In-depth analysis of the world's first new process for making MMA from methyl acetate-formaldehyde: technology iteration, coupling mechanism and value of industrial disruption In-depth analysis of the world's first new process for making MMA from methyl acetate-formaldehyde: technology iteration, coupling mechanism and value of industrial disruption

Preface: Long-standing technical shackles and industrial pain points in the MMA industry Preface: Long-standing technical shackles and industrial pain points in the MMA industry

Methyl methacrylate (MMA) is a core monomer in the field of high-end fine chemicals and new materials. It is widely used in acrylic sheets, optical materials, coatings, adhesives, polymer composites and other tracks. It is a key high value-added product in the modern petrochemical and coal chemical industry chain. For a long time, the global MMA production capacity has been highly dependent on traditional process routes. The technical system is solidified, the environmental pressure is huge, and the raw material cost is rigid. The industry always has structural problems of "high safety risk, large amount of three wastes, poor atomic economy, and high-end technology is stuck." Methyl methacrylate (MMA) is a core monomer in the field of high-end fine chemicals and new materials. It is widely used in acrylic sheets, optical materials, coatings, adhesives, polymer composites and other tracks. It is a key high value-added product in the modern petrochemical and coal chemical industry chain. For a long time, the global MMA production capacity has been highly dependent on traditional process routes. The technical system is solidified, the environmental pressure is huge, and the cost of raw materials is high. The industry always has structural problems of "high safety risk, large amount of three wastes, poor atomic economy, and high-end technology is stuck."

The successful launch of the world's first MMA pilot plant for methyl acetate and formaldehyde by Sunburst Technology is not the technical landing of a single device, but a landmark breakthrough in the high-end, green and differentiated transformation of the domestic coal chemical industry. This process has completely jumped out of the global traditional MMA technology track and opened up Sunburst Technology's world's first MMA pilot plant for methyl acetate and formaldehyde. It is not the technical landing of a single device, but a landmark breakthrough in the high-end, green and differentiated transformation of the domestic coal chemical industry. This process has completely jumped out of the global traditional MMA technology track, opening up a new synthesis path of coal-based light ester + aldehyde-based coal-based light ester + aldehyde , solving the traditional process of highly toxic raw materials, high pollution, short-lived catalysts, cumbersome processes and other industries. At the same time, it provides high-value exports for the domestic excess production capacity of acetic acid, formaldehyde, and methanol coal chemical industry, which has strong technological innovation value and industrial reshaping significance. The new synthesis path solves the stubborn problems of traditional process highly toxic raw materials, high pollution, short-lived catalysts, and cumbersome processes. At the same time, it provides high-value exports for the domestic excess production capacity of acetic acid, formaldehyde, and methanol coal chemical industry, which has strong technological innovation value and industrial reshaping significance.

1. Bottom-layer defects and technical iteration bottlenecks of the global mainstream MMA process 1. Bottom-layer defects and technical iteration bottlenecks of the global mainstream MMA process

The current global industrialized mature MMA processes are mainly divided into three categories: ACH acetone cyanohydrin method, C4 isobutylene oxidation method, and C2 ethylene Alpha method. All kinds of routes have unavoidable bottom-level shortcomings, which are also the core direction of long-term technology iteration in the industry. The current global industrialized mature MMA processes are mainly divided into three categories: ACH acetone cyanohydrin method, C4 isobutylene oxidation method, and C2 ethylene Alpha method. All kinds of routes have unavoidable bottom-level shortcomings, which are also the core direction of long-term technology iteration in the industry.

The traditional mainstream ACH method accounts for more than 70% of the domestic production capacity, making it the most mature and lowest threshold process for localization, but it has fatal flaws: the core raw material is highly toxic hydrocyanic acid, which is highly dangerous throughout the production process, has a high level of control, and has a high risk of safety accidents; the reaction process is lengthy, a large number of waste salts and acidic waste liquids are produced by side, and the cost of waste treatment remains high; the atomic utilization rate is low, the raw material loss is large, and the comprehensive production cost is rigid, which is completely inconsistent with the current industrial policy orientation of green chemical industry and low-carbon production. The traditional mainstream ACH method accounts for more than 70% of the domestic production capacity share, making it the most mature and lowest threshold process for localization, but it has fatal flaws: the core raw material is highly toxic hydrocyanic acid, the production process is high-risk, the control level is extremely high, and the risk of safety accidents is high; the reaction process is lengthy, a large number of waste salts and acidic waste liquids are produced by side, and the treatment cost of three wastes remains high; the atomic utilization rate is low, the raw material loss is large, and the comprehensive production cost is rigid, which is completely inconsistent with the current industrial policy orientation of green chemical industry and low-carbon production.

