Abstract: A catalyzed interfacial phosgenation process with controlled feed ratios and controlled reaction pH levels allows for the formation of high heat polycarbonate random copolymers having high loadings of bis (4-hydroxyphenyl)-2-phenylisoindolin-1-one (“PPPBP”) or a structurally related comonomer. The process produces a polycarbonate copolymer having improved hydrolytic stability.

Abstract: In an embodiment, a method of producing a carbonate comprises reacting carbon monoxide and chlorine in a phosgene reactor in the presence of a catalyst to produce a first product comprising phosgene; wherein carbon tetrachloride is present in the first product in an amount of 0 to 10 ppm by volume based on the total volume of phosgene; and reacting a monohydroxy compound with the phosgene to produce the carbonate; wherein the phosgene reactor comprises a tube, a shell, and a space located between the tube and the shell; wherein the tube comprises one or more of a mini-tube section and a second tube section; a first concentric tube concentrically located in the shell; a twisted tube; an internal scaffold; and an external scaffold.

Abstract: In an embodiment, a method of producing carbonate can comprise: reacting a feed comprising carbon monoxide and chlorine in a tube of a reactor to produce a product composition comprising phosgene, wherein the tube has a particulate catalyst contained therein, wherein a thermally conductive material separate from the tube contacts at least a portion of the particulate catalyst, and wherein carbon tetrachloride is present in the product composition in an amount of 0 to 10 ppm by volume based on the volume of the phosgene; and reacting a monohydroxy compound with the phosgene to produce the carbonate.

Abstract: A reactor for producing phosgene, the reactor comprising: tube located in a shell and a space located between the tube and the shell; a cooling medium located in the space and a catalyst located in the tube or cooling medium located in the tube and a catalyst located in the space; a feed inlet; and a product mixture outlet; wherein the tube comprises one or more of: a mini-tube and a second tube section; a first concentric tube concentrically located in the shell; a twisted tube; an internal scaffold; and an external scaffold.

Abstract: In another embodiment, a process of purifying an interfacially polymerized polycarbonate from a feed comprising an aqueous phase and an organic phase comprising an organic solvent, the interfacially polymerized polycarbonate, a catalyst, and ions, can comprise: separating the aqueous phase and the organic phase from the feed, wherein during the separating the feed is subjected to at least one of: energy of less than or equal to 0.5 kJ/kg of feed, a shear rate of less than 150,000 S?1, and centrifugal forces of 100 to 2,000 g-force; to form a purified aqueous phase and a purified organic phase comprising a purified polycarbonate.

Abstract: In an embodiment, a process of purifying a polycarbonate from an interfacial polymerization product mixture comprising an aqueous phase and an organic phase comprising a first organic solvent, the polycarbonate, a catalyst, and ions, the process comprises: separating the aqueous phase and the organic phase to form a separated aqueous feed stream and a separated organic stream; extracting the catalyst and the ions from the separated organic stream to form a purified polycarbonate stream and an extracted aqueous feed stream, wherein at least one of the separated aqueous feed stream and the extracted aqueous feed stream comprise an organic portion and an aqueous portion; purifying an aqueous stream comprising one or both of the separated aqueous feed stream and the extracted aqueous feed stream by adjusting a viscosity of the organic portion to be less than or equal to 40 centipoise by adding a second organic solvent to the aqueous stream to form a combined stream; optionally, adjusting a ratio of the aqueous po

Abstract: In an embodiment, a method of producing a carbonate comprises reacting carbon monoxide and chlorine in a phosgene reactor in the presence of a catalyst to produce a first product comprising phosgene; wherein carbon tetrachloride is present in the first product in an amount of 0 to 10 ppm by volume based on the total volume of phosgene; and reacting a monohydroxy compound with the phosgene to produce the carbonate; wherein the phosgene reactor comprises a tube, a shell, and a space located between the tube and the shell; wherein the tube comprises one or more of a mini-tube section and a second tube section; a first concentric tube concentrically located in the shell; a twisted tube; an internal scaffold; and an external scaffold.

