Bayer steps up research into CO2 as raw material in plastics

Bayer MaterialScience’s research into carbon dioxide as a new raw material for making plastics has taken another step forward. In laboratory tests, the company has succeeded in significantly further reducing the need for petroleum at precursor level through the incorporation of CO2. Plastics and their components are normally based entirely on oil. The new process also extends the range of plastics that CO2 can be used to produce. This is the result of the Dream Polymers research project in which Bayer MaterialScience is continuing its activities to find new uses for CO2.

A technology using the greenhouse gas to produce a key component for high-quality foam (polyurethane) is already moving toward commercial use. The proportion of petroleum in this chemical is 80%.

"We have now succeeded in reducing the petroleum content for making other plastics to just 60%," said project manager Dr. Christoph Gürtler.

Carbon dioxide is used twice in the new process. First, the greenhouse gas is incorporated directly into a new kind of precursor (polyoxymethylene polycarbonate polyol), replacing 20% of the petroleum. Second, it is also used indirectly, producing a chemical that is also incorporated into the precursor for a further 20% saving in petroleum.

"As a result, the proportion of alternative raw materials is already 40 percent," remarked Gürtler.

In addition to this, the number of plastics that can be produced using carbon dioxide is increasing.

"It is now also possible to manufacture thermoplastic polyurethanes, films and casting elastomers in this way," said Gürtler.

The researchers have already proved in laboratory tests that the manufacturing process works in principle.

"Initial application tests have been positive," said Gürtler, but he added that there is some way to go before the process is commercially viable.