The C4 isobutylene method relies on petrochemical carbon four resources, and the process safety is better than the ACH method, but it is highly dependent on petrochemical cracking raw materials. Resources are scarce, raw material prices fluctuate violently, and the production capacity layout is restricted by petrochemical bases. The regional adaptability is poor, making it difficult to popularize on a large scale. The C4 isobutylene method relies on petrochemical carbon four resources, and the process safety is better than the ACH method, but it is highly dependent on petrochemical cracking raw materials. Resources are scarce, raw material prices fluctuate violently, and the production capacity layout is restricted by petrochemical bases. The regional

The foreign-monopolized Lucite Alpha ethylene process is a globally recognized green and high-quality route, with the advantages of good atomic economy, simple process, no pollution, and low investment cost. However, its core technology has engineering shortcomings that cannot be broken through: the two-stage methyl propionate and formaldehyde condensation reaction adopts a fixed-bed reactor, the catalyst is prone to carbon deposition, the deactivation rate is fast, and the one-way life is short. It requires frequent shutdowns and replacements. The continuous operation stability of the device is poor, and the industrialization economy is greatly reduced. It has become a core bottleneck that restricts the large-scale industrialization of this technology for a long time. The foreign-monopolized Lucite Alpha ethylene method is a globally recognized green and high-quality route, with the advantages of good atomic economy, simple process, no pollution, and low investment cost. However, its core technology has engineering shortcomings that cannot be broken through: the condensation reaction of two-stage methyl propionate and formaldehyde adopts a fixed-bed reactor. The catalyst is prone to carbon deposition, has a fast deactivation rate, and has a short one-way life. It requires frequent shutdowns and replacements. The continuous operation stability of the device is poor, and the industrialization economy is greatly reduced. It has become a core bottleneck that restricts the large-scale industrialization of this technology for a long time.

Overall, the global MMA industry has long been caught in the ternary dilemma of "high-risk and high-pollution mature processes, unstable green processes, and high-end processes monopolized by foreign countries". The industry urgently needs a set of overall. The global MMA industry has long been caught in the ternary dilemma of "high-risk and high-pollution mature processes, unstable green processes, and foreign monopoly of high-end processes". The industry urgently needs a set of safe and non-toxic, easy-to-obtain raw materials, stable operation, green and low-carbon, self-controllable safe and non-toxic, easy-to-obtain raw materials, stable operation, green and low-carbon, and self-controllable new alternative technologies.

2. Core innovation of Sunburst new process: subverting the traditional coupling reaction system Breakthrough 2. Core innovation of Sunburst new process: subverting the traditional coupling reaction system Breakthrough

The core value of Sunburst Technology's success in this pilot test is not a small improvement of the traditional process, but the core value of Sunburst Technology's success in this pilot test. It is not a small improvement of the traditional process, but an all-round original breakthrough of reaction path, reactor structure, catalyst system, continuous production logic reaction path, reactor structure, catalyst system, continuous production logic , which completely solves the pain points of short-lived and unstable operation of foreign Alpha process catalysts, and builds a unique methyl acetate-formaldehyde synthesis MMA technology system. The all-round original breakthrough completely solves the pain points of short-lived and unstable operation of foreign Alpha process catalysts, and builds a unique methyl acetate-formaldehyde synthesis MMA technology system.

