Process to Manufacture Branched Caprolactone

Two-stage process manufactures methyl-ε-caprolactone (MCL)

A cost effective, new two-stage chemical process manufactures methyl-ε-caprolactone (MCL) from cresol, a fossil or bio-renewable feedstock. Details for designing a process optimized for net present value (including unit operation design of two reactors, distillation and integrated heat transfer) were determined via process simulation. The two-reaction process first hydrogenates cresol to methyl-cyclohexanone, which is then followed by Baeyer-Villiger oxidation to MCL. Improvements in overall selectivity via catalytic performance of the Baeyer-Villiger oxidation catalyst boost the overall economics of the process, rendering it a low-cost process broadly applicable to multiple classes of alkyl-phenol feedstocks. The novel process can manufacture MCL for use in polymer/plastics.

Combines all reaction, separation and purification operations

Polymers related to poly-ε-caprolactone (PCL), which have many biomedical and industrial field applications, could be derived from biobased starting materials, but the challenge has been finding a cost effective route to the starting monomer. This new process uses already-existing chemistry in a brand new way, putting all reaction, separation and purification operations together in a cost-competitive manner. The result is a high yield and inexpensive method of producing 4-methyl-ε-caprolactone (and other alkyl caprolactones) from lignin or petroleum-based starting materials.

Phase of Development

• Proof of concept. Simulation models with technical description of chemical process conditions and unit connectivity with economic analysis.

Benefits

• Low-cost process; potential for extremely lucrative chemical product
• High process yield potential
• Broadly applicable to multiple classes of alkyl-phenol feedstocks
• Aspen model based technoeconomic analysis available

Features

• Manufactures methyl-ε-caprolactone (MCL) (and other alkyl caprolactones) from biobased cresol, lignin or petroleum based starting materials
• Two-stage chemical process
• Baeyer-Villiger oxidation catalyst improves overall selectivity
• Combines all reaction, separation and purification operations together

Applications

• Chemicals/polymers
• Caprolactone
• Monomers
• Methyl-e-caprolactone (MCL) manufacture