MMA (methyl methacrylate) monomer at
Asahi Chemical is used in PMMA and MBS resins, as well
as in resins for paints, etc. We have established a
new production process which is simpler than ordinary
MMA production processes, making lower production costs
possible. The decision was taken at our Kawasaki works
to commercialize production using this new process.
The new production process
Like the "direct oxidation" process, which is presently
in commercial use, Asahi Chemical's new "direct oxidative
esterification" (DOE) process uses isobutylene as the
initial raw material. In the direct oxidation process,
methacrolein is first oxidized to produce methacrylic
acid, which is then converted to MMA by esterification.
In Asahi Chemical's new process, however, MMA is created
through the simultaneous oxidization and esterification
of methacrolein, eliminating the intermediate methacrylic
acid step.
We have been studying the industrial
potential of this new process on a pilot plant scale
in Mizushima since August 1994, but the newly developed
catalysts which make the elimination of the methacrylic
acid intermediate step possible, a compound oxide and
an intermetallic compound, are the fruits of Asahi Chemical's
catalyst development technology which has been cultivated
for many years.
This new process will not only allow
significantly reduced production costs, but the simplicity
of the process, when compared with the direct oxidation
process, also allows reduced plant construction expenditure.
We are proud to have succeeded in the creation of this
world- leading new production process.
Commercialization of the new process
While the Asian market for MMA is expected to grow at
a 5% annual rate for the near future, MMA makers each
have plans underway to expand production capacity. Therefore,
despite steady demand growth, we have reason to expect
that the business environment for MMA makers will be
extremely competitive. This makes it all the more important
that we enhance our cost competitiveness in MMA production,
in order to secure our position in the market.
At present, we are producing MMA at
our Kawasaki Works using our proprietary MAN process,
which also begins with isobutylene but goes through
a methacrylonitrile (MAN) intermediate phase before
the final MMA product.
Construction of a plant of 60
kilotons annual capacity which will use the new process
began in February of this year, and is scheduled to
be completed in July of 1998. This new plant will replace
our MMA production by the MAN process.
Since it will be possible to incorporate
some of the existing equipment in the new plant, total
production cost will be only 6 billion Yen. The existing
MAN plant at our Mizushima works will be converted to
produce acrylonitrile (AN) and MAN. As a result, our
position in AN, as well as in MMA, will be strengthened.
At present, our total capacity for
MMA, using both the MAN and ACH processes, is 90 kilotons
annually. Production volume of MMA after conversion
to the new process will be unchanged.
Outlook for the future
Our new MMA production technology has already aroused
great interest among makers across Europe, North America,
and Asia. The establishment and commercialization of
this new process is a key element in heightening our
technological foundation in MMA, which will serve to
further strengthen our MMA operations in preparation
for the 21st century.
Overview of MMA monomer production processes:
Asahi Chemical's new direct oxidative esterification
(DOE) process:
isobutylene  methacrolein MMA
Direct oxidation process: Involves
a two-step oxidation and esterification of methacrolein.
isobutylene methacrolein methacrylic
acid MMA
ACH process: Over 80% of MMA monomer
worldwide is produced through this process.
acetone + HCN acetone
cyanohydrin (ACH) methacrylamide MMA
MAN process: Currently used only by
Asahi Chemical.
isobutylene methacrylonitrile methacrylamide MMA
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