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Formaldehyde (HCHO) is primarily produced from methanol, with about 60% used in resin manufacturing and one-third in chemical derivatives. India has 25 production plants with a capacity of 0.36 million tons annually, while global capacity is around 15 million tons, mainly from the USA. The production process involves dehydrogenation and partial oxidation of methanol, requiring careful control of reaction conditions to prevent explosive mixtures and manage emissions.

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Suyash Abnave
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12 views3 pages

For Made Hyde

Formaldehyde (HCHO) is primarily produced from methanol, with about 60% used in resin manufacturing and one-third in chemical derivatives. India has 25 production plants with a capacity of 0.36 million tons annually, while global capacity is around 15 million tons, mainly from the USA. The production process involves dehydrogenation and partial oxidation of methanol, requiring careful control of reaction conditions to prevent explosive mixtures and manage emissions.

Uploaded by

Suyash Abnave
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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Formadehyde [HCHO]

About 35% methanol produced worldwide goes into the manufacture of HCHO. It is
produced and used as formalin, its aqueous solution containing 37-50% HCHO. About 60%
of HCHO is used in the manufacture of several resins such as urea-formaldehyde, phenol-
formaldehyde and melamine formaldehyde. These are extensively applied in wood/
plywood, inks, cars and trucks for electric transmission systems etc. About one-third of
HCHO is used in the synthesis of high volume chemical derivatives, including
pentaerythritol, hexamethylenetetramine and butanediol.

There are 25 plants in India producing HCHO with an installed capacity of 0.36 million tons
per annum. The world wide capacity is about 15 million tons per annum with USA being the
major producer.

Reactions in the manufacture of HCHO are:

1. Dehydrogenation of methanol to produce HCHO and H2.

𝐶𝐻3 𝑂𝐻 ⇌ 𝐻𝐶𝐻𝑂 + 𝐻2 ∆𝐻 𝑜 = +85 𝐾𝐽/𝑚𝑜𝑙

2. Partial oxidation of methanol to give HCHO and water.

1
𝐶𝐻3 𝑂𝐻 + 𝑂 ⇌ 𝐻𝐶𝐻𝑂 + 𝐻2 𝑂 ∆𝐻 𝑜 = −158 𝐾𝐽/𝑚𝑜𝑙
2 2

Reaction 2 is exothermic and it can supply heat to reaction 1, which is endothermic.

Is a catalyst necessary for partial oxidation? Why?

Do you expect side reactions to occur? List them.

42
Commercially, the above reactions are carried out over a silver-based catalyst. Methanol, like
other hydrocarbons, forms explosive mixture with air. The flammability limits are:

Lower flammability limit (LFL): 6 vol % methanol in air; Upper flammability limit (UFL):
36 vol % methanol in air.

If the methanol concentration falls between the lower and upper limits, then the methanol-air
mixture is likely to explode.

The reactor for HCHO production should be operated at:

A. Below LFL

B. Above UFL [Think about economic and technical feasibility]

C. Either A or B

Reactions 1 and 2 shown in the previous page are carried out at 610-620 oC, 1.5 atm.
Oxidation reactions are very fast at these temperatures and therefore need very short contact
time. What type of reactor configuration do you recommend for formaldehyde synthesis?
Draw the configuration.

Sometimes steam is added to the reaction feed mixture (methanol + air) to control the
reaction temperature. Is this control critical? Is steam addition beneficial in the production
of formalin?

The reactor effluents need to be quenched immediately to prevent side reactions. What are
the next logical steps to produce formalin (37-50%, formaldehyde solution in water)?

Remember: Neat formaldehyde is never produced because it is unstable and forms formic
acid and/or para formaldehyde.

43
Draw a block diagram for HCHO manufacture.

The off-gas from the absorber contains ~ 1.5 vol % CO, 0.5 vol % formaldehyde, CO and
HCHO, especially the latter is carcinogen and exposure to it can be fatal. A catalyst has been
developed to incinerate the off-gas at < 600 oC.

The off-gas is passed through a catalytic incineration unit where CO (20 mg/Nm3) and
HCHO (5 mg/Nm3) emissions are reduced to below acceptable limits. Also, the incineration
process does not generate any NOx because the temperatures are below 600 oC.

For the incineration to be effective, the off-gas should be:

A. Heated B. Cooled C. Supplied as is

Draw flow sheet for the off gas treatment. Use energy integration in the flowsheet.

44

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