Challenges in Commercial Scale up of Novel Poly(phenylene ether)-Polysiloxane Block Copolymer Process

Poly(phenylene ether) is an engineering thermoplastic known for its excellent hydrolytic stability, dimensional stability and inherent flame retardancy. A block copolymer of poly(phenylene ether)-polysiloxane (PPE-Si), produced by the oxidative coupling polymerization of 2,6 xylenol and polysiloxane, has been developed to deliver significant improvements in mechanical properties and flame retardancy.

Process development for new technology to culminate in production in an existing operating commercial chemical plant requires conscientious planning and risk mitigation efforts. This presentation illustrates the challenges involved in the commercial scale up of PPE-Si copolymer, covering areas such as: lab and pilot plant scale testing, determination of feasibility and process conditions for all unit operations, cross contamination of existing processes, management of transitions, quality specifications and testing methods, EHS and product stewardship considerations.