FORMALDEHYDE 37% [3597]
The commercial production of formaldehyde was first started in Germany in the 1880s but the development of a methanol synthesis route in the 1920s gave the spur to the development of large-scale manufacture. Today there are two main routes: oxidation-dehydrogenation using a silver catalyst involving both the complete or incomplete conversion of methanol; and the direct oxidation of methanol to formaldehyde using metal oxide catalysts (Formox process). In the silver catalyst route, vapourised methanol with air and steam is passed over a thin bed of silver-crystal catalyst at about 650oC. Formaldehyde is formed by the dehydrogenation of methanol. The heat required for the endothermic reaction is obtained by burning hydrogen contained in the off-gas produced from the dehydrogenation reaction. The other route involves the oxidation of methanol over a catalyst of molybdenum and iron oxide. A mixture of air and methanol is vapourised and passed into catalyst-packed reactor tubes. The reaction which takes place at 350oC is highly exothermic and generates heat to provide steam for turbines and process heating. Perstorp offers a high pressure version of the Formox process which can be retrofitted to existing plants to boost capacity. The high conversion rate of the Perstorp process eliminates the need for methanol recovery via distillation and it can produce formaldehyde at concentrations up to 57%. Yields from both processes are around 90% to 92% but the oxidation route has a lower reaction temperature and the metal catalyst is cheaper than silver. However, the partial oxidation-dehydrogenation route is still the most prevalent. Though, there are several routes to manufacture formaldehyde only routes based on catalytic oxidation of methanol are being employed today. Today, all of the world's commercial formaldehyde is manufactured from methanol and air using either a silver catalyst or a metal oxide catalyst. Silver catalyst process combines dehydrogenation and oxidation to obtain formaldehyde, while metal oxide process employs an oxide catalyst for a direct oxidation route to formaldehyde. In comparison to conventional silver process which is based on incomplete conversion and distillative recovery of methanol, metal oxide process has higher yield, lower energy consumption through excess steam generation and produces highly concentrated formaldehyde solutions without distillation, allowing for low operating cost. The improved version of silver process, which employs complete conversion of methanol avoiding distillation step, has made it possible to produce formaldehyde of higher concentration with substantial reduction in energy consumption levels.
COST ESTIMATION
Plant Capacity 80 Ton/Day
Land & Building (2 Acre) Rs. 4.54 Cr
Plant & Machinery Rs. 3.42 Cr
Working Capital for 2 Months Rs. 5.96 Cr
Total Capital Investment Rs. 14.40 Cr
Rate of Return 31%
Break Even Point 52%
INTRODUCTION
USES OF FORMALDEHYDE
FORMALDEHYDE USES IN INDUSTRY:
FORMALDEHYDE USES IN MEDICINE:
FORMALDEHYDE USES IN BUILDING AND CONSTRUCTION:
FORMALDEHYDE USES IN FOOD AND OTHERS:
PROPERTIES & CHARACTERISTICS
FORMALDEHYDE GAS
FORMALDEHYDE SOLUTIONS (37 PER CENT)
FORMALIN
CONTAINERS & REGULATIONS
GRADES OF FORMALDEHYDE
HAZARD
TOLERANCE
EXPLOSIVE LIMITS
