Formaldehyde 37% (Capacity: 80 TPD)

FORMALDEHYDE 37% (CAPACITY: 80 TPD)

[EIRI/EDPR/4558] J.C.: 2775XL 

INTRODUCTION

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.

COST ESTIMATION

Plant Capacity            80 MT/Day  

Land & Building (8000 sq.mt.)    Rs. 4.85 Cr    

Plant & Machinery                    Rs. 5.44 Cr 

Working Capital for 2 Months    Rs. 7.77 Cr 

Total Capital Investment          Rs. 18.75 Cr 

Rate of Return                          31%

Break Even Point                      54%

CONTENTS

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

FORMALDEHYDE SPECIFICATIONS

FORMS OF FORMALDEHYDE

USES AND APPLICATIONS

AGRICULTURE

AUTOMOBILES

CEMENT CONCRETE

COSMETICS

DISINFECTANT

EMBALMING AGENT

EXPLOSIVES

FUELS

FERTILIZERS

PAPER

RUBBER

SURFACE-ACTIVE AGENTS

TEXTILES

POLYACETALS

CARDANOL RESINS

NEWER APPLICATIONS

TOXICOLOGY OF FORMALDEHYDE

SYMPTOMATOLOGY

A. INHALATION

B. INGESTION

C. SKIN CONTACT

TREATMENT

LABORATORY

B.I.S. SPECIFICATION

SCOPE

REQUIREMENTS

TABLE REQUIREMENTS FOR FORMALDEHYDE SOLUTION

PACKING AND MARKING

SAMPLING

ANALYSIS OF FORMALDEHYDE SOLUTION

QUALITY OF REAGENTS

DETERMINATION OF ACIDITY

REAGENTS

CALCULATION

WHERE

DETERMINATION OF ASH

CALCULATION –

WHERE

DETERMINATION OF ALDEHYDE CONTENT

REAGENTS

PROCEDURE

CALCULATION

WHERE

DETERMINATION OF IRON

REAGENTS

PROCEDURE

CALCULATION

WHERE

METHOD B (2,2'-BIPYRIDYL METHOD)

CALCULATION

WHERE

DETERMINATION OF METHANOL CONTENT

METHOD A (GRAPHICAL METHOD)

PROCEDURE-

METHOD B (CHEMICAL METHOD)

REAGENTS

CALCULATION

WHERE

WHERE

TEST FOR HEAVY METALS (OTHER THAN IRON)

REAGENTS

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

MARKET POSITION OF FORMALDEHYDE

INSTALLED CAPACITY AND PRODUCTION OF FORMALDEHYDE

CONSUMPTION OF FORMALDEHYDE

EXPORT OF FORMALDEHYDE

IMPORT OF FORMALDEHYDE

TOP FIVE EXPORT DESTINATION OF FORMALDEHYDE (2020-21)

CAPACITY OF FORMALDEHYDE

FUTURE OF FORMALDEHYDE IN INDIA

GLOBAL MARKET OF FORMALDEHYDE

CONSUMPTION PATTERN OF FORMALDEHYDE

GLOBAL PATTERN OF DEMAND

TECHNOLOGY LICENSORS

MANUFACTURERS/SUPPLIERS

ROUTES AVAILABLE FOR PRODUCTION OF FORMALDEHYDE

PROCESS DESCRIPTION:

PRODUCTION OF FORMALDEHYDE FROM METHANOL

UNIT OPERATION IN FORMALDEHYDE MANUFACTURING

PROCESS WASTE

MANUFACTURING PROCESS OF FORMALDEHYDE 37%

REACTION:

PROCESS IN DETAILS

SILVER-CATALYST PROCESS

BY-PRODUCTS

LIFE OF SILVER CATALYST

POISONING OF CATALYST

OVERCOMING CATALYST POISONS

FLOW DIAGRAM OF TYPICAL SILVER-CATALYST PROCESS

TESTING OF FORMALDEHYDE

1. PYROGALLOL TEST:-

2. REMINI'S TEST:-

3. SCHRYVER"S TEST.

PROCESS FLOW SHEET FOR THE MANUFACTURE OF FORMALDEHYDE FROM METHANOL

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF MIXING VESSEL

SUPPLIERS OF REACTORS

SUPPLIERS OF LABORATORY EQUIPMENTS

SUPPLIERS OF BOILERS

SUPPLIERS OF D.G. SETS

SUPPLIERS OF EFFLUENT 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)