The biggest innovation highlight of this technology is that the biggest innovation highlight of this technology is fluidized bed + fixed bed dual reactor coupling, catalyst online regeneration circulating fluidized bed + fixed bed dual reactor coupling, catalyst online regeneration cycle The new process architecture is different from the traditional single fixed bed and batch production mode, and realizes the whole process of continuous, stable and low-loss production. After the traditional fixed bed process catalyst is deactivated, it must be shut down, disassembled and replaced, resulting in low start-up rate of the device, discontinuous production, and high operation and maintenance costs. Sunburst's innovative fluidized bed circulation system can realize online transportation, regeneration, and re-investment of deactivated catalysts, which fundamentally guarantees the long-term stable operation of the device and solves the common engineering problems in the industry. The new process architecture is different from the traditional single fixed bed and intermittent production mode, and realizes the continuous, stable and low-loss production of the whole process. After the catalyst is deactivated in the traditional fixed bed process, it must be shut down, disassembled and replaced, resulting in low start-up rate, discontinuous production and high operation and maintenance costs of the device; Sunburst's innovative fluidized bed circulation system can realize online transportation, regeneration and return of the deactivated catalyst, which fundamentally guarantees the long-term stable operation of the device and solves the common engineering problems in the industry.

From the perspective of technical barriers, the company has spent many years tackling key problems and formed a total of 12 independent intellectual property patents, including 10 authorized patents, covering reaction process design, special catalyst preparation, special reactor structure, product separation and refining, catalyst regeneration system and other core technologies of the whole chain, completely breaking the patent monopoly of overseas enterprises in high-end green MMA process, and realizing the independent control of domestic MMA core technology. From the perspective of technical barriers, the company has been tackling problems for many years and has formed a total of 12 independent intellectual property patents, including 10 authorized patents, covering the whole chain of core technologies such as reaction process design, special catalyst preparation, special reactor structure, product separation and refining, and catalyst regeneration system. This has completely broken the patent monopoly of overseas enterprises in high-end green MMA processes and realized the independent control of domestic MMA core technologies.

The pilot test data verified the technical superiority: the amplification effect of the whole process was controllable, the reaction efficiency and product selectivity after amplification were better than the small test level, and the separated and refined MMA products reached the national standard of excellent quality. The purity and impurity indicators fully met the production needs of high-end new materials and optical grade products, and had the technical conditions for direct industrialization. At the same time, the pilot test successfully accumulated complete amplification design parameters and process package data, laying a solid foundation for the implementation of the 100,000-ton industrialization project. The pilot test data verified the technical superiority: the amplification effect of the whole process was controllable, the reaction efficiency and product selectivity after amplification were better than the small test level, and the separated and refined MMA products reached the national standard of excellent quality. The purity and impurity indicators fully met the production needs of high-end new materials and optical grade products, and had the technical conditions for direct industrialization. At the same time, the pilot test successfully accumulated complete amplification design parameters and process package data, laying a solid foundation for the implementation of the 100,000-ton industrialization project.

III. Four-step tandem mechanism and deep disassembly of the new process III. Four-step tandem mechanism and deep disassembly of the process

Based on the published patent of Sunburst Technology (CN104513163A, CN102775302B), the process adopts the published patent of Sunburst Technology (CN104513163A, CN102775302B), the process adopts the closed-loop series logic of two-stage acetal reaction + one-stage hydrogenation reaction + online catalyst regeneration two-stage acetal reaction + one-stage hydrogenation reaction + online catalyst regeneration , each process is precisely connected, the reaction layer is clear, and the side reactions are controllable, forming a unique low-carbon synthesis path. The closed-loop series logic of each process is precisely connected, the reaction layer is clear, and the side reactions are controllable, forming a unique low-carbon synthesis path.

The first step is the primary acetal reaction in the fluidized bed. Methyl acetate and formaldehyde are used as the core raw materials, methanol is used as the solvent, and inert fluidized gas is used as the protective medium. Under the action of a special acetal catalyst, a hydroxyaldehyde condensation reaction occurs to form a directional methacrylate intermediate. The advantages of the fluidized bed system are that the materials are uniformly mixed, the temperature field is uniform, and the mass transfer efficiency is high, which can effectively avoid the side reactions caused by local overheating and improve the selectivity of intermediate products. The first step is the primary acetal reaction in the fluidized bed. Methyl acetate and formaldehyde are used as the core raw materials, methanol is used as the solvent, and inert fluidized gas is used as the protective medium. Under the action of a special acetal catalyst, a hydroxyaldehyde condens The advantages of fluidized bed system lie in uniform mixing of materials, uniform temperature field, and high mass transfer efficiency, which can effectively avoid side reactions caused by local overheating and improve the selectivity of intermediate products.