SHIPPING REGULATIONS
SPECIFICATION, QUALITY CONTROL OF FORMALDEHYDE
FORMS OF FORMALDEHYDE
USES AND APPLICATIONS
INDUSTRIAL APPLICATIONS
DISINFECTANT AND BIOCIDE
TOXICOLOGY
SYMPTOMATOLOGY
A. INHALATION
B. INGESTION
C. SKIN CONTACT
TREATMENT
LABORATORY
B.I.S. SPECIFICATION
REQUIREMENTS
TABLE REQUIREMENTS FOR FORMALDEHYDE SOLUTION
PACKING AND MARKING
ANALYSIS OF FORMALDEHYDE SOLUTION
QUALITY OF REAGENTS
DETERMINATION OF ACIDITY
DETERMINATION OF ASH
DETERMINATION OF ALDEHYDE CONTENT
DETERMINATION OF IRON
DETERMINATION OF METHANOL CONTENT
METHOD A (GRAPHICAL METHOD)
METHOD B (CHEMICAL METHOD)
TEST FOR HEAVY METALS (OTHER THAN IRON)
ECONOMIC ASPECTS
PHYSICAL PROPERTIES OF FORMALDEHYDE
PROPERTIES OF AQUEOUS SOLUTION OF FORMALDEHYDE
MANUFACTURE OF FORMALDEHYDE
COMMERCIAL MANUFACTURE
SILVER PROCESS
OXIDE PROCESS
TYPICAL SPECIFICATIONS OF DIFFERENT GRADES OF FORMALDEHYDE
RAW MATERIALS RESOURCE
USES
PRODUCTION
USES OF FORMALDEHYDE
AGRICULTURE
AUTOMOBILES
CEMENT CONCRETE
COSMETICS
DISINFECTANT
EMBALMING AGENT
EXPLOSIVES
FUELS
FERTILIZERS
PAPER
RUBBER
SURFACE-ACTIVE AGENTS
TEXTILES
POLYACETALS
CARDANOL RESINS
NEWER APPLICATIONS
MARKET POSITION OF FORMALDEHYDE
FORMALDEHYDE TO CONTINUE AS A SIGNIFICANT METHANOL CONSUMER
INSTALLED CAPACITY & PRODUCTION OF FORMALDEHYDE
CONSUMPTION OF FORMALDEHYDE
EXPORT DATA OF FORMALDEHYDE
IMPORT OF FORMALDEHYDE
TOP FIVE DESTINATION OF FORMALDEHYDE
CAPACITY OF FORMALDEHYDE
GLOBAL OUTLOOK
WORLD PRODUCTION OF FORMALDEHYDE: (BILLION POUNDS, 27%)
CONSUMPTION PATTERN OF FORMALDEHYDE
SAFE HANDLING
GLOBAL PATTERN OF DEMAND
TECHNOLOGY LICENSORS
ECONOMICS
SAFETY AND HEALTH CONCERNS
MANUFACTURERS/SUPPLIERS
ROUTES AVAILABLE FOR PRODUCTION OF FORMALDEHYDE
PROCESS DESCRIPTION:
PRODUCTION OF FORMALDEHYDE FROM METHANOL
MANUFACTURING PROCESS OF FORMALDEHYDE 37%
DIFFERENT PROCESSES TO MANUFACTURE FORMALDEHYDE
1. FROM METHYL ALCOHOL:
2. FORMALDEHYDE PRODUCTION FROM METHANE:
3. FROM WATER GAS.
MANUFACTURE:
MATERIAL REQUIREMENTS
PROCESS
SILVER-CATALYST PROCESS
BY-PRODUCTS
LIFE OF SILVER CATALYST
POISONING OF CATALYST
OVERCOMING CATALYST POISONS
OCCURENCE OF REACTION
FLOW DIAGRAM OF TYPICAL SILVER-CATALYST PROCESS
METAL OXIDE CATALYST PROCESS
FROM NATURAL GAS
TESTING OF FORMALDEHYDE
1. PYROGALLOL TEST:-
2. REMINI'S TEST:-
3. SCHRYVER"S TEST.
PROCESS FLOW SHEET FOR THE MANUFACTURE OF FORMALDEHYDE
FROM METHANOL
FORMALDEHYDE PRODUCTION PROCESSES
METHANOL YIELD
ENERGY CONSUMPTION
CATALYST
STEAM
PLANT CAPACITY
PROCESSES FEATURES
SAFETY
PRODUCT QUALITY
SPECIAL PRODUCT
SYNTHESIS AND INDUSTRIAL PRODUCTION OF FORMALDEHYDE
ORGANIC CHEMISTRY
SELF-CONDENSATION AND HYDRATION
OXIDATION
HYDROXYMETHYLATION AND CHLOROMETHYLATION
BASE REACTIONS
PLANT LAYOUT
SUPPLIERS OF RAW MATERIALS
SUPPLIERS OF PLANT AND MACHINERY
MIXING VESSEL
REACTORS
LABORATORY EQUIPMENTS
BOILERS
D.G. SETS
EFFULENT TREATMENT PLANT (ETP PLANT)
APPENDIX – A:
01. PLANT ECONOMICS
02. LAND & BUILDING
03. PLANT AND MACHINERY
04. OTHER FIXED ASSESTS
05. FIXED CAPITAL
06. RAW MATERIAL
07. SALARY AND WAGES
08. UTILITIES AND OVERHEADS
09. TOTAL WORKING CAPITAL
10. TOTAL CAPITAL INVESTMENT
11. COST OF PRODUCTION
12. TURN OVER/ANNUM
13. BREAK EVEN POINT
14. RESOURCES FOR FINANCE
15. INSTALMENT PAYABLE IN 5 YEARS
16. DEPRECIATION CHART FOR 5 YEARS
17. PROFIT ANALYSIS FOR 5 YEARS
18. PROJECTED BALANCE SHEET FOR (5 YEARS)
