Detailed Project Report on Formalin from Methanol

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)