Production
World production capacity of this compound was 1 million tons in the 80s, and more than 2.2 million tons in 2009. In 2003, U.S. consumption was 856,000 tons, 72% of which was used to make polycarbonate plastic and 21% going into epoxy resins. In the U.S., less than 5% of the BPA produced is used in food contact applications, but remains in the canned food industry and printing applications such as sales receipts.
Bisphenol A was first synthesized by the Russian chemist A.P. Dianin in 1891. This compound is synthesized by the condensation of acetone (hence the suffix A in the name) with two equivalents of phenol. The reaction is catalyzed by a strong acid, such as hydrochloric acid (HCl) or a sulfonated polystyrene resin. Industrially, a large excess of phenol is used to ensure full condensation; the product mixture of the cumene process (acetone and phenol) may also be used as starting material:
A large number of ketones undergo analogous condensation reactions. Commercial production of BPA requires distillation – either extraction of BPA from many resinous byproducts under high vacuum, or solvent-based extraction using additional phenol followed by distillation.
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