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)
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