OIL & GAS PROCESSING TECHNOLOGY

PRODUCTION
OF
FORMALDEHYDE

FARAH NADIAH SIDEK (KKE 18004)

INTRODUCTION
FORMALDEHYDE

 Formaldehyde is an organic compound

with chemical formula CH2O.
 It is the simplest Aldehyde.
Formaldehyde is colorless gas with a
pungent smell
 It has found great significance in many
chemical compounds as a precursor
especially in the polymers industry.
INTRODUCTION
USES OF FORMALDEHYDE
 Intermediate substance for a large
variety of organic compounds ranging
from ammonia to phenolic resins to slow
release fertilizer
 Manufacturing of Glues and Resins
 As a Disinfectant
 In the Textile Industry
 In the Automobile Industry
 Preserving Cells and Tissues
INTRODUCTION
PHYSICAL PROPERTIES OF FORMALDEHYDE
INTRODUCTION
HAZARD ASSOCIATED WITH FORMALDEHYDE
FORMALDEHYDE TECHNOLOGIES
 Formaldehyde is manufactured commercially from methanol
and air by using metal catalyst or metal oxide catalyst.
 Two types of catalysts that are currently used for methanol
oxidation:
 Iron Molybdenum oxide catalyst

 Silver or copper catalyst

 Silver catalyst process is the predominant process, accounting

for 75 percent of formaldehyde manufactured while metal
oxide process accounts for the remaining 25 percent.
FORMALDEHYDE TECHNOLOGIES
 However, a new approach, which is direct catalytic conversion
of biogas methane to form formaldehyde, has been tested
experimentally.
 This method utilized organic solid waste such as cattle waste to
generate biogas and methane gas. After purification of
methane gas, a direct conversion of methane to formaldehyde
is achieved
FORMALDEHYDE TECHNOLOGIES
1. Metal Oxide Catalyst Process

 The metal oxide catalyst process is licensed in the United

States by Reichhold and Lummus.
 In this process, Iron Molybdenum oxide catalyst is employed in
this selective oxidation process for best efficiency.
 A typical metal oxide catalyst has an effective life of 12 to 18
months
 In the metal oxide catalyst process, the major products are
formaldehyde and water.
FORMALDEHYDE TECHNOLOGIES

Figure : Block Diagram for Metal Oxide Process

FORMALDEHYDE TECHNOLOGIES
Economic Potential :
FORMALDEHYDE TECHNOLOGIES

Advantages Disadvantages

 Process yield: 91 – 93%  Larger equipment is required for high

 Product contains only small amount of yield.
methanol  Space consuming.
 Further purification by distillation is not
required.
 Lower methanol-air ratio (Less raw
material is required)
 Longer catalyst lifespan
FORMALDEHYDE TECHNOLOGIES
2. Silver Catalyst Process

 A methanol-rich air mixture is passed over a stationary silver

catalyst. It has useful lifespan of 3 to 8 months
 Reaction conditions are approximately atmospheric pressure
and temperature of 450℃ to 650℃.
 By using silver catalyst, by-products such as carbon monoxide
and dioxide, methyl formate and formic acid will be produced.
 In addition, there are also physical losses, liquid phase
reactions, and small quantity of methanol in the product,
resulting in an overall plant yield of about 83 to 92 percent.
FORMALDEHYDE TECHNOLOGIES
 The major products of the silver catalyst process are
formaldehyde, hydrogen and water.
 Two simultaneous chemical reaction involved in the
reactor:
FORMALDEHYDE TECHNOLOGIES

Figure : Block Diagram for Silver Catalyst Process

FORMALDEHYDE TECHNOLOGIES
Economic Potential :
FORMALDEHYDE TECHNOLOGIES

Advantages Disadvantages

 Process yield : 83 – 92%  Products contain excess methanol and

 Less space consuming. further purification is required by using
distillation process.
 Large amount of raw material is needed
in the process.
 Formation of undesired by-products.
 Short catalyst lifespan.
 Silver catalyst can be poisoned easily
with the presence of sulphur or
transition metal.
FORMALDEHYDE TECHNOLOGIES
3. Biogas/Methane Gas Process

 Conversion of Methane gas into Formaldehyde is one of the many

processes that is available out there.
 This process uses methane gas, whether it a biogas or natural gas, to
produce formaldehyde.
 As with other processes, this process uses various catalysts to improve
the conversion rate.
 Among the catalysts that are usually used are Silicon Dioxide and
combination of Silicon Dioxide with other metal oxides such as
Vanadium Oxide.
 This process is usually conducted in the range of 400℃ to 850℃
and pressure of up to 15 atm.
FORMALDEHYDE TECHNOLOGIES
 Conversion of Methane gas into Formaldehyde is one of the
many processes that is available out there.
 This process uses methane gas, whether it a biogas or natural
gas, to produce formaldehyde.
 As with other processes, this process uses various catalysts to
improve the conversion rate.
 Among the catalysts that are usually used are Silicon Dioxide
and combination of Silicon Dioxide with other metal oxides
such as Vanadium Oxide.
 This process is usually conducted in the range of 400℃ to
850℃ and pressure of up to 15 atm.
FORMALDEHYDE TECHNOLOGIES

Figure : Block Diagram for formation of methane gas from biogas

FORMALDEHYDE TECHNOLOGIES

Figure : Block Diagram for Production of Formaldehyde from the methane gas
FORMALDEHYDE TECHNOLOGIES
Economic Potential:
 No economic potential can be evaluated as this process
is still in research stage.
 It has not been commercialized as one of the
formaldehyde production process in the industry.
FORMALDEHYDE TECHNOLOGIES

Advantages Disadvantages

 Green energy.  Still in research phase.

 Low initial cost.  Highest yield: 3.18% with MoO3/SiO2
catalyst
CONCLUSION
Based on the advantages and disadvantages of each
process, the metal oxide catalyst process is selected due
to several factors:
 Higher yield compared to silver catalyst process.
 Further purification is not required by distillation (less
operating cost).
 Lower methanol consumption (lower raw material cost).
 Longer catalyst life span up to one year (lower
maintenance cost
References
 Douglas, J. M. (1988). Conceptual Design for Processes. The University of Michigan. McGraw-
Hill.
 Fixed-Bed Catalytic Reactors. (2011). Retrieved 3 December 2014, from Nob Hill Publishing
 Formaldehyde & Acetaldehyde. (2001). In Pentwell (Ed.), Formaldehyde & Acetaldehyde (pp.
11): www.knovel.com.
 Glen Barret, D.D., Williams McKinnery, Preliminary Plant Visit in Industrial Hygiene Report.
1982, Reichhold Chemicals Incorporated: North Carolina.
 Henry S. Cole, W.M.A., Final Report of Environmental Liaisons' Investigation Georgia-Pacific
Resins, Inc, Columbus, Ohio, in Plant Safety and Environmental Issues. 2005.
 Jauhianen, K. (2012). Recycling of by-products from formalin production by introduction of a
new absorption unit. Department of Cemical Engineering and Biological Engineering Chalmers
University of Technology. Goteborg, Sweden.
 Laws Of Malaysia Act 139, Factories and Machinery Act 1967, The Commissioner of Law
Revision, Malaysia.
 Lunn, R., Jahnke, G., Spencer, D. (2010). Report on Carcinogens Background Document for
Thank You
Questions and Answers