The second step is the fixed bed hydrogenation saturation reaction. The intermediate material of methyl acrylate generated by the fluidized bed is sent to the fixed bed reactor, and the selective hydrogenation is completed under the action of hydrogen atmosphere and hydrogenation catalyst to generate methyl propionate. This step takes advantage of the fixed bed reactor catalyst bed stability and the precise and controllable hydrogenation reaction to achieve directional saturation of unsaturated double bonds, without excessive hydrogenation by-products, and ensure the purity of the intermediate. The second step is the fixed bed hydrogenation saturation reaction. The intermediate material of methyl acrylate generated by the fluidized bed is sent to the fixed bed reactor, and the selective hydrogenation is completed under the action of hydrogen atmosphere and hydrogenation catalyst to generate methyl propionate. This step makes use of the advantages of fixed-bed reactor catalyst bed stability and precise and controllable hydrogenation reaction to achieve directional saturation of unsaturated double bonds, without excessive hydrogenation by-products, and to ensure the purity of intermediates.

The third step is the secondary acetal reaction in the fluidized bed. The refined methyl propionate reacts with formaldehyde again, and finally directionally generates the end point product methyl methacrylate (MMA). The secondary fluidized bed reaction continues the advantage of efficient mass transfer, adapts to the needs of deep condensation reaction, and guarantees the yield of end point products. The third step is the secondary acetal reaction in the fluidized bed. The refined methyl propionate reacts with formaldehyde again, and finally directionally generates the end point product methyl methacrylate (MMA). The secondary fluidized bed reaction continues the advantage of efficient mass transfer, adapts to the needs of deep condensation reaction, and guarantees the yield of end point products.

The fourth step is on-line closed-loop regeneration of the catalyst. The catalyst deactivated due to carbon deposition and active check point coverage during the reaction process can be automatically sent to a special regenerator, and the activation and regeneration are completed through high-temperature regeneration gas. The regenerated catalyst is re-flowed to the corresponding reactor to participate in the reaction. The closed-loop design completely bid farewell to the traditional process shutdown and agent change mode, and realizes 24-hour continuous operation of the device, which greatly improves the capacity utilization rate and production economy. The fourth step is on-line closed-loop regeneration of the catalyst. The catalyst deactivated due to carbon deposition and active check point coverage during the reaction process can be automatically sent to a special regenerator, and the activation and regeneration are completed through high-temperature regeneration gas. The regenerated catalyst is re-flowed to the corresponding The closed-loop design completely breaks away from the traditional process shutdown and reagent replacement mode, realizes 24-hour continuous operation of the unit, and greatly improves capacity utilization and production economy.

The overall process has no highly toxic raw materials involved, no high-risk reaction conditions, no large amount of waste salt and waste liquid by-products, high atomic utilization rate, simple and compact process, and takes into account safety, environmental protection and economy. It is a typical green fine chemical synthesis process. The overall process has no highly toxic raw materials involved, no high-risk reaction conditions, no large amount of waste salt and waste liquid by-products, high atomic utilization rate, simple and compact process, and takes into account safety, environmental protection and economy. It is a typical green fine chemical synthesis process.

4. The differentiated core advantages of the new process (exclusive in-depth summary) 4. The differentiated core advantages of the new process (exclusive in-depth summary)

Compared with all the mainstream MMA processes in the world, the new process of Xuyang methyl acetate-formaldehyde has four irreplaceable core advantages and builds a new technical competition barrier. Compared with all the mainstream MMA processes in the world, the new process of Xuyang methyl acetate-formaldehyde has four irreplaceable core advantages and builds a new technical competition barrier.

