Mitsubishi Chemical Group (MCG) announced that it will discontinue the production of methyl methacrylate (MMA) monomers by the acetone cyanohydrin (ACH) process and the production of acrylonitrile and its derivatives at its Hiroshima plant in Japan by July 2024. The decision is part of the group’s strategy to enhance its competitiveness and optimize its supply system in the MMA and acrylonitrile businesses.
MMA production by the ACH process
MMA is a versatile chemical that is used as a raw material for polymethyl methacrylate (PMMA), a transparent plastic with applications in various industries such as automotive, construction, electronics, and medical. MMA can be produced by several methods, such as the ACH process, the C4 process, and the Alpha technology.
The ACH process is one of the oldest and most widely used methods for MMA production. It involves the reaction of acetone and hydrogen cyanide (HCN) to form acetone cyanohydrin, which is then hydrolyzed to MMA and ammonium bisulfate. The ACH process has the advantage of using relatively cheap and abundant feedstocks, but it also has some drawbacks, such as the use of hazardous HCN, the generation of large amounts of waste acid, and the low selectivity and yield of MMA.
Acrylonitrile and its derivatives production
Acrylonitrile is another important chemical that is used as a raw material for acrylic fibers, ABS resins, and other products. Acrylonitrile can be produced by the ammoxidation of propylene or by the dehydration of acrylamide. Acrylonitrile can also be used to produce various derivatives, such as chelating agents, acetonitrile, and ammonium sulfate.
Chelating agents are chemicals that can bind to metal ions and prevent them from forming unwanted complexes or precipitates. They are used in various applications, such as water treatment, detergents, pulp and paper, and agriculture. Acetonitrile is a solvent that is used in pharmaceuticals, pesticides, and organic synthesis. Ammonium sulfate is a fertilizer that provides nitrogen and sulfur to plants.
Reasons for discontinuing production
According to MCG, the reasons for discontinuing the production of MMA by the ACH process and the production of acrylonitrile and its derivatives at the Hiroshima plant are as follows:
- To enhance the group’s competitiveness in the MMA and acrylonitrile businesses and optimize the supply system, the group has decided to focus on the C4 process and the Alpha technology for MMA production and to consolidate its acrylonitrile production at the Okayama plant.
- The ACH process and the acrylonitrile production at the Hiroshima plant have been facing challenges such as rising feedstock prices, environmental regulations, and aging facilities.
- The demand for MMA and acrylonitrile and their derivatives has been affected by the COVID-19 pandemic and the structural changes in the end-use markets, such as the decline of acrylic fibers and the shift to electric vehicles.
Impacts of discontinuing production
The impacts of discontinuing the production of MMA by the ACH process and the production of acrylonitrile and its derivatives at the Hiroshima plant are as follows:
- The group will withdraw from the chelating agent and acetonitrile businesses, which are mainly based on the acrylonitrile derivatives produced at the Hiroshima plant.
- The group will continue to produce MMA by the C4 process at the Hiroshima plant, as well as at its other plants in Japan, China, Thailand, Singapore, and the US. The group will also continue to develop and expand its Alpha technology, which is a proprietary process that produces MMA from ethylene and methanol with high efficiency and low environmental impact.
- The group will continue to produce acrylonitrile and sodium glycinate (a chelating agent) at the Okayama plant and acrylamide (a precursor of acrylonitrile) at the Kanto plant. The group will also continue to supply HCN, a byproduct of acrylonitrile production, as a feedstock for MMA production by the ACH process to other companies.
