Published December 1988
Bisphenol A and other alkylphenols are chemical intermediates that have been commercially important for many years. Bisphenol A is used primarily in the production of polycarbonate and epoxy resins. Butylphenols generally are used as plastic and gasoline additives, and in the manufacture of modified phenolic resins, antioxidants, dyestuffs, and herbicides. Higher alkylphenols, such as octylphenol, nonylphenol, and dodecylphenol, are used as inter- mediates for surfactants, antioxidants, and lubricating oil additives.
This report reviews the technology and costs for manufacturing bisphenol A, o-tert-butyl-phenol, 2,6-di-tert-butylphenol, p-tert-butylphenol, octylphenol, nonylphenol, and dodecylphenol. Preliminary process designs and associated costs for commercial processes for each of these products are evaluated. Bisphenol A process economics were previously evaluated in PEP Report No. 61, Bisphenol A and phosgene (November 1972)) and PEP Review No. 82-1-1. Bisphenol-A from Phenol and Acetone with an Ion Exchange Resin Catalyst-Union Carbide Technology (September 1982). The process economics for nonylphenol were initially studied in PEP Report No. 168, Nonionic Surfactants (March 1984).
This report includes a discussion of the present status of bisphenol A, as well as alkyl- phenol production and markets. In addition, the chemistry of the various processes is discussed and summaries of patents related to bisphenol A and phenol alkylation technology are generated.
We prepared this report with the assistance of referenced books, trade publications, journals, information from industry sources, and patent literature.