FORMALIN FROM METHANOL
[EIRI/EDPR/1380] J.C.156
INTRODUCTION
Formalin is one of the most versatile chemicals and is a basic building block to many important industries, Formalin is used to manufacture resins; as an intermediate for synthesizing other chemicals and is also directly used without further processing. The various applications of formaldehyde as resins, as an intermediate and as itself are described below:
As Resins: The largest amount of formalin finds application in the manufacture of Resins, viz., Phenol Formalin (PF), Urea Formalin (UF) and Melamine Formalin (MF) - which finds applications in laminates, plywood, MDF, particle board and hard boards. These resins are also used for the following;
To produce curable moulding materials
As raw materials for surface coatings
As binders for foundry sand
As an Intermediate: Formalin is also used for synthesizing chemicals like:
Pentaerythritol
Hexamine
Paraformaldehyde
1,4-Butanediol
Polyacetal Resins
(ixj Methylene Diplineylene Di-isocynates (MDI)
Trimethylolpropane
Neopentylglycol
Direct Use: Formalin is also used directly for the following:
Mirror finishing and electroplating
Preservation and disinfection
Film development in photography industry
Though, there are several routes to manufacture formalin, only routes based on catalytic oxidation of methanol are being employed today. Today, all of the world's commercial formalin 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 formalin, while metal oxide process employs an oxide catalyst for a direct oxidation route to formalin.
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 formalin of higher concentration with substantial reduction in energy consumption levels.
COST ESTIMATION
Plant Capacity 10 MT/Day
Land & Building (5000 sq.mt.) Rs. 5.78 Cr
Plant & Machinery Rs. 1.34 Cr
Working Capital for 2 Months Rs. 1.20 Cr
Total Capital Investment Rs. 9.00 Cr
Rate of Return 50%
Break Even Point 39%
CONTENTS
INTRODUCTION
PROPERTIES
ANALYSIS AND SPECIFICATIONS
USES AND APPLICATIONS
INDIAN STANDARD SPECIFICATION
ANALYSIS OF FORMALDEHYDE SOLUTION
DETERMINATION OF METHANOL CONTENT
TEST FOR HEAVY METALS (OTHER THAN IRON)
ECONOMIC ASPECTS
MARKET SURVEY
MANUFACTURERS/SUPPLIERS OF FORMALDEHYDE
PROCESS OF MANUFACTURE
PROCESS OF MANUFACTURING
OCCURENCE OF REACTION
FLOW DIAGRAM OF TYPICAL SILVER-CATALYST PROCESS
PRODUCTION PROCESS
FLOW SHEET
TESTING OF FORMALIN
PROCESS FLOW SHEET FOR THE MANUFACTURE OF FORMALIN FROM METHANOL
PLANT LAYOUT
OTHER RELATED INFORMATIONS
PROCESS FOR THE NON-OXIDATIVE PREPARATION OF FORMALDEHYDE FROM METHANOL
SUPPLIERS OF PLANT AND MACHINERY FOR FORMALDEHYDE
MANUFACTURERS/SUPPLIERS OF RAW MATERIALS
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)
