of hydrogen produced by water decomposition using a renewable energy source and hydrogen produced by steam reforming of an organic compound.

[0048] According to the fifth aspect, the burden on the environment during the production of the synthetic resin (X) can be further reduced.

[0049] In a sixth aspect of the present disclosure, in any one of the first to fifth aspects, the first raw material (A) contains at least one of methanol and formaldehyde.

[0050] According to the sixth aspect, a synthetic resin (X) can be produced using at least one of methanol and formaldehyde as a raw material.

[0051] In a seventh aspect of the present disclosure, in any one of the first to sixth aspects, the carbon dioxide used to synthesize the second raw material (B) includes at least one selected from the group consisting of carbon dioxide produced by combustion of organic matter, carbon dioxide produced by steam reforming of organic matter, and carbon dioxide extracted from volcanic gas during geothermal power generation.

[0052] According to the seventh aspect, the amount of carbon dioxide released into the environment can be reduced, and the burden on the environment during the production of the synthetic resin (X) can be further reduced.

[0053] In an eighth aspect of the present disclosure, in any one of the first to seventh aspects, the second raw material (B) is synthesized by a process including reacting carbon dioxide and ammonia.

[0054] According to the eighth embodiment, a resin containing nitrogen atoms, such as an amino resin, can be synthesized as the synthetic resin (X).

[0055] In a ninth aspect of the present disclosure, in the eighth aspect, the ammonia includes ammonia synthesized from hydrogen and nitrogen, the hydrogen includes at least one of hydrogen produced by decomposition of water using a renewable energy source and hydrogen produced by steam reforming of organic matter, and the nitrogen includes nitrogen in air.

[0056] According to the ninth aspect, the burden on the environment during the production of the synthetic resin (X) can be further reduced.

[0057] In a tenth aspect of the present disclosure, in any one of the first to ninth aspects, the first raw material (A) is formaldehyde, the second raw material (B) is urea, and the synthetic resin (X) is a urea resin.

[0058] According to the tenth aspect, it is easy to significantly reduce the burden on the environment.

[0059] A method for fixating carbon dioxide according to an eleventh aspect of the present disclosure includes reacting a first raw material (A) having carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide and different from the first raw material (A).

[0060] According to the eleventh aspect, carbon dioxide can be immobilized by synthesizing the synthetic resin (X) using biomass and carbon dioxide as carbon sources.

Claims

1. A method for producing a synthetic resin, comprising reacting a first raw material (A) having carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide and different from the first raw material (A), At least one of the first raw material (A) and the second raw material (B) is synthesized from carbon dioxide containing at least one of carbon dioxide produced by combustion of an organic substance and carbon dioxide produced by steam reforming of an organic substance; The organic matter includes at least one of the synthetic resin synthesized by the manufacturing method and a product made from the synthetic resin synthesized by the manufacturing method. Methods for manufacturing synthetic resins.

2. The first raw material (A) contains a compound (A1) synthesized from a raw material containing carbon monoxide and hydrogen produced by gasification of the biomass. A method for producing the synthetic resin according to claim 1.

3. The first raw material (A) contains a compound (A2) synthesized from a raw material containing carbon dioxide produced from the biomass. A method for producing the synthetic resin according to claim 1.

4. The raw material for synthesizing the compound (A2) further contains hydrogen. The method for producing the synthetic resin according to claim 3.

5. The hydrogen for synthesizing the compound (A2) includes at least one of hydrogen produced by decomposition of water using a renewable energy source and hydrogen produced by steam reforming of the organic material. The method for producing the synthetic resin according to claim 4.

6. The first raw material (A) contains at least one of methanol and formaldehyde. A method for producing the synthetic resin according to claim 1 or 2.

7. The carbon dioxide for synthesizing the second raw material (B) further includes carbon dioxide extracted from volcanic gas during geothermal power generation. A method for producing the synthetic resin according to claim 1 or 2.

8. The second raw material (B) is synthesized by a process including reacting the carbon dioxide with ammonia. A method for producing the synthetic resin according to claim 1 or 2.

9. The ammonia includes ammonia synthesized from hydrogen and nitrogen, The hydrogen includes at least one of hydrogen produced by decomposition of water using a renewable energy source and hydrogen produced by steam reforming of the organic matter; The nitrogen includes nitrogen in air. The method for producing the synthetic resin according to claim 8.

10. The first raw material (A) is formaldehyde, the second raw material (B) is urea, The synthetic resin is a urea resin. A method for producing the synthetic resin according to claim 1 or 2.

11. A method for fixation of carbon dioxide, comprising synthesizing a synthetic resin by reacting a first raw material (A) having carbon derived from biomass with a second raw material (B) synthesized from carbon dioxide and different from the first raw material (A), At least one of the first raw material (A) and the second raw material (B) is synthesized from carbon dioxide containing at least one of carbon dioxide produced by combustion of an organic substance and carbon dioxide produced by steam reforming of an organic substance; The organic matter includes at least one of the synthetic resin synthesized by the immobilization method and a product made from the synthetic resin synthesized by the immobilization method. Methods for fixing carbon dioxide.

12. The synthetic resin is a thermosetting resin. The method for fixation of carbon dioxide according to claim 11.

13. The synthetic resin is a urea resin. The method for fixation of carbon dioxide according to claim 11.

14. A product is made from the synthetic resin, and carbon dioxide is immobilized in the product. The method for fixation of carbon dioxide according to any one of claims 11 to 13.

15. The product is a component of a wiring device. The method for fixation of carbon dioxide according to claim 14.

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