Direct synthesis

DegussaHeadwaters, the joint venture between the German firm Degussa and the American firm Headwaters, has successfully integrated a pilot plant that uses the direct synthesis hydrogen peroxide (DSHP) process into a propylene oxide (PO) manufacturing plant.

DegussaHeadwaters expects to complete its development of the new DSHP process by end of 2006, making the technology commercially available in 2007.

The industrial process for the direct synthesis uses a nanocatalyst developed by Headwaters to react hydrogen (H2) and oxygen (O2) to form hydrogen peroxide.

“The hydrogen peroxide is produced as a dilute solution in methanol and can be directly converted into propylene oxide in the PO process,” explained Dr. Thomas Haas, general manager of DegussaHeadwaters.

Direct synthesis is expected to provide a cost-effective process for the production of H2O2 as an intermediate product for chemical synthesis.

“Versus conventional technology, we project that we can reduce our investment cost for integrated H2O2 plants by one-third to one-half,“ said José Berges, vice president and general manager of New Technologies, in Degussa's Active Oxygens Business Line.

Propylene oxide is a starting material for polyurethane, which is used in applications such as cushions and car seats. While Degussa itself will not produce propylene oxide commercially, it believes that the new H2O2 produced from direct synthesis by the DegussaHeadwaters joint venture offers significant market opportunities for companies that do.

Berges also envisions applications in the chemical synthesis of other major chemicals such as caprolactam, phenol, and epichlorohydrin.