From waste product to high-quality materials

Researchers from Bayer MaterialScience and Bayer Technology Services are working together with RWE Power AG and academic partner RWTH Aachen University on the sustainable use of carbon dioxide (CO₂). At the heart of what has been called the “Dream Production” project sits the construction and commissioning of a pilot plant at Chempark Leverkusen. This is to be the location for the kilogram-scale production of polyether polycarbonate polyols (PPPs) that will be processed into polyurethanes and will involve the chemical bonding of CO₂, an integral raw material in this sustainable process. The key technology for this is catalysis.

Catalysis is currently used in the manufacture of more than 85 percent of all chemical products, including so-called “dream reactions” – those created in a laboratory but the industrial application of which have so far remained a “dream.” This is because the low energy density of carbon dioxide has hindered the application of this technology in any attempt to put CO₂ to practical use. In recent laboratory tests, however, this dream reaction has been achieved. For the first time, these promising results will be transferred from the laboratory to a larger scale in the “Dream Production” project. Over the next three years, the German Ministry of Education and Research will invest a total of more than €4.5 million in the initiative, which will be overseen by the German Aerospace Center (DLR).

Polyether polycarbonate polyols (PPPs) produced using catalysis are extremely attractive materials. As well as the direct use of CO₂, there are also further interesting possibilities for reducing CO₂ emissions through the use of polyurethanes made from PPPs. “Using the waste product CO₂ to manufacture versatile materials is an amazing achievement made possible by catalysis – and one which both we and our project partners are very proud of,” says Patrick Thomas, Chief Executive Officer of Bayer MaterialScience. “What’s more, as an ultra-efficient organic insulating material, polyurethanes save around 80 times more energy during their service life than is required for their production. This ensures that PPPs have a doubly positive effect on climate protection.”