First, the adaptability of raw materials is extremely strong, and the contradiction of overcapacity in coal chemical industry is resolved. Domestic methanol, acetic acid, and formaldehyde are all typical overcapacity in coal chemical industry. The industry has long been facing the dilemma of insufficient operating rate, low-cost internal winding, and low added value. This process directly uses excess coal-based raw materials as the core substrate, realizes the leap of low-end basic chemical products to high-end MMA new materials, and completes the high-value extension of the coal chemical industry chain. The industrial adaptability is unique. First, the adaptability of raw materials is extremely strong, and the contradiction of overcapacity in coal chemical industry is resolved. Domestic methanol, acetic acid, and formaldehyde are all typical overcapacity in coal chemical industry. The industry has long been facing the dilemma of insufficient operating rate, low-cost internal winding, and low added value. The process directly uses excess coal-based raw materials as the core substrate to achieve the leap from low-end basic chemicals to high-end MMA new materials, and completes the high-value extension of the coal chemical industry chain.

Second, it is inherently safe and green, and completely avoids high-risk risks. The whole process does not use highly toxic raw materials such as hydrogen cyanic acid, and there is no high-risk process link. The emission of three wastes is greatly reduced, and the environmental protection treatment cost is much lower than that of the traditional ACH law. It fully adapts to the increasingly strict safety and environmental protection control policies in China, and has significant advantages in project approval, landing, and operation and maintenance. Second, it is inherently safe and green, and completely avoids high-risk risks. The whole process does not use highly toxic raw materials such as hydrogen cyanic acid, and there is no high-risk process link. The emission of three wastes is greatly reduced, and the environmental protection treatment cost is much lower than that of the traditional ACH law. It fully adapts to

Third, the coupling process solves the shortcomings of foreign technology. Through the complementary coupling of fluidized bed and fixed bed, and the online regeneration cycle of catalysts, the fatal defects of overseas Alpha process catalysts with fast deactivation, unstable operation, and inability to continuous production can be perfectly solved, and the stable industrialization of green process can be realized. The technical maturity and engineering practicality can be reversed. Third, the coupling process solves the shortcomings of foreign technology. Through the complementary coupling of fluidized bed and fixed bed, and the online regeneration cycle of catalysts, the fatal defects of overseas Alpha process catalysts with fast deactivation, unstable operation, and inability to continuous production can be perfectly solved. The stable industrialization of green process can be realized, and the technical maturity and engineering practicality can be reversed.

Fourth, the raw material route is flexible and has strong industrial ductility. This process can not only rely on the production of coal-based methyl acetate and formaldehyde, but also flexibly adapt to petrochemical raw materials such as ethylene and propylene to adjust the production path. It can be compatible with the dual raw material system of coal chemical industry and petrochemical industry. The price fluctuation ability of antigen material is extremely strong, and the market fault tolerance rate is much higher than that of the traditional process of a single raw material route. Fourth, the raw material route is flexible and the industrial ductility is strong. This process can not only rely on the production of coal-based methyl acetate and formaldehyde, but also flexibly adapt the production path of petrochemical raw materials such as ethylene and propylene. It can be compatible with the dual raw material system of coal chemical industry and petrochemical industry. The price fluctuation ability of antigen material

V. Industrialization Prospects and Industry Reconstruction Value V. Industrialization Prospects and Industry Reconstruction Value

At present, Sunburst Technology has completed the feasibility study of the 100,000-ton/year MMA industrialization project. The calculation data shows that the project has outstanding profitability, strong market competitiveness, and an economic foundation for large-scale landing. The breakthrough of this pilot technology indicates that the domestic MMA industry is about to usher in the current Sunburst Technology has completed the feasibility study of the 100,000-ton/year MMA industrialization project. The calculation data shows that the project has outstanding profitability, strong market competitiveness, and an economic foundation for large-scale landing. The breakthrough of this pilot technology indicates that the domestic MMA industry is about to usher in the triple transformation of process iteration, pattern reconstruction, industrial chain upgrade process iteration, pattern reconstruction, and industrial chain upgrade .

