Detailed Project Report on formaldehyde 37% (capacity: 80 tpd)

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)