Bisphenol A is produced by the condensation of phenol and acetone in the presence of an acid catalyst (hydrogen chloride) and usually a promoter such as methyl mercaptan. Cation exchange resins can replace the acid catalyst in newer plants.
After the reaction and recovery of acid and phenol, the BPA is washed with water, neutralised with calcium hydroxide and distilled under vacuum. Newer processes employ distillation and extractive crystallisation under pressure to purify the BPA.
Two grades of BPA are produced; one suitable for epoxy resin manufacture and a higher purity grade for polycarbonate production.
Bisphenol A
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Bisphenol A
Uses and Outlook
The main market for bisphenol-A (BPA) is in the production of polycarbonate (PC) with the second largest outlet being epoxy resins. Other uses include flame retardants (mainly tetrabromobisphenol-A), unsaturated polyester resins and polyacrylate, polyetherimide and polysulphone resins.
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