Abstract: In an embodiment, a method of producing carbonate can comprise: reacting a feed comprising carbon monoxide and chlorine in a tube of a reactor to produce a product composition comprising phosgene, wherein the tube has a particulate catalyst contained therein, wherein a thermally conductive material separate from the tube contacts at least a portion of the particulate catalyst, and wherein carbon tetrachloride is present in the product composition in an amount of 0 to 10 ppm by volume based on the volume of the phosgene; and reacting a monohydroxy compound with the phosgene to produce the carbonate.

Abstract: A catalyzed interfacial phosgenation process with controlled feed ratios and controlled reaction pH levels allows for the formation of high heat polycarbonate random copolymers having high loadings of bis (4-hydroxyphenyl)-2-phenylisoindolin-1-one (“PPPBP”) or a structurally related comonomer. The process produces a polycarbonate copolymer having improved hydrolytic stability.

Abstract: In an embodiment, a method of producing phosgene in a tube reactor comprises introducing a feed comprising carbon monoxide and chlorine to a tube of the reactor, the tube having a particulate catalyst disposed therein, wherein a thermally conductive material separate from the tube contacts at least a portion of the particulate catalyst; to produce a product composition comprising phosgene, and carbon tetrachloride in an amount of 0 to 10 ppm by volume based on the volume of the phosgene.

Abstract: A reactor for producing phosgene, the reactor comprising: tube located in a shell and a space located between the tube and the shell; a cooling medium located in the space and a catalyst located in the tube or cooling medium located in the tube and a catalyst located in the space; a feed inlet; and a product mixture outlet; wherein the tube comprises one or more of: a mini-tube and a second tube section; a first concentric tube concentrically located in the shell; a twisted tube; an internal scaffold; and an external scaffold.

Abstract: In another embodiment, a process of purifying an interfacially polymerized polycarbonate from a feed comprising an aqueous phase and an organic phase comprising an organic solvent, the interfacially polymerized polycarbonate, a catalyst, and ions, can comprise: separating the aqueous phase and the organic phase from the feed, wherein during the separating the feed is subjected to at least one of: energy of less than or equal to 0.5 kJ/kg of feed, a shear rate of less than 150,000 S?1, and centrifugal forces of 100 to 2,000 g-force; to form a purified aqueous phase and a purified organic phase comprising a purified polycarbonate.

Abstract: In an embodiment, a process of purifying a polycarbonate from an interfacial polymerization product mixture comprising an aqueous phase and an organic phase comprising a first organic solvent, the polycarbonate, a catalyst, and ions, the process comprises: separating the aqueous phase and the organic phase to form a separated aqueous feed stream and a separated organic stream; extracting the catalyst and the ions from the separated organic stream to form a purified polycarbonate stream and an extracted aqueous feed stream, wherein at least one of the separated aqueous feed stream and the extracted aqueous feed stream comprise an organic portion and an aqueous portion; purifying an aqueous stream comprising one or both of the separated aqueous feed stream and the extracted aqueous feed stream by adjusting a viscosity of the organic portion to be less than or equal to 40 centipoise by adding a second organic solvent to the aqueous stream to form a combined stream; optionally, adjusting a ratio of the aqueous po

Abstract: A method to recover caustic from a caustic waste stream comprises reducing the temperature of a caustic waste stream comprising dissolved Na2CO3 to a temperature less than or equal to the temperature at which the Na2CO3 precipitates from the caustic waste stream to form a caustic waste stream comprising precipitated Na2CO3 and separating the precipitated Na2CO3.

Abstract: A method to recover caustic from a caustic waste stream comprises reducing the temperature of a caustic waste stream comprising dissolved Na2CO3 to a temperature less than or equal to the temperature at which the Na2CO3 precipitates from the caustic waste stream to form a caustic waste stream comprising precipitated Na2CO3 and separating the precipitated Na2CO3.

Abstract: A crosslinked poly(arylene ether) film is prepared by a method that includes forming a film from a composition that includes a poly(arylene ether) having an intrinsic viscosity of at least 0.25 deciliter per gram and a polydispersity index less than or equal to 10, and irradiating the poly(arylene ether) film with a dosage of about 50 to about 50,000 kiloGrays of accelerated electrons. The films exhibit good flexibility and solvent resistance. Films prepared by the method are described, as are articles that include such films.