China Successfully Completes Industrial Trial for Phosgene-Free MDI Production via Urea Method

The Institute of Process Engineering at the Chinese Academy of Sciences recently announced a major breakthrough in the industrialization of phosgene-free diphenylmethane diisocyanate (MDI) production using the urea method. Developed in collaboration with Shaanxi Coal Chemical Technology Development Center and Shaanxi Coal & Chemical Technology Institute, the innovative green manufacturing technology has successfully completed the full-process calibration of its industrial trial unit. During the trial, the system operated stably with high-quality data, meeting all expected performance indicators.

Isocyanates are critical raw materials for manufacturing strategic engineering plastics, particularly polyurethane, which is widely used in the automotive, wind energy, and high-speed rail industries. The conventional phosgene-based method dominates global MDI production, relying on benzene, liquid chlorine, and carbon monoxide as key feedstocks. This process involves benzene amination, phosgenation, and subsequent purification steps.

Lower Raw Material Costs: Uses cost-effective and readily available urea and aniline, whereas phosgene-based production requires highly toxic phosgene, which incurs storage, transportation, and safety management costs.

Enhanced Safety & Reduced Environmental Impact: Eliminates phosgene, minimizing toxic by-products such as hydrogen chloride, thereby lowering emissions and waste treatment expenses.

Simplified Production Process: The urea method features a less complex workflow, reducing both capital investment and operational costs compared to the highly intricate phosgene-based method.

Regulatory & Policy Support: Aligns with China's “Dual Carbon” Strategy, increasing the likelihood of government incentives such as subsidies and tax benefits, whereas phosgene-based production faces stricter environmental regulations.

This pioneering technology utilizes aniline, urea, and formaldehyde as key feedstocks, establishing a phosgene-free route for MDI synthesis. After a decade of dedicated R&D, the research team has overcome key technical challenges, achieving a fully integrated and independently patented green MDI production system.

With high atom economy and intrinsically safer process conditions, this breakthrough facilitates the development of scalable production facilities and diversified product lines, unlocking immense market potential. Moving forward, the research team will continue to optimize the technology and accelerate its commercial-scale deployment.