From the perspective of the industry landscape, the traditional ACH production capacity will be gradually replaced by new green processes, the old devices with high pollution and high risk will be cleared at an accelerated pace, and the industry as a whole will be transformed into green, safe, and high-end; the high-end green MMA technical barriers monopolized by foreign countries will be completely broken, and domestic enterprises will achieve independent control of technology and no longer rely on overseas patent authorization. From the perspective of the industry landscape, the traditional ACH production capacity will be gradually replaced by new green processes, and the old devices with high pollution and high risk will be cleared at an accelerated pace. The industry as a whole will be transformed into green, safe, and high-end; the high-end green MMA technical barriers monopolized by foreign countries will be completely broken, and domestic enterprises will achieve independent control of technology and no longer rely on overseas patent authorization. <

From the perspective of industrial chain value, this technology has opened up the complete high-end coal chemical industry chain of "methanol-acetic acid-formaldehyde-MMA-high-end new materials", revitalized the low-end excess coal chemical production capacity, improved the refinement and high value-added level of the domestic coal chemical industry, and changed the long-term low-end internal winding industry status quo of the domestic coal chemical industry. At the same time, it can drive the development of downstream high-end industries such as optical materials, high-end coatings, medical polymers, and aviation composites, forming a complete industrial cluster effect. From the perspective of industrial chain value, this technology has opened up the complete high-end chain of "methanol-acetic acid-formaldehyde-MMA-high-end new materials" in the coal chemical industry, revitalized the low-end excess coal chemical production capacity, improved the refinement and high value-added level of the domestic coal chemical industry, and changed the long-term low-end internal winding industrial status of the domestic coal chemical industry. At the same time, it can drive the development of downstream high-end industries such as optical materials, high-end coatings, medical polymers, and aviation composites, forming a complete industrial cluster effect.

From a long-term market perspective, with the continuous expansion of the new energy, optical electronics, and high-end building materials industries, the demand for high-end MMA is growing steadily, while the existing traditional process capacity is difficult to add due to environmental protection and safety restrictions. Green new processes will become the core force for future MMA capacity additions, with huge market space and commercialization potential. From a long-term market perspective, with the continuous expansion of new energy, optical electronics, and high-end building materials industries, the demand for high-end MMA is growing steadily, while the existing traditional process capacity is difficult to add due to environmental protection and safety restrictions. Green new processes will become the core force for future MMA capacity additions, with huge market space and commercialization potential.

VI. Industry summary and future development anticipated VI. Industry summary and future development anticipated

Sunburst Technology is the world's first MMA process from methyl acetate to formaldehyde, which is a milestone achievement in the transformation and upgrading of the domestic coal chemical industry. This technology jumps out of the global traditional MMA technology iterative framework, and solves the industry's decades of safety, environmental protection and stability problems with its independent innovative coupling reaction system and online regenerative catalytic technology. At the same time, it accurately digests the domestic excess coal chemical production capacity and realizes the reshaping of industrial value. Sunburst Technology is the world's first MMA process from methyl acetate to formaldehyde, which is a milestone achievement in the transformation and upgrading of the domestic coal chemical industry. This technology has jumped out of the global traditional MMA technology iterative framework, and has solved the industry's decades-old safety, environmental protection and stability problems with its independently innovative coupling reaction system and online regenerative catalytic technology. At the same time, it has accurately digested the domestic excess coal chemical production capacity and realized the industrial value reshaping.

In the short term, with the improvement of pilot data and the finalization of process packages, after the 100,000-ton industrialization project is launched, the cost advantage and product quality advantage of the new process will be quickly verified, and the domestic MMA process replacement wave will be opened; in the medium and long term, the original technology is expected to become the mainstream route of global MMA green production, and promote the transformation of our country from a large MMA production capacity country to a MMA technology power, providing a new technical paradigm and industrial path for the high-end development of fine chemical industry and modern coal chemical industry. In the short term, with the improvement of the pilot data and the finalization of the process package, after the 100,000-ton industrialization project is launched, the cost advantage and product quality advantage of the new process will be quickly verified, and the domestic MMA process replacement wave will be opened; in the medium and long term, the original technology is expected to become the mainstream route of global MMA green production, promote our country from a large MMA production capacity country to a MMA technology power, and provide a new technical paradigm and industrial path for the high-end development of fine chemical industry and modern coal chemical industry.

| (Note: Parts of the document may be AI-generated) | (Note: Parts of the document may be